Titanium and zirconium mixtures and emulsions for use in preparing gypsum wallboard
View Patent ↗Provided herein are mixtures, emulsions and other additives for use in manufacturing gypsum wallboard. The mixtures and emulsions may be wax-based emulsions or wax-free mixtures or emulsions, with wax-based emulsions including water, at least one wax, a dispersant which may include sulfur or a sulfur-containing group, and an additive comprising an organic titanium compound or organic zirconium compound. Mixtures may also be prepared including water, a dispersant; and an additive comprising an organic titanium compound or organic zirconium compound. Gypsum slurries may be prepared using such emulsions and mixtures and/or through addition of an organic titanium compound or organic zirconium compound.
1. A wax emulsion useful for gypsum-based building products, comprising,
water;
at least one wax;
a dispersant; and
an additive comprising an organic zirconium compound and/or an organic titanium compound having a chemical formula:
wherein R 1 may be a straight or branched chain, substituted or unsubstituted, alkyl, alkenyl, aralkyl, aralkenyl group of from about 5 to about 30 carbon atoms, wherein the group has from zero to or about 10 oxygen atoms; R 2 may be the same or different than R 1 ; m and n are integers and each is at least 1 and no greater than 4.
2. The wax emulsion according to claim 1 , wherein the at least one wax comprises one or more of montan wax, paraffin wax, carnauba wax, a Fischer-Tropsch wax, and derivatives and blends thereof.
3. The wax emulsion according to claim 2 , wherein the at least one wax is a blend of paraffin wax with montan wax.
4. The wax emulsion according to claim 1 , comprising a paraffinic hydrocarbon.
5. The wax emulsion according to claim 1 , further comprising at least one stabilizer.
6. The wax emulsion according to claim 5 , wherein the at least one stabilizer comprises polyvinyl alcohol.
7. The wax emulsion according to claim 6 , wherein the polyvinyl alcohol is about 97% to about 100% hydrolyzed polyvinyl alcohol.
8. The wax emulsion according to claim 1 , further comprising a saponifying agent.
9. The wax emulsion according to claim 8 , wherein the saponifying agent is an alkali metal hydroxide.
10. A mixture useful for gypsum-based building products, comprising:
water;
a dispersant or blend of dispersants; and
an additive comprising an organic zirconium compound and/or an organic titanium compound having a chemical formula:
wherein R 1 may be a straight or branched chain, substituted or unsubstituted, alkyl, alkenyl, aralkyl, aralkenyl group of from about 5 to about 30 carbon atoms, wherein the group has from zero to or about 10 oxygen atoms; R 2 may be the same or different than R 1 ; m and n are integers and each is at least 1 and no greater than 4.
11. The mixture according to claim 10 , wherein the dispersant comprises a sulfonate or a sulfonate-containing group.
12. The mixture according to claim 10 , wherein the dispersant is lignosulfonic acid, naphthalene sulfonic acid, and combinations and salts thereof.
13. The mixture according to claim 10 , comprising: about 70 percent by weight to about 99.9 percent by weight of the water; about 0.01 percent by weight to about 10 percent by weight of the dispersant; about 0.001 percent by weight to about 10 percent by weight of the additive; and 0 to about 30 percent by weight of at least one stabilizer.
14. The mixture according to claim 13 , comprising: about 80 percent by weight to about 99.9 percent by weight of the water; about 0.01 percent by weight to about 8 percent by weight of the dispersant; about 0.1 percent by weight to about 2.0 percent by weight of the additive; and about 0 percent by weight to about 10 percent by weight of the at least one stabilizer.
15. The mixture according to claim 10 , wherein the additive is selected from the group consisting of titanium IV 2,2(bis-2-propenolatomethyl)butanolato, tris-neodecanato-O; titanium IV 2,2(bis-2-propenolatomethyl)butanolato, tris(dodecyl)benezenesulfanato-O; titanium IV 2,2(bis-2-propenolatomethyl)butanolato, tris(dioctyl)pyrophosphate-O; titanium IV 2-propenolatomethyl, tris-isooctadecanoato-O; sodium zirconium lactate; triethanolamine titanium complex; titanium phosphate complex; alkanolamine titanate; and titanium chelate.
16. The mixture according to claim 10 , wherein R 1 is a branched chain alkenyloxy group of about 5 to about 12 carbon atoms and R 2 is different from R 1 and is a straight chain alkyl group of about 10 to about 15 carbon atoms; m is 1 and n is 3.
17. The mixture according to claim 10 , wherein the additive has a chemical formula:
18. A method for reducing energy use in the manufacture of a building product, wherein the building product is gypsum wallboard, comprising,
adding to a formulation for forming the building product a mixture comprising:
water;
a dispersant; and
an additive comprising an organic zirconium compound and/or an organic titanium compound having the chemical formula:
wherein R 1 may be a straight or branched chain, substituted or unsubstituted, alkyl, alkenyl, aralkyl, aralkenyl group of from about 5 to about 30 carbon atoms, wherein the group has from zero to or about 10 oxygen atoms; R 2 may the same or different than R 1 ; m and n are integers and each is at least 1 and no greater than 4.
19. The method according to claim 18 , wherein the building product is a water-resistant building product and the mixture is a wax emulsion, and wherein the wax emulsion comprises at least one wax.