Claims
- 1. An emulsion useful in providing water resistance to a gypsum product, the emulsion comprising:
a first wax, the first wax having a melting point of 120° F. or greater; a second wax having a melting point of 180° F. or greater, the second wax having a saponification value; an alkyl phenol; a co-surfactant, selected from the group consisting of sodium lignosulfonate, potassium lignosulfonate and trisodium phosphate; a strong alkali; water; and a complexed starch; wherein the strong alkali saponifies the second wax to provide a surfactant.
- 2. The emulsion of claim 1 wherein the first wax has a melting point of from about 120° F. to about 150° F.
- 3. The emulsion of claim 1 wherein the strong alkali is potassium hydroxide.
- 4. The emulsion of claim 1 wherein the alkyl phenol is a long chain C24-C34 methylene coupled alkyl phenol.
- 5. The emulsion of claim 1 wherein the complexed starch is a complex of sodium tetraborate decahydrate and starch.
- 6. The emulsion of claim 1 wherein the second wax is present in an amount ranging from about 3 percent to about 10 percent of the total weight of the emulsion.
- 7. The emulsion of claim 1 wherein the co-surfactant is present in an amount ranging from about 0.5 percent to about 5 percent of the total weight of the emulsion.
- 8. The emulsion of claim 1 wherein the complexed starch is present in an amount ranging from about 0.5 percent to about 15 percent of the total weight of the emulsion.
- 9. An emulsion useful in providing water resistance to a gypsum product, the emulsion comprising:
a wax, the wax having a melting point of 135° F. or greater; an alkyl phenol; a dual surfactant system, the dual surfactant system comprising a mixture of two surfactants such that a HLB value of the mixture is from about 8.9 to about 14; water; and a complexed starch.
- 10. The emulsion of claim 9 wherein the wax has a melting point of from about 135° F. to about 150° F.
- 11. The emulsion of claim 9 wherein the alkyl phenol is a long chain C24-C34 methylene coupled alkyl phenol.
- 12. The emulsion of claim 9 wherein the dual surfactant system is a mixture of dodecylisopropanolamine benzene sulfonate and a nonionic ethoxylated aryl phenol.
- 13. The emulsion of claim 9 wherein the dual surfactant system is a mixture of dodecylisopropanolamine benzene sulfonate and an alkoxylated fatty acid ester.
- 14. The emulsion of claim 9 wherein the complexed starch is a complex of sodium tetraborate decahydrate and starch.
- 15. The emulsion of claim 9 further comprising a fluidity modifier.
- 16. The emulsion of claim 15 wherein the fluidity modifier is poly(oxy-1,2-ethanedyl), alpha-phenyl-omega-hydroxy styrenate.
- 17. The emulsion of claim 9 wherein the wax is present in an amount ranging from about 33 percent to about 38 percent of the total weight of the emulsion.
- 18. The emulsion of claim 9 wherein the dual surfactant system is present in an amount ranging from about 1 percent to about 10 percent of the total weight of the emulsion.
- 19. The emulsion of claim 9 wherein the complexed starch is present in an amount ranging from about 0.5 percent to about 15 percent of the total weight of the emulsion.
- 20. A gypsum slurry useful in making a gypsum product, the gypsum slurry comprising:
(a) calcium sulfate dihydrate; and (b) an emulsion comprising:
a first wax, the first wax having a melting point greater than about 120° F.; a second wax, the second wax having a saponification value; an alkyl phenol; a co-surfactant, the co-surfactant selected from the group consisting of sodium lignosulfonate, potassium lignosulfonate and trisodium phosphate; a strong alkali; water; and a complexed starch; wherein the strong alkali saponifies the second wax to provide a surfactant.
- 21. The gypsum slurry of claim 20 wherein the first wax has a melting point of from about 120° F. to about 150° F.
- 22. The gypsum slurry of claim 20 wherein the strong alkali is potassium hydroxide.
- 23. The gypsum slurry of claim 20 wherein the alkyl phenol is a long chain C24-C28 methylene coupled allkyl phenol.
- 24. The gypsum slurry of claim 20 wherein the co-surfactant is sodium lignosulfonate.
- 25. The gypsum slurry of claim 20 wherein the co-surfactant is trisodium phosphate.
- 26. The gypsum slurry of claim 20 wherein the complexed starch is a complex of sodium tetraborate decahydrate and starch.
- 27. A gypsum slurry useful in making a gypsum product, the gypsum slurry:
(a) calcium sulfate dihydrate; and (b) a wax emulsion comprising:
a wax, the wax having a melting point of 135° F. or greater; an alkyl phenol; a dual surfactant system, the dual surfactant system comprising a mixture of two surfactants such that the HLB value of the mixture is from about 8.9 to about 14; water; and a complexed starch.
