Aqueous asphalt/wax emulsions for use in gypsum compositions and building products
View Patent ↗Aqueous asphalt/wax emulsions are disclosed herein for use in gypsum formulations and other building products. The emulsions may include water; a wax component; an asphalt component; and at least one emulsifier. Optional additives may also be included in the emulsion or in a slurry formed from such emulsion for preparing a settable gypsum composition herein. Methods of making such emulsions are also provided.
1. An aqueous wax emulsion for use in a gypsum formulation, comprising:
about no less than 50 percent to about no more than 75 percent by weight of water;
about no less than 10 percent to about no more than 40 percent by weight of a wax component comprising a montan wax;
about no less than 5 percent to about no more than 15 percent by weight of a asphalt component; and
about no less than 0.5 percent to about no more than 5 percent by weight of at least one emulsifier.
2. The aqueous wax emulsion according to claim 1 , wherein the emulsion comprises about 70 percent by weight of water; about 21 percent by weight of the wax component; about 8 percent by weight of the asphalt component; and about 1 percent by weight of the at least one emulsifier.
3. The aqueous wax emulsion according to claim 1 , wherein the wax component further comprises a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified by oxidizing and/or refining through distillation or stripping, carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof and/or a paraffinic hydrocarbon.
4. The aqueous wax emulsion according to claim 1 , wherein the wax component further comprises a paraffinic hydrocarbon.
5. The aqueous wax emulsion according to claim 1 , wherein the wax component comprises a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified by oxidizing and/or refining through distillation or stripping, natural or synthetic carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof.
6. The aqueous wax emulsion according to claim 1 , wherein the wax component comprises a paraffinic hydrocarbon and the paraffinic hydrocarbon is a paraffin wax having a melting point of about 40° C. to about 80° C.
7. The aqueous wax emulsion according to claim 6 , wherein the paraffin wax comprises no more than about 1 percent by weight oil.
8. The aqueous wax emulsion according to claim 7 , wherein the paraffin wax comprises no more than about 0.5 percent by weight oil.
9. The aqueous wax emulsion according to claim 1 , wherein the emulsion comprises no less than about 0.5 to no more than about 5 percent by weight of a montan wax; no less than about 0.1 to no more than about 5 percent by weight of a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified by oxidizing and/or refining through distillation or stripping, carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof; and no less than about 5 to no more than about 30 percent by weight of a paraffinic hydrocarbon.
10. The aqueous wax emulsion according to claim 1 , wherein the emulsion comprises no less than about 1 to no more than about 4 percent by weight of a montan wax; no less than about 0.25 to no more than about 3 percent by weight of a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified by oxidizing and/or refining through distillation or stripping, carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof; and no less than about 10 to about no more than 30 percent by weight of a paraffinic hydrocarbon.
11. The aqueous wax emulsion according to claim 1 , wherein the emulsion comprises no less than about 1.5 to no more than about 3 percent by weight of a montan wax; no less than about 0.5 to no more than about 1.5 percent by weight of a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified by oxidizing and/or refining through distillation or stripping, carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof; and no less than about 15 to about no more than 25 percent by weight of a paraffinic hydrocarbon.
12. The aqueous wax emulsion according to claim 1 , wherein the emulsion comprises about 2 percent by weight of a montan wax; about 1 percent by weight of a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified b oxidizing and/or refining through distillation or stripping, carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof; and about 18 percent by weight of a paraffinic hydrocarbon.
13. The aqueous wax emulsion according to claim 1 , wherein the wax component comprises a paraffinic hydrocarbon and wherein the ratio of the asphalt component to the paraffinic hydrocarbon is about 0.1:1 to about 1:1 by weight.
14. The aqueous wax emulsion according to claim 13 , wherein the ratio of the asphalt component to the paraffinic hydrocarbon is about 0.4:1 by weight.
15. The aqueous wax emulsion according to claim 1 , wherein the asphalt component has a penetration grade no more than about 60.
16. The aqueous wax emulsion according to claim 1 , wherein the asphalt component has a penetration grade no more than about 20.
17. The aqueous wax emulsion according to claim 1 , wherein the asphalt component has a penetration grade no less than about 0 to no more than about 10.
