Wax Emulsion for Use in Building Products
Provided herein are an aqueous wax emulsion, comprising water; a paraffinic hydrocarbon; polyvinyl alcohol and a wax component comprising synthetic olefin wax component. The synthetic olefin wax component may be selected from the group consisting of (i) a synthetic normal α-olefin wax; (ii) a synthetic olefin wax of a carbon chain length of about 20 or more carbon atoms, that is modified by oxidizing and/or by refining through distillation or stripping; and (iii) combinations thereof. Such emulsions are also useful for and disclosed herein are settable gypsum compositions and water-resistant wallboard formed therefrom. Also included herein is a montan wax substitute for use in an aqueous montan-based wax emulsion having paraffinic hydrocarbon, a wax component, water and polyvinyl alcohol wherein the wax component includes the montan wax substitute in place of use of a montan wax in the wax component such that the montan wax substitute is about 1 part to about 100 percent of the wax component and includes a synthetic olefin wax.
1 . An aqueous wax emulsion, comprising:
water;
a paraffinic hydrocarbon; and
a wax component comprising a synthetic olefin wax component, wherein the synthetic olefin wax component is selected from the group consisting of (i) a synthetic normal α-olefin wax; (ii) a synthetic olefin wax of a carbon chain length of about 20 or more carbon atoms, that is modified by oxidizing and/or by refining through distillation or stripping; and (iii) combinations thereof.
2 . The aqueous wax emulsion according to claim 1 , wherein the synthetic olefin wax component is the synthetic olefin wax (ii) and has a carbon chain length of at least 28.
3 . The aqueous wax emulsion according to claim 2 , wherein the synthetic olefin wax component is the synthetic olefin wax (ii) and has a carbon chain length of at least 30.
4 . The aqueous wax emulsion according to claim 1 , wherein the synthetic olefin wax component is the synthetic olefin wax (ii) and comprises a mixture of one or more of (a) an olefin having a carbon chain of about 28 to about 54 carbons; (b) one or more component selected from an aldehyde, a ketone, a carboxylic acid and a carboxylic ester; and (c) a dimer prepared from olefins having carbon chain lengths of about 28 to about 54 so as to have dimer carbon chain lengths of about 65 to about 108.
5 . The aqueous wax emulsion according to claim 1 , wherein the wax component further comprises montan wax in a blend with the synthetic olefin wax component.
6 . The aqueous wax emulsion according to claim 1 , wherein the wax component is a blend of the synthetic olefin wax component with one or more of natural or synthetic carnauba wax, palm wax, Fischer-Tropsch wax, a polymeric alkene, and an oxidized polyethylene wax.
7 . The aqueous wax emulsion according to claim 1 wherein the synthetic olefin wax component is from about 1 percent to about 100 percent of the wax component.
8 . The aqueous wax emulsion according to claim 7 , wherein the synthetic olefin wax component is from about 20 percent to about 80 percent of the wax component.
9 . The aqueous wax emulsion according to claim 8 , wherein the synthetic olefin wax component is from about 30 percent to about 70 percent of the wax component.
10 . The aqueous wax emulsion according to claim 9 , wherein the synthetic olefin wax component is from about 40 percent to about 60 percent of the wax component.
11 . The aqueous wax emulsion according to claim 1 , further comprising a stabilizer.
12 . The aqueous wax emulsion according to claim 11 , wherein the stabilizer is polyvinyl alcohol.
13 . The aqueous wax emulsion according to claim 12 , wherein the polyvinyl alcohol is present in an amount of about 1 part to about 20 parts, by weight, per 100 parts of said paraffin hydrocarbon.
14 . The aqueous wax emulsion according to claim 13 , wherein the polyvinyl alcohol is about 97% to about 100% hydrolyzed polyvinyl alcohol.
15 . The aqueous wax emulsion according to claim 1 , further comprising a saponifying agent.
16 . The aqueous wax emulsion according to claim 15 , wherein the saponifying agent is an alkali metal.
17 . The aqueous wax emulsion according to claim 16 , wherein the alkali metal is potassium hydroxide.