- 28. The gypsum slurry of claim 27 wherein the wax has a melting point of from about 135° F. to about 150° F.
- 29. The gypsum slurry of claim 27 wherein the alkyl phenol is a long chain C24-C34 methylene coupled alkyl phenol.
- 30. The gypsum slurry of claim 27 wherein the dual surfactant system is a mixture of dodecylisopropanolamine benzene sulfonate and a nonionic ethoxylated aryl phenol.
- 31. The gypsum slurry of claim 27 wherein the dual surfactant system is a mixture of dodecylisopropanolamine benzene sulfonate and an alkoxylated fatty acid ester.
- 32. The gypsum slurry of claim 27 wherein the complexed starch is a complex of sodium tetraborate decahydrate and starch.
- 33. The gypsum slurry of claim 27 further comprising a fluidity modifier.
- 34. The gypsum slurry of claim 33 wherein the fluidity modifier is poly(oxy-1,2-ethanedyl), alpha-phenyl-omega-hydroxy styrenate.
- 35. A method of making an emulsion, the emulsion useful in providing water resistance to a gypsum product, the method comprising:
(a) providing:
a first wax, the first wax having a melting point of 120° F. or greater; a second wax having a melting point of 180° F. or greater, the second wax having a saponification value; an allyl phenol; a co-surfactant, selected from the group consisting of sodium lignosulfonate, potassium lignosulfonate and trisodium phosphate; a strong alkali; water; and a complexed starch; (b) mixing the first wax, the second wax, the alkyl phenol and the co-surfactant to provide a first pre-mix; (c) mixing the strong alkali, water and complexed starch to provide a second pre-mix; (d) combining the first pre-mix and the second pre-mix to provide a mixture; and (e) homogenizing the mixture; wherein the homogenized mixture contains a distribution of micelles; and wherein the strong alkali saponifies the second wax to provide a surfactant.
- 36. The method of claim 35 wherein the distribution of micelles have a range of micelle diameters from about 0.5 microns to about 2.5 microns.
- 37. A method for making an emulsion, the emulsion useful in providing water resistance to a gypsum product, the method comprising:
(a) providing:
a wax having a melting point of 135° F. or greater; an alkyl phenol; water; and a complexed starch; (b) mixing a plurality of surfactants to provide a dual surfactant system such that the HLB value of the dual surfactant system is from about 8.9 to about 14; (c) mixing the wax, the alkyl phenol and the dual surfactant system to provide a first pre-mix; (d) mixing the water and complexed starch to provide a second pre-mix; (e) combining the first pre-mix and the second pre-mix to provide a mixture; and (h) homogenizing the mixture; wherein the homogenized mixture contains a distribution of micelles.
- 38. The method of claim 37 wherein the distribution of micelles have a range of micelle diameters from about 0.5 microns to about 2.5 microns.
- 39. The method of claim 37 wherein the wax has a melting point of from about 135° F. to about 150° F.
- 40. The method of claim 37 wherein the alkyl phenol is a long chain C24-C34 methylene coupled alkyl phenol.
- 41. The method of claim 37 wherein the dual surfactant system is a mixture of dodecylisopropanolamine benzene sulfonate and a nonionic ethoxylated aryl phenol.
- 42. The method of claim 37 wherein the dual surfactant system is a mixture of dodecylisopropanolamine benzene sulfonate and an alkoxylated fatty acid ester.
- 43. The method of claim 37 wherein the complexed starch is a complex of sodium tetraborate decahydrate and starch.
- 44. The method of claim 37 further comprising the step of mixing a fluidity modifier with the emulsion.
- 45. The method of claim 44 wherein the fluidity modifier is poly(oxy-1,2-ethanedyl), alpha-phenyl-omega-hydroxy styreniate.
- 46. A gypsum product comprising:
calcium sulfate dihydrate; and an effective amount of the emulsion of claim 1.
- 47. A gypsum product comprising:
calcium sulfate dihydrate; and an effective amount of the emulsion of claim 9.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119(e) from co-pending U.S. Provisional Application Serial No. 60/303,635, filed Jul. 6, 2001, bearing an identical title.
Provisional Applications (1)
|
Number |
Date |
Country |
|
60303635 |
Jul 2001 |
US |
Divisions (1)
|
Number |
Date |
Country |
Parent |
09993196 |
Nov 2001 |
US |
Child |
10357720 |
Feb 2003 |
US |