WO2025038561A2

WO2025038561A2 - Prograde premix ready-to-use (rtu) adhesive

Info

Publication number: WO2025038561A2
Application number: PCT/US2024/041949
Authority: WO
Inventors: Suxin WANG; Yunbo CHEN; Rajeswari KOMPALLI; Eerik Maandi; Alex Rodriguez; Heath SALVATI
Original assignee: Laticrete International Inc
Current assignee: Laticrete International Inc
Priority date: 2023-08-11
Filing date: 2024-08-12
Publication date: 2025-02-20
Anticipated expiration: 2026-02-11
Also published as: WO2025038561A3

Abstract

Ready-to-use tile/ stone adhesive formulations that meet performance requirements of a modified dry-set cement mortar. The adhesive formulations at least include an acrylic-styrene low-medium Tg latex binder present from greater than 0 wt.% to 35 wt.%, an acrylic-styrene water resistant latex binder present from greater than 0 wt.% to 20 wt.%, and an acrylic-styrene high Tg latex binder present from greater than 0 wt.% to 10 wt.%. The adhesives further include an acrylated tackifier present from greater than 0 wt.% to 6 wt.%, an in-can stabilizer present from greater than 0 wt.% to 2 wt.%, an anti-microbial present from greater than 0 wt.% to 2 wt.%, an adhesion promoter present from greater than 0 wt.% to 4 wt.%, and sand present from 40 wt.% to 85 wt.%. The adhesives further include pigment, one or more thickeners, one or more tiller materials, and optionally perlite-based tiller, flocking fibers and/or zinc oxide.

Description

PROGRADE PREMIX READ Y-TO-USE (RTU) ADHESIVE

Cross Reference to Related Applications

This invention disclosure claims priority from U.S. provisional patent application no. 63/532,224 filed August 11, 2023.

Technical Field

The present invention is directed to a ready-to-use tile and stone adhesive that meets performance requirements of a modified dry-set cement mortar.

Description of Related Art

Various types of mastic materials exist in today's market for a wide variety of applications. A common use of mastic is in the construction industry, and in particular, for use as an adhesive to adhere tile, stone, masonry and other types of building materials to a surface area.

In the field, there are a variety of different types of tiles, stone, masonry, etc. that can be attached to different types of surfaces. As such, a number of different adhesives exist for adhering these varying materials together. For instance, well known currently available tile adhesives include polymer modified cement-based adhesives, two-part or three-part polymer adhesives (e.g., epoxy-based adhesives), as well as one-part polymer ready-to-use (RTU) adhesives. Each of these types of tile adhesives has its advantages and disadvantages. In analyzing these tile adhesives, performance of each is determined by several International

Standards (ISO/EN Standards) & domestic standards (ANSI). In doing so, it has been found that epoxy-based adhesives (2- or 3-part systems) have superior performance as compared to cement or RTU adhesives. However, a disadvantage is that epoxy-based adhesives all require mixing prior to use thereof, and are only used in special projects due to their high cost and toxicity.

Other popular adhesives are polymer modified cement-based adhesives. These cement-based adhesives are readily available, cost effective and can function in most projects, making them the most widely used materials among all tile adhesives. However, both cement-based and epoxybased adhesives need mixing prior to use thereof, with the cement-based adhesives needing to be mixed with a predetermined amount of water and the epoxy-based adhesives consisting of 2 or more component parts that need to be mixed together. These steps are burdensome and time consuming.

As an alternative to cement-based and epoxy-based adhesives that require mixing, currently available adhesives also include premixed and/or one-part adhesive compositions that do not require mixing. Since these adhesives come ready-to-use (RTU) in a pre-mixed state, these types of adhesives are often easier to use than cementitious adhesives and/or two- or three-part adhesive systems. One of the biggest advantages of such premixed RTU adhesives is that they do not need to be mixed with other constituent(s) prior to use thereof, which aids in their ease of use. Another advantage of RTU adhesives is that they are relatively safe as they do not generate dust. Today, RTU adhesives are the most preferred technology for modem consumers in the construction markets. However, limitations to the current commercially available RTU tile adhesives are that they lack the same kind of durability and performance as compared to cementbased adhesives. They also do not have sufficient water resistance and physical strength as compared to that of the cement-based adhesives, which limits their use and applications.

In view of the foregoing, there continues to be a need for new and improved RTU adhesives having superior chemical and physical properties (e.g., durability, water resistance, etc.) as compared to currently available adhesives discussed herein, for which the present invention provides a solution thereto.

Summary of the Invention

Bearing in mind the problems and deficiencies of the prior art, it is therefore an object of the present invention to provide ready-to-use adhesive formulations, particularly tile and stone adhesive formulations, that meets performance requirements of a modified dry-set cement mortar.