18 . The aqueous wax emulsion according to claim 1 , further comprising at least one of a dispersant and a surfactant.
19 . The aqueous wax emulsion according to claim 18 , wherein the dispersant comprises sulfur or a sulfur-containing group.
20 . The aqueous wax emulsion according to claim 19 , wherein the dispersant is lignosulfonate.
21 . The aqueous wax emulsion according to claim 1 , wherein the paraffinic hydrocarbon is a paraffin wax having a melting point of about 40° C. to about 80° C.
22 . A settable gypsum composition suitable for forming a water-resistant gypsum product comprising:
a) 100 parts by weight of gypsum; and
b) about 0.5 part to about 20 parts, by weight, of emulsion solids, per 100 parts, by weight, of gypsum, of an aqueous emulsion comprising:
i) water;
ii) a paraffinic hydrocarbon; and
iii) a wax component comprising synthetic olefin wax component, wherein the wax component is present in an amount of about 1 part to about 200 parts, by weight, per 100 parts of the paraffinic hydrocarbon.
23 . The settable gypsum composition according to claim 22 , wherein the synthetic olefin wax component is selected from the group consisting of (i) a synthetic normal α-olefin wax; (ii) a synthetic olefin wax of a carbon chain length of about 20 or more carbon atoms, that is modified by oxidizing and/or by refining through distillation or stripping; and (iii) combinations thereof.
24 . The settable gypsum composition according to claim 23 , wherein the synthetic olefin wax component is the synthetic olefin wax (ii) and has a carbon chain length of at least 30.
25 . The composition according to claim 22 , further comprising a stabilizer.
26 . The composition according to claim 25 , wherein the stabilizer is polyvinyl alcohol in an amount of about 1 part to about 50 parts, by weight, per 100 parts of said paraffin hydrocarbon.
27 . The composition according to claim 26 , wherein the polyvinyl alcohol is about 97% to about 100% hydrolyzed polyvinyl alcohol.
28 . A water-resistant gypsum board having a core sandwiched between a pair of liners, said core comprising a set composition of claim 22 .
29 . A method of manufacturing a water-resistant gypsum board comprising:
a) forming a mixture of
i) 100 parts by weight of gypsum; and
ii) about 0.5 part to about 20 parts, by weight, of emulsion solids, per 100 parts, by weight, of the gypsum, of an aqueous emulsion comprising:
a. water;
b. a paraffinic hydrocarbon; and
c. a wax component comprising a synthetic olefin wax component in an amount of about 1 part to about 200 parts, by weight, per 100 parts of said paraffinic hydrocarbon;
b) forming the mixture into a structure; and
c) drying the structure while permitting hydration of the gypsum to form a gypsum wallboard.
30 . The method according to claim 29 , wherein the synthetic olefin wax component in the mixture is selected from the group consisting of (i) a synthetic normal α-olefin wax; (ii) a synthetic olefin wax of a carbon chain length of about 20 or more carbon atoms, that is modified by oxidizing and/or by refining through distillation or stripping; and (iii) combinations thereof.
31 . The method according to claim 29 , wherein the structure is an assembly and the method further comprising placing a layer of the mixture on a first liner, disposing a second liner on the layer in opposed relationship with the first liner to form the assembly of the first and the second liners with the layer sandwiched therebetween.
32 . The method according to claim 29 , wherein the mixture further comprises polyvinyl alcohol in an amount of about 1 part to about 50 parts, by weight, per 100 parts of said paraffin hydro carbon.
33 . A montan wax substitute for use in an aqueous montan-based wax emulsion comprising a paraffinic hydrocarbon, a wax component, water and polyvinyl alcohol, wherein the wax component comprises the montan wax substitute in an amount of about 1 part to about 100 percent of the wax component in the emulsion, and the montan wax substitute comprises a synthetic olefin wax component selected from the group consisting of (i) a synthetic normal α-olefin wax; (ii) a synthetic olefin wax of a carbon chain length of about 20 or more carbon atoms, that is modified by oxidizing and/or by refining through distillation or stripping; and (iii) combinations thereof.