18. The aqueous wax emulsion according to claim 1 , wherein the at least one emulsifier comprises a resin, a Kraft lignin, styrene maleic anhydride, and/or a polyolefin maleic grafted anhydride.
19. The aqueous wax emulsion according to claim 1 , wherein the at least one emulsifier comprises a resin and/or a Kraft lignin.
20. The aqueous wax emulsion according to claim 19 , wherein the resin comprises one or more of poly(phenolate carboxylate) resin, a hydrocarbon resin, a thermoplastic resin, and blends thereof, and wherein the Kraft lignin comprises a tall oil fatty acid based amidoamine and blends thereof.
21. The aqueous wax emulsion according to claim 20 , wherein the emulsion comprises about 0.5 percent by weight of the poly(phenolate carboxylate) resin and about 0.6 percent by weight of the thermoplastic resin.
22. The aqueous wax emulsion according to claim 1 , wherein the at least one emulsifier comprises styrene maleic acid and/or a polyolefin maleic grafted anhydride.
23. The aqueous wax emulsion according to claim 22 , wherein the polyolefin maleic grafted anhydride is polyethylene grafted maleic anhydride.
24. The aqueous wax emulsion according to claim 1 , further comprising a saponifying agent, wherein the emulsion comprises less than about 5 percent by weight of the saponifying agent.
25. The aqueous wax emulsion according to claim 1 , further comprising a saponifying agent, wherein the emulsion comprises no less than about 0.1 percent by weight to no more than about 3 percent by weight of the saponifying agent.
26. The aqueous wax emulsion according to claim 25 , wherein the emulsion comprises about 0.5 percent by weight of the saponifying agent.
27. The aqueous wax emulsion according to claim 26 , wherein the saponifying agent is an alkali metal.
28. The aqueous wax emulsion according to claim 1 , further comprising a stabilizer and/or a dispersant.
29. An aqueous wax emulsion for use in a gypsum formulation, comprising:
about no less than 50 percent to about no more than 75 percent by weight of water;
about no less than 10 percent to about no more than 40 percent by weight of a wax component;
about no less than 5 percent to about no more than 15 percent by weight of an asphalt component having a penetration grade no more than about 60; and
about no less than 0.5 percent to about no more than 5 percent by weight of at least one emulsifier.
30. The aqueous wax emulsion according to claim 29 , wherein the emulsion comprises about 70 percent by weight of water; about 21 percent by weight of the wax component; about 8 percent by weight of the asphalt component; and about 1 percent by weight of the at least one emulsifier.
31. The aqueous wax emulsion according to claim 29 , wherein the wax component comprises at least one of montan wax, a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified by oxidizing and/or refining through distillation or stripping, carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof, and/or a paraffinic hydrocarbon.
32. The aqueous wax emulsion according to claim 29 , wherein the wax component comprises a montan wax.
33. The aqueous wax emulsion according to claim 29 , wherein the emulsion comprises no less than about 0.5 to no more than about 5 percent by weight of a montan wax; no less than about 0.1 to no more than about 5 percent by weight of a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified by oxidizing and/or refining through distillation or stripping, carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof; and no less than about 5 to no more than about 30 percent by weight of a paraffinic hydrocarbon.
34. The aqueous wax emulsion according to claim 29 , wherein the wax component comprises a paraffinic hydrocarbon and wherein the ratio of the asphalt component to the paraffinic hydrocarbon is about 0.1:1 to about 1:1 by weight.
35. The aqueous wax emulsion according to claim 29 , wherein the at least one emulsifier comprises a resin, a Kraft lignin, styrene maleic anhydride, and/or a polyolefin maleic grafted anhydride.
36. The aqueous wax emulsion according to claim 29 , further comprising a saponifying agent, wherein the emulsion comprises less than about 5 percent by weight of the saponifying agent.
37. The aqueous wax emulsion according to claim 29 , further comprising a stabilizer and/or a dispersant.
38. An aqueous wax emulsion for use in a gypsum formulation, comprising:
about no less than 50 percent to about no more than 75 percent by weight of water;
about no less than 10 percent to about no more than 40 percent by weight of a wax component;
about no less than 5 percent to about no more than 15 percent by weight of an asphalt component; and
about no less than 0.5 percent to about no more than 5 percent by weight of at least one emulsifier comprising about 0.5 percent by weight of a poly(phenolate carboxylate) resin and about 0.6 percent by weight of a thermoplastic resin.