Another object of the present invention is to provide tile and stone adhesive formulations that have enhanced durability, water resistance, and strength, as compared to currently known adhesives.

It is another object of the present invention to provide tile and stone adhesive formulations that perform as well as cement-based adhesives. The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention which is directed to adhesives in a ready-to-use formulation that includes a first binder material comprising a low-medium Tg latex binder, a second binder material comprising a water resistant latex binder, a third binder material comprising a high Tg latex binder, a tackifier, an in-can stabilizer, an anti-microbial, an adhesion promoter, sand, pigment, one or more thickeners, and one or more filler materials. The foregoing adhesive formulations of the invention are one-part formulations requiring no mixing prior to use thereof.

In one or more embodiments the first binder material may comprise an acrylic-styrene low- medium Tg latex binder, the second binder material may comprise an acrylic-styrene water resistant latex binder, and the third binder material may comprise an acrylic-styrene high Tg latex binder. The acrylic-styrene low-medium Tg latex binder may be present in an amount ranging from greater than 0 wt.% to 35 wt.%. The acrylic-styrene water resistant latex binder may be present in an amount ranging from greater than 0 wt.% to 20 wt.%. The acrylic-styrene high Tg latex binder may be present in an amount ranging from greater than 0 wt.% to 10 wt.%.

All weight percentages are based on a total weight of the adhesive formulation.

In the various adhesive formulations of the invention the tackifier may comprise an acrylated compound present in an amount ranging from greater than 0 wt.% to 6 wt.%. The in-can stabilizer may be present in an amount ranging from greater than 0 wt.% to 2 wt.%. The antimicrobial may be present in an amount ranging from greater than 0 wt.% to 2 wt.%. The adhesion promoter may be present in an amount ranging from greater than 0 wt.% to 4 wt.%, while the sand may be present in an amount ranging from 40 wt.% to 85 wt.%. In the present adhesive formulations the first thickener may comprise a clay thickener present in an amount ranging from greater than 0 wt.% to 5 wt.%. The second thickener may comprise a cellulose thickener present in an amount ranging from greater than 0 wt.% to 2 wt.%. The third thickener may comprise a silica fume thickener present in an amount ranging from greater than 0 wt.% to 5 wt.%. The adhesives also include filler materials including a fine filler in an amount greater than 0 wt.% to 6 wt.%, and a fiber filler in an amount from greater than 0 wt.% to 6 wt.%.

In certain embodiments the adhesive formulations may also include a perlite-based filler present in an amount from greater than 0 wt.% to 4 wt.%. The adhesive formulations may farther include flocking fibers present in an amount from greater than 0 wt.% to 5 wt.%. Still further, the adhesive formulations may include zinc oxide as a crosslinker present in an amount from greater than 0 wt.% to 6 wt.%.

In the various embodiments of the invention, the acrylic-styrene low-medium Tg latex binder may be present in an amount ranging from about 12 wt.% to 20 wt.%. The acrylic-styrene water resistant latex binder may be present in an amount ranging from about 2 wt.% to 8 wt.%. The acrylic-styrene high Tg latex binder may be present in an amount ranging from about 1 wt.% to 3 wt.%. The tackifier may be an acrylated compound present in an amount ranging from 1 wt.% to

3 wt.%. The in-can stabilizer may be present in an amount from 0.01 wt.% to 0.1 wt.%. The anti-microbial may be present in an amount from 0.01 wt.% to 0.1 wt.%. The adhesion promoter may be present in an amount from 0.1 wt.% to 0.6 wt.%. The sand may be present in an amount ranging from 65 wt.% to 75 wt.%. The first thickener may be a clay thickener present in an amount from 0.3 wt.% to 1 wt.%. The second thickener may be a cellulose thickener present in an amount from 0.05 wt.% to 0.3 wt.%.

The third thickener may be a silica fume thickener present in an amount from 0.2 wt.% to 0.6 wt.%. The fine filler material may be present in an amount from 0.3 wt.% to 1.0 wt.%, while the fiber filler may be present in an amount from 0.5 wt.% to 1.5 wt.%. The pigment may be present in an amount from 0.5 wt.% to 3 wt.%, the perlite-based filler present in an amount from 0.1 wt.% to 0.6 wt.%, the flocking fibers present in an amount from 0.3 wt.% to lwt.%, and the zinc oxide present in an amount from 1 wt.% to 3 wt.%.

It should be appreciated and understood that all above weight percentages are based on a total weight of the adhesive formulation.

Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.

Mode(s) For Carrying Out Invention

The embodiments of the present invention can comprise, consist of, and consist essentially of the features and/or steps described herein, as well as any of the additional or optional ingredients, components, steps, or limitations described herein or would otherwise be appreciated by one of skills in the art. It is to be understood that all concentrations disclosed herein are by weight percent (wt. %.) based on a total weight of the composition unless otherwise indicated.

The present invention refers to unique cement-free tile and stone ready-to-use adhesives or mortars that meet performance requirements of a modified dry-set cement mortar (hereinafter referred to as adhesive(s)). The term “ready-to-use” (“RTU”) refers to an adhesive or mortar formulation that is a one-part formulation that requires no mixing prior to use thereof, which may be referred to herein as a “RTU” adhesive.

In accordance with the various embodiments, the present invention is directed to cement-free ready-to-use tile and stone adhesives, and their methods and use thereof, that have properties and perform like that of a cement-based adhesive. It has been found that the present adhesives meet

ANSI Al 18.4 (the American National Standard Specifications for Modified Dry-Set Cement

Mortar (modified mortar)), and ANSI Al 18.15 standards (the American National Standard

Specifications for Improved Modified Dry-Set Cement Mortar (improved modified mortar)).

Both ANSI A118.4 and ANSI A118.15 standards are the highest standards for cement based ceramic tile adhesives.

In referring to the adhesives of the invention being premixed and ready-to-use, it should be understood that no additional water needs to be added to the compositions of the invention prior to use thereof. The RTU adhesives of the invention are suited for use with tile and in tiling applications. The present various RTU adhesives provide superior water resistance and physical strength, as compared to currently available RTU adhesives. They can be used in interior and exterior applications, and may be exposed to water and/or used in submerged application installations. The testing for physical performance have been confirmed and validated by ANSI

A118.4 and ANSI A118.15.

In accordance with invention, the instant premixed ready-to-use adhesives includes a combination of binder materials. In one or more embodiments, the present RTU adhesives include a low to medium glass transition temperature (Tg) latex binder. Suitable latex binders for use in the invention include acrylic-styrene low-medium (Tg) latex binders. For instance, a suitable acrylic-styrene low-medium (Tg) latex binder may be a modified styrene acrylic latex having excellent water resistance and barrier properties (e.g., Ligos C9502). The acrylic-styrene low-medium (Tg) latex binder may be present in the RTU adhesive formulation in amounts ranging from 0 wt.% to 35 wt.%, from greater than 0 wt.% to 35 wt.%, preferably from about 12 wt.% to 20 wt.%, based on a total weight of the RTU formulation.

In one or more preferred embodiments, the RTU adhesives may include a second binder material.

The second binder material may be a water-resistant latex binder. The water-resistant latex binder may be an acrylic-styrene water-resistant latex binder. In one or more embodiments, the acrylic- styrene water-resistant latex binder may have a solids content of 50% (%+/-!), a pH of 7.5-9.0, a viscosity of 1000 (mPa.s, max) and a Tg of about 24deg. C (e.g., Orgal Tibonder D). Suitable acrylic-styrene water-resistant latex binders also have excellent workability, adhesion after heat aging, and adhesion after water immersion. The water-resistant latex binder may be present in the RTU adhesive formulation in amounts ranging from 0 wt.% to 20 wt.%, from greater than 0 wt.% to 20 wt.%, and preferably from about 2 wt.% to 8 wt.%, based on a total weight of the

RTU formulation.

The present RTU adhesives may further include a third binder material. The third binder material may be a high glass transition temperature (Tg) latex binder, and in certain embodiments, an acrylic-styrene high (Tg) latex binder. In one or more embodiments the high (Tg) latex binder may be a modified styrene acrylate latex or a styrene acrylic emulsion. The high (Tg) latex binder may be present in the formulation in amounts ranging from 0 wt.% to 10 wt.%, from greater than 0 wt.% to 10 wt.%, and preferably from about 1 wt.% to 3 wt.%, based on a total weight of the RTU formulation.

In one or more embodiments, the present RTU adhesives may further include a tackifier. The tackifier may be an acrylated compound tackifier. In one or more embodiments the tackifier may be a solvent-free, soft waterborne emulsion of rosin ester resin for tackifying latex polymers that is stable when mixed with latexes having a pH greater than 7.0. Properties of such a tackifier may include, but are not limited to, a total solids content of about 56.0 ± 1.0, a viscosity (at

23°C) of about 1200 ± 400 cps, a pH of 9.5 ± 1.0, an average particle size 0.5 micron, and a softening point of about 40°C. In the various RTU adhesives of the invention, the tackifier may be present in the formulation in amounts ranging from 0 wt.% to 6 wt.%, from greater than 0 wt.% to 6 wt.%, and preferably from about 1 wt.% to 3 wt.%, based on a total weight of the RTU formulation.