39. The aqueous wax emulsion according to claim 38 , wherein the emulsion comprises about 70 percent by weight of water; about 21 percent by weight of the wax component; about 8 percent by weight of the asphalt component; and about 1 percent by weight of the at least one emulsifier.
40. The aqueous wax emulsion according to claim 38 , wherein the wax component comprises at least one of montan wax, a wax selected from the group consisting of a normal α-olefin wax, an olefin wax of a carbon chain length of about 20 or more carbon atoms that is modified by oxidizing and/or refining through distillation or stripping, carnauba wax, palm wax, Fischer-Tropsch wax, bees wax, polyethylene wax, polymeric alkenes, oxidized polyethylene waxes, and mixtures, blends and derivatives thereof, and/or a paraffinic hydrocarbon.
41. The aqueous wax emulsion according to claim 38 , wherein the wax component comprises a montan wax.
42. The aqueous wax emulsion according to claim 38 , wherein the emulsion comprises no less than about 0.5 to no more than about 5 percent by weight of a montan wax; no less than about 0.1 to no more than about 5 percent by weight of a synthetic montan wax; and no less than about 5 to no more than about 30 percent by weight of a paraffinic hydrocarbon.
43. The aqueous wax emulsion according to claim 38 , wherein the wax component comprises a paraffinic hydrocarbon and wherein the ratio of the asphalt component to the paraffinic hydrocarbon is about 0.1:1 to about 1:1 by weight.
44. The aqueous wax emulsion according to claim 38 , wherein the at least one emulsifier comprises a resin, a Kraft lignin, styrene maleic anhydride, and/or a polyolefin maleic grafted anhydride.
45. The aqueous wax emulsion according to claim 38 , further comprising a saponifying agent, wherein the emulsion comprises less than about 5 percent by weight of the saponifying agent.
46. The aqueous wax emulsion according to claim 38 , further comprising a stabilizer and/or a dispersant.
47. An aqueous wax emulsion for use in a gypsum formulation, comprising:
about no less than 50 percent to about no more than 75 percent by weight of water;
about no less than 10 percent to about no more than 40 percent by weight of a wax component;
about no less than 5 percent to about no more than 15 percent by weight of an asphalt component; and
about no less than 0.5 percent to about no more than 5 percent by weight of at least one emulsifier comprising styrene maleic acid and/or polyolefin maleic grafted anhydride.
48. The aqueous wax emulsion according to claim 47 , wherein the emulsion comprises about 70 percent by weight of water; about 21 percent by weight of the wax component; about 8 percent by weight of the asphalt component; and about 1 percent by weight of the at least one emulsifier.
49. The aqueous wax emulsion according to claim 47 , wherein the wax component comprises at least one of montan wax, a synthetic montan wax, and/or a paraffinic hydrocarbon.
50. The aqueous wax emulsion according to claim 47 , wherein the wax component comprises a montan wax.
51. The aqueous wax emulsion according to claim 47 , wherein the emulsion comprises no less than about 0.5 to no more than about 5 percent by weight of a montan wax; no less than about 0.1 to no more than about 5 percent by weight of a synthetic montan wax; and no less than about 5 to no more than about 30 percent by weight of a paraffinic hydrocarbon.
52. The aqueous wax emulsion according to claim 47 , wherein the wax component comprises a paraffinic hydrocarbon and wherein the ratio of the asphalt component to the paraffinic hydrocarbon is about 0.1:1 to about 1:1 by weight.
53. The aqueous wax emulsion according to claim 47 , wherein the at least one emulsifier comprises a resin, a Kraft lignin, styrene maleic anhydride, and/or a polyolefin maleic grafted anhydride.
54. The aqueous wax emulsion according to claim 47 , further comprising a saponifying agent, wherein the emulsion comprises less than about 5 percent by weight of the saponifying agent.
55. The aqueous wax emulsion according to claim 47 , further comprising a stabilizer and/or a dispersant.