In accordance with the invention, the present RTU adhesives may further include an adhesion promoter. The adhesion promoter may be an epoxy functional silane oligomer having a polyfunctional structure with gamma-glycidoxy groups. In these adhesion promoters, the gamma-gylcidoxy propyl epoxide ring reacts with many organic groups while its alkoxy silane groups promote adhesion to most inorganic substrates. Suitable adhesion promoters of the invention may have limited volatile organics (e.g., reduce methanol emissions as compared to monomeric epoxy silanes), improved wet and dry adhesion, improved corrosion resistance, as well as be compatible with and used in small amounts in water-based, solvent-bome or high- solids systems. In one or more embodiments, the adhesion promoter may be present in the formulation in amounts ranging from 0 wt.% to 4 wt.%, from greater than 0 wt.% to 4 wt.%, and preferably from about 0.1 wt.% to 0.6 wt.%, based on a total weight of the RTU formulation.

In one or more embodiments, the present RTU adhesives may further include an in-can stabilizer.

Suitable in-can stabilizers may be those acting as microbiocides that control bacteria, fungi, and algae growth. For instance, the in-can stabilizer may include 2-Methyl-4-isothiazolin-3-one as a main ingredient. The in-can stabilizer may be present in the inventive formulations in amounts ranging from 0 wt.% to 2 wt.%, from greater than 0 wt.% to 2 wt.%, and preferably from about

0.01 wt.% to 0.1 wt.%, based on a total weight of the RTU formulation.

The present RTU adhesives of the invention may further include an antimicrobial agent. The antimicrobial agent preferably includes an active ingredient that resists the growth of microbes such as bacteria, mold and mildew. In certain embodiments, the antimicrobial agent may be a quaternary ammonium compound such as, for instance, a formulation containing ortho- phenylphenol (0.21%), a quaternary ammonium complex (di-isobutylphenoxy-ethoxy- ethyldimethylbenzyl-ammonium chloride, 0.69%), and bromine (0.04%). While not meant to be limiting, in one or more embodiments the antimicrobial agent may be a flowable microban product. The antimicrobial agent may be present in the formulation in amounts ranging from 0 wt.% to 2 wt.%, from greater than 0 wt.% to 2 wt.%, and preferably from about 0.01 wt.% to 0.1 wt. %. It should be appreciated that all the wt.% measures disclosed herein are based on a total weight of the RTU formulation. As a main constituent, the present RTU adhesives also include sand as a first filler, preferably medium grade or bulk sand. For instance, in one or more embodiments the sand may be a medium grade having dimensions of about 0.1mm to about 0.3 mm, or medium bulk 5010/5030.

The sand may be present in the formulation in amounts ranging from about 40 wt.% to 85 wt.%, and preferably from about 65 wt.% to 75 wt.%, based on a total weight of the RTU formulation.

The RTU adhesives of the invention may also include one or more other filler materials. For instance, the present RTU formulations may include a fine filler, such as calcium carbonate. The fine fillers may be a fine particle size, wet ground white calcitic material having a dry free- flowing powder form. In one or more embodiments, the fine fillers may have properties including, but not limited to, a high whiteness, closely controlled particle size, ease of dispersion, and the like. The fine fillers may be in the present formulations in amounts ranging from 0 wt.% to 6 wt.%, from greater than 0 wt.% to 6 wt.%, and preferably from about 0.3 wt.% to 1.0 wt.%, based on a total weight of the RTU formulation.

In one or more embodiments the present RTU adhesives may include a lightweight filler, such as, a perlite-based filler. The lightweight filler is preferably a low density, hydrophobic, closed-cell expanded perlite-based material that replaces at least a portion of heavier fillers, such as silica sand. Use of lightweight fillers in the present formulations provides RTU adhesives having reduced weight per volume unit of product, as compared to adhesives composed only of heavy filler materials. The addition of a lightweight, hydrophobic expanded filler also improves workability and sag resistance of the resultant RTU adhesive. The lightweight filler may be in the present formulations in amounts ranging from 0 wt.% to 4 wt.%, from greater than 0 wt.% to 4 wt.%, and preferably from about 0.1 wt.% to 0.6 wt.%, based on a total weight of the RTU formulation

The present RTU adhesives may include one or more types of fiber materials. In one or more embodiments, the formulations include a first and second fiber material. The first fiber materials/particles may be plant-based functional fillers, and in particular, a powdered cellulose filler. The fiber particles may have good binding properties, exhibit low moisture absorption and are stable. In the present FTU formulas, the fiber particles may be present in amounts ranging from 0 wt.% to 6 wt.%, from greater than 0 wt.% to 6 wt.%, and preferably from about 0.5 wt.% to 1.5 wt.%, based on a total weight of the RTU formulation. The second fiber materials/particles may be flocking fibers, and in particular, white polyester flocking fibers. The flocking fibers provide excellent reinforcement, durability, compressive strength, toughness, abrasion resistance and weatherability. The flocking fibers may be in the present formulations in amounts ranging from 0 wt.% to 4 wt.%, from greater than 0 wt.% to 4 wt.%, and preferably from about 0.3 wt.% to 1.0 wt.%, based on a total weight of the RTU formulation.

A crosslinker or crosslinking agent may be included in the present RTU adhesives to strengthen the properties of the resultant adhesives. In one or more embodiments, the crosslinker may include a zinc oxide material having a medium particle size (e.g., about 0.23m) and exhibiting excellent tack retention. The flocking fibers provide excellent reinforcement, durability, compressive strength, toughness, abrasion resistance and weatherability. The zinc oxide filler material may be in the present formulations in amounts ranging from 0 wt.% to 6 wt.%, from greater than 0 wt.% to 6 wt.%, and preferably from about 1.0 wt.% to 3.0 wt.%, based on a total weight of the RTU formulation.

In one or more embodiments, the present RTU adhesives may further include one or more thickeners. In certain embodiments the present RTU adhesives include a first thickener comprising a clay thickener. For instance, the clay thickener may be a white kaolin sourced from intermediate kaolins, such as those having plate-like crystal structures and high aspect ratios to provide moisture barrier properties. Suitable white kaolin fillers may provide semi -reinforcing properties, enhanced chemical resistance, and provide slow viscosity building properties to allow increased filler loadings without adversely affecting performance and/or handling properties of the resultant RTU adhesive. In one or more embodiments the white kaolin fillers/thickener may be an ultrafine kaolin product having properties including, but not limited to, good semireinforcing properties, good color quality, effective TiO2 spacing, and light scattering properties.

The first thickener may be present in the instant RTU adhesives in amounts ranging from 0 wt.% to 5 wt.%, from greater than 0 wt.% to 5 wt.%, and preferably from about 0.3 wt.% to 1.0 wt.%, based on a total weight of the RTU formulation.

The present RTU adhesives may also include a second thickener comprising a cellulose ether thickener. In one or more embodiments the cellulose ether thickener may be a methylcellulose

(MC) derivatives, which are cellulose ethers that, when dissolved in water, offer a variety of functional properties. For instance, the cellulose ether thickener may be a methylhydroxyethylcellulose (MHEC) thickener that provides water retention, workability and cohesiveness to mixtures. Preferably the methylcellulose thickener has properties to control thickening, water demand, improve open time, sag resistance, strength, and importantly, slowing down hydration to allow use in the present RTU adhesives. The second thickener may be in the

RTU adhesives in amounts ranging from 0 wt.% to 2 wt.%, from greater than 0 wt.% to 2 wt.%, and preferably from about 0.05 wt.% to 0.3 wt.%, based on a total weight of the RTU formulation.

In one or more embodiments the present RTU adhesives may further have a third thickener comprising a silica fume thickener. The silica fume thickener may be a medium surface fumed silica thickener that provides thickening efficiency and dispersibility, shear-thinning, and anti- settling behavior of the instant RTU adhesives. The third thickener may be present in the instant

RTU adhesives in amounts ranging from 0 wt.% to 5 wt.%, from greater than 0 wt.% to 5 wt.%, and preferably from about 0.2 wt.% to 0.6 wt.%, based on a total weight of the RTU formulation.

The various RTU adhesives of the invention may also include one or more pigments. In certain embodiments the pigment may be a titanium dioxide white powder having good whiteness and dispersibility. The titanium dioxide pigment product preferably has a titanium dioxide content of at least equal to or greater than 93%, with an overall whiteness of about 96%, based on the total product concentration itself. In one or more embodiments the titanium dioxide colorant may be made by advanced chlorination process with special surface treatments. For instance, the titanium dioxide colorant may be a high quality rutile TiO2, coated with dense ZrO2, A12O3.

The pigments/colorants preferably have good whiteness, dispersibility, essentially uniform particle size, weather stability, and high tinting (coloring) power. The pigments may be present in the instant RTU adhesives in amounts ranging from 0 wt.% to 6 wt.%, from greater than 0 wt.% to 6 wt.%, and preferably from about 0.5 wt.% to 3.0 wt.%, based on a total weight of the RTU formulation.

The various materials that may be provided within the premixed cement-free RTU adhesive formulations, and thereby the resultant adhesives, of the invention are detailed below in Table 1.

It should be appreciated that various combinations of the materials described herein may be used in combination with each other to formulate the dispersion-based RTU adhesives of the invention. It should also be appreciated that these formulations render the adhesive material of the invention as well as the resultant adhesive layer after deposition and curing.

Referring to Table 1 below, and the examples of the invention that follow, the premixed RTU dispersion-based formulations of the invention at least include one or more binders, a tackifier, in-can preservative, an anti-microbial, adhesion promoter, one or more fillers (including medium grade and fine grade), one or more thickening agents, and at least one colorant. Preferably, at least or more of the binders have high water resistance to provide the resultant RTU adhesives with superior water resistance and physical strength.

In accordance with one or more embodiments of the invention, various ready-to-use adhesive formulations of the present invention are described in Table 1 below:

TABLE 1:

In accordance with other embodiments of the invention, various RTU adhesive formulations of the invention are described in Table 2 below: TABLE 2

It has been found that the cement-free ready-to-use dispersion-based formulations of the invention, for use as adhesives, and thereby the resultant adhesive products, advantageously meet performance requirements of a cement-based adhesive. It is further beneficial that the formulations of the invention are formulate as ready-to-use compositions that does not require mixing as they are premixed water-based formulations. It has been found that the present adhesives meet ANSI A118.4 and ANSI A118.15 standards, both of which are the highest standards for cement based ceramic tile adhesives. The present RTU adhesives may be used in interior or exterior applications, as well as be exposed to water and be installed for submerged applications. The instant RTU adhesive formulations are low in VOCs, do not have any potential health risks to the user/applicator, and potentially no skin sensitization. It has further been found that the RTU adhesive formulations provide resultant adhesive products with superior water resistance and superior physical strength, as compared to known RTU adhesives.

While not meant to be limiting, for ease of understanding the invention, an exemplary RTU dispersion-based adhesive formulation of the invention is described below in Table 2. TABLE 3: In accordance with the invention, while not meant to be limiting, a first exemplary

RTU adhesive formulation of the invention that meets performance requirements of a modified dry-set cement mortar is as follows:

TABLE 4: In the comparative tests as described below in relation to Examples 2 of the invention, the measured test results evidence that the inventive formulation(s) meet the below

ANSI standards, and perform more like a commercially available cement-based adhesive.

TABLE 5: In accordance with the invention, a second exemplary RTU adhesive formulation of the invention that meets performance requirements of a modified dry-set cement mortar is as follows:

While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.

Thus, having described the invention, what is claimed is:

Claims

1. An adhesive in a ready-to-use formulation comprising: a first binder material comprising a low-medium Tg latex binder; a second binder material comprising a water resistant latex binder; a third binder material comprising a high Tg latex binder; a tackifier; an in-can stabilizer; an anti-microbial; an adhesion promoter; sand; pigment; one or more thickeners, and one or more filler materials, wherein the adhesive formulation is a one-part formulation requiring no mixing prior to use.

2. The adhesive of claim 1 wherein, the first binder material comprises an acrylic-styrene low-medium Tg latex binder; the second binder material comprises an acrylic-styrene water resistant latex binder; and the third binder material comprises an acrylic-styrene high Tg latex binder.

3. The adhesive of claim 2 wherein, the acrylic-styrene low-medium Tg latex binder is present in an amount ranging from greater than 0 wt.% to 35 wt.%; the acrylic-styrene water resistant latex binder is present in an amount ranging from greater than 0 wt.% to 20 wt.%; and the acrylic-styrene high Tg latex binder is present in an amount ranging from greater than 0 wt.% to 10 wt.%, wherein weight % is based on total weight of the adhesive formulation.

4. The adhesive of claim 1 wherein the tackifier comprises an acrylated compound present in an amount ranging from greater than 0 wt.% to 6 wt.% based on total weight of the adhesive formulation.

5. The adhesive of claim 1 wherein the in-can stabilizer is present in an amount ranging from greater than 0 wt.% to 2 wt.% based on total weight of the adhesive formulation.

6. The adhesive of claim 1 wherein the anti-microbial is present in an amount ranging from greater than 0 wt.% to 2 wt.% based on total weight of the adhesive formulation.

7. The adhesive of claim 1 wherein the adhesion promoter is present in an amount ranging from greater than 0 wt.% to 4 wt.% based on total weight of the adhesive formulation.

8. The adhesive of claim 1 wherein the sand is present in an amount ranging from 40 wt.% to 85 wt.% based on total weight of the adhesive formulation.

9. The adhesive of claim 1 wherein the one or more thickeners comprise: a first thickener comprising a clay thickener present in an amount ranging from greater than 0 wt.% to 5 wt.%; a second thickener comprising a cellulose thickener present in an amount ranging from greater than 0 wt.% to 2 wt.%; and a third thickener comprising a silica fume thickener present in an amount ranging from greater than 0 wt.% to 5 wt.%, wherein weight % is based on total weight of the adhesive formulation.

10. The adhesive of claim 1 wherein the one or more filler materials comprise: a fine filler material present in an amount ranging from greater than 0 wt.% to 6 wt.%; and a fiber filler present in an amount ranging from greater than 0 wt.% to 6 wt.%’ wherein weight % is based on total weight of the adhesive formulation.

11. The adhesive of claim 1 further including a perlite-based filler present in an amount ranging from greater than 0 wt.% to 4 wt.% based on total weight of the adhesive formulation.

12. The adhesive of claim 1 further including flocking fibers present in an amount ranging from greater than 0 wt.% to 5 wt.% based on total weight of the adhesive formulation.

13. The adhesive of claim 1 further including zinc oxide as a crosslinker present in an amount ranging from greater than 0 wt.% to 6 wt.% based on total weight of the adhesive formulation.

14. The adhesive of claim 2 wherein, the acrylic-styrene low-medium Tg latex binder is present in an amount ranging from about

12 wt.% to 20 wt.%; the acrylic-styrene water resistant latex binder is present in an amount ranging from about 2 wt.% to 8 wt.%; and the acrylic-styrene high Tg latex binder is present in an amount ranging from about 1 wt.% to

3 wt.%, wherein weight % is based on total weight of the adhesive formulation.

15. The adhesive of claim 14 wherein the tackifier comprises an acrylated compound present in an amount ranging from 1 wt.% to 3 wt.% based on total weight of the adhesive formulation.

16. The adhesive of claim 14 wherein the in-can stabilizer is present in an amount ranging from 0.01 wt.% to 0.1 wt.% based on total weight of the adhesive formulation.

17. The adhesive of claim 14 wherein the anti-microbial is present in an amount ranging from

0.01 wt.% to 0.1 wt.% based on total weight of the adhesive formulation.

18. The adhesive of claim 14 wherein the adhesion promoter is present in an amount ranging from 0.1 wt.% to 0.6 wt.% based on total weight of the adhesive formulation.

19. The adhesive of claim 14 wherein the sand is present in an amount ranging from 65 wt.% to 75 wt.% based on total weight of the adhesive formulation.

20. The adhesive of claim 14 wherein the one or more thickeners comprise: a first thickener comprising a clay thickener present in an amount ranging from 0.3 wt.% to 1 wt.%; a second thickener comprising a cellulose thickener present in an amount ranging from 0.05 wt.% to 0.3 wt.%; and a third thickener comprising a silica fume thickener present in an amount ranging from 0.2 wt.% to 0.6 wt.%, wherein weight % is based on total weight of the adhesive formulation.

21. The adhesive of claim 14 wherein the one or more filler materials comprise: a fine filler material present in an amount ranging from 0.3 wt.% to 1.0 wt.%; and a fiber filler present in an amount ranging from 0.5 wt.% to 1.5 wt.%, wherein weight % is based on total weight of the adhesive formulation.

22. The adhesive of claim 14 wherein the pigment is present in an amount ranging from 0.5 wt.% to 3 wt.% based on total weight of the adhesive formulation.

23. The adhesive of claim 14 further including a perlite-based filler present in an amount ranging from 0.1 wt.% to 0.6 wt.% based on total weight of the adhesive formulation.

24. The adhesive of claim 14 further including flocking fibers present in an amount ranging from 0.3 wt.% to lwt.% based on total weight of the adhesive formulation.

25. The adhesive of claim 14 further including zinc oxide as a crosslinker present in an amount ranging from 1 wt.% to 3 wt.% based on total weight of the adhesive formulation.

26. A tile and stone adhesive in a ready-to-use formulation comprising: an acrylic-styrene low-medium Tg latex binder is present in an amount ranging from about

12 wt.% to 20 wt.%; an acrylic-styrene water resistant latex binder is present in an amount ranging from about 2 wt.% to 8 wt.%; an acrylic-styrene high Tg latex binder is present in an amount ranging from about 1 wt.% to

3 wt.%; a tackifier present in an amount ranging from 1 wt.% to 3 wt.%; an in-can stabilizer is present in an amount ranging from 0.01 wt.% to 0.1 wt.%; an anti-microbial is present in an amount ranging from 0.01 wt.% to 0.1 wt.%. an adhesion promoter is present in an amount ranging from 0.1 wt.% to 0.6 wt.%. sand present in an amount ranging from 65 wt.% to 75 wt.%; a first thickener comprising a clay thickener present in an amount ranging from 0.3 wt.% to 1 wt.%; a second thickener comprising a cellulose thickener present in an amount ranging from 0.05 wt.% to 0.3 wt.%; a third thickener comprising a silica fume thickener present in an amount ranging from 0.2 wt.% to 0.6 wt.%; a fine filler material present in an amount ranging from 0.3 wt.% to 1.0 wt.%; and a fiber filler present in an amount ranging from 0.5 wt.% to 1.5 wt.%, wherein the adhesive formulation is a one-part formulation requiring no mixing prior to use, and weight % is based on total weight of the adhesive formulation.

27. A tile and stone adhesive in a ready-to-use formulation comprising: an acrylic-styrene low-medium Tg latex binder is present in an amount ranging from about

3 wt.%; a tackifier present in an amount ranging from 1 wt.% to 3 wt.%; an in-can stabilizer is present in an amount ranging from 0.01 wt.% to 0.1 wt.%; an anti-microbial is present in an amount ranging from 0.01 wt.% to 0.1 wt.%. an adhesion promoter is present in an amount ranging from 0.1 wt.% to 0.6 wt.%. sand present in an amount ranging from 65 wt.% to 75 wt.%; a first thickener comprising a clay thickener present in an amount ranging from 0.3 wt.% to 1 wt.%; a second thickener comprising a cellulose thickener present in an amount ranging from 0.05 wt.% to 0.3 wt.%; a third thickener comprising a silica fume thickener present in an amount ranging from 0.2 wt.% to 0.6 wt.%; a fine filler material present in an amount ranging from 0.3 wt.% to 1.0 wt.%; a fiber filler present in an amount ranging from 0.5 wt.% to 1.5 wt.% a perlite-based filler present in an amount ranging from 0.1 wt.% to 0.6 wt.%; flocking fibers present in an amount ranging from 0.3 wt.% to lwt.%; and zinc oxide as a crosslinker present in an amount ranging from 1 wt.% to 3 wt.%, wherein the adhesive formulation is a one-part formulation requiring no mixing prior to use, and weight % is based on total weight of the adhesive formulation.

28. The adhesive of claim 27 wherein the perlite-based filler comprises a low density, hydrophobic, closed-cell expanded perlite-based material.

29. The adhesive of claim 27 wherein the flocking fibers comprise polyester flocking fibers.

30. The adhesive of claim 27 wherein the crosslinker comprises a zinc oxide material having a medium particle size.

31. A tile and stone adhesive in a ready-to-use formulation comprising: an acrylic-styrene low-medium Tg latex binder is present in an amount ranging from about

14.8 wt.% to 18.2 wt.%; an acrylic-styrene water resistant latex binder is present in an amount ranging from about 4.5 wt.% to 5.5 wt.%; an acrylic-styrene high Tg latex binder is present in an amount ranging from about 1.8 wt.% to 2.2 wt.%; a tackifier present in an amount ranging from 1.8 wt.% to 2.2 wt.%; an in-can stabilizer is present in an amount ranging from 0.027 wt.% to 0.033wt.%; an anti-microbial is present in an amount ranging from 0.018 wt.% to 0.022 wt.%. an adhesion promoter is present in an amount ranging from 0.027 wt.% to 0.033 wt.%. sand present in an amount ranging from 62.5 wt.% to 76.5 wt.%; a first thickener comprising a clay thickener present in an amount ranging from 0.54 wt.% to

0.66 wt.%; a second thickener comprising a cellulose thickener present in an amount ranging from 0.108 wt.% to 0.132 wt.%; a third thickener comprising a silica fume thickener present in an amount ranging from 0.027 wt.% to 0.033 wt.%; a fine filler material present in an amount ranging from 0.54 wt.% to 0.66 wt.%; and a fiber filler present in an amount ranging from 0.9 wt.% to 1.1 wt.%, wherein the adhesive formulation is a one-part formulation requiring no mixing prior to use, and weight % is based on total weight of the adhesive formulation.

32. The adhesive of claim 31 further comprising: a perlite-based filler present in an amount ranging from 0.198 wt.% to 0.242 wt.%; flocking fibers present in an amount ranging from 0.396 wt.% to 0.484 wt.%; and zinc oxide as a crosslinker present in an amount ranging from 1.8 wt.% to 2.2 wt.%’ wherein weight % is based on total weight of the adhesive formulation.