Note: Descriptions are shown in the official language in which they were submitted.
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WATER-RESISTANT PRODUCTS USING A WAX EMULSION
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] This application claims priority to US Patent Application No.
14/567,018,
filed December 11, 2014 which is incorporated by reference herein in its
entirety.
FIELD
[0002] Water-resistant products, such as joint compounds, using a wax
emulsion are
disclosed.
BACKGROUND
[0003] Wax emulsions have been used in composite wallboard (e.g.,
gypsum
wallboard) for many years. For example, wax emulsions sold under the trade
name
AQUALITE by Henry Company, and several wax emulsion formulations are
disclosed in the
prior art, such as U.S. Patent No. 5,437,722.
[0004] Gypsum is employed in a gypsum panel or board product known as
wallboard
which is widely used as a structural building panel. Gypsum products may be
produced by
mixing anhydrous calcium sulfate or calcium sulfate hemihydrate with water and
allowing the
mixture to hydrate or set as calcium sulfate dihydrate, which is relatively
hard. Gypsum
wallboard may comprise a panel-like core of set gypsum sandwiched between a
pair of paper
liners which form the exposed outer surfaces of the wallboard. Fiberglass
liners have also been
used. In many applications wallboard is exposed to water. A problem with set
gypsum is that it
absorbs water, and such absorption reduces the strength of the wallboard.
[0005] Further, in order to achieve a smooth, visually appealing
surface, the joints
between boards, cracks, screw holes, and/or nail holes must be concealed.
Conventional
wallboard joint compounds are commonly used to cover and finish gypsum
wallboard joints,
cornerbead, and screw or nail holes. Joint compounds can be spread over mesh
or tape used to
connect wallboards. It may also be used to patch and texture interior walls.
[0006] The intrusion of water through wall spaces, either through
prolonged direct
contact or via high humidity, has a debilitating effect (mold and structural
damage) on standard
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wall systems. It is for this reason that moisture resistant wallboard, passing
ASTM C473, was
developed. An integral part of the wall system is the tape joint compound
which, so far, has no
accepted standards for water resistance.
[0007] Some specially formulated gypsum wallboards (also called
"Green" boards)
contain a water repellent additive such as a wax emulsion to impart the added
functionality of
water resistance to the board. While such "green" gypsum wallboards meet
strict water
repellency performance requirements (ASTM C473), there are no such
requirements and indeed,
no ready-mix joint compound that offers commensurate water repellency.
Consequently, the
ready-mixed joint compound is a severe vulnerability in existing wall systems
where protection
against water damage is crucial. The result of water seepage through joint
compound to the studs
on the other side of the wall ultimately has devastating structural and
microbial implications for
the wall system, first by absorption of the seeped water into the wood studs
followed by their
swelling and deformation (leading to expensive structural problems) and then,
the creation of a
fertile ground for rapid mold growth. Conventional ready mixed joint compound
is therefore a
weak link in the long term microbial resistance and integrity of the wall
system.
SUMMARY
[0008] The following presents a simplified summary of one or more
aspects in order
to provide a basic understanding of such aspects. This summary is not an
extensive overview of
all contemplated aspects, and is intended to neither identify key or critical
elements of all aspects
nor delineate the scope of any or all aspects. Its sole purpose is to present
some concepts of one
or more aspects in a simplified form as a prelude to the more detailed
description that is
presented later.
[0009] Disclosed herein are embodiments of a water-resistant joint
compound which
can comprise water, preservative, and wax emulsion, or silicone, or
siliconate, or fluorinated
compound, or stearate, or combinations thereof.
[0010] In some embodiments, the joint compound can comprise a wax
emulsion and
can have a contact angle of about 90 to about 130 degrees, a pH below 12, and
a Cobb value of
about 1.0 to about 200 grams per square meter.
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[0011] In some embodiments, the joint compound can further comprise
about 20 to
about 55 wt. % water, about 0.02 to about 1.0 wt. % preservatives, about 10 to
about 50 wt. %
calcium carbonate, about 0.0 to about 10 % mica, about 0.0 to about 10 wt. %
attapulgite clay,
about 0.0 to about 10 wt. % talc, about 0.0 to about 40 wt. % perlite, about
0.0 to about 10 wt. %
polyethylene oxide, about 0.0 to about 10 wt. % polyether siloxane, about 0.1
to about 20 wt. %
wax emulsion, about 0.5 to about 10 wt. % latex binder, and about 0.1 to about
8.0 wt. %
cellulose ether thickener.
[0012] In some embodiments, the joint compound can further comprise a
rheology
modifier, a binder, a thickener, and a filler. In some embodiments, the joint
compound can
further comprise calcium carbonate, or cristobalite, or a micro-roughened
filler, or gypsum, or
mica, or clay, or thickener, or a latex binder, or talc, or perlite, or
expanded perlite, or
combinations thereof In some embodiments, the joint compound can comprise a
wax emulsion
which can comprise water. polyvinyl alcohol, paraffin wax, or montan wax, or
synthetic wax, or
combinations thereof, a base, and a dispersant.
[0013] In some embodiments, the joint compound can comprise wax
emulsion, the
wax emulsion can comprise paraffin wax, or montan wax, or carnauba wax, or
sunflower wax, or
rice wax, or tallow wax, or a wax containing organic acids and/or esters, or a
emulsifier
containing a mixture of organic acids such as stearic acid and/or esters, or
combinations thereof
In some embodiments, the joint compound can comprise wax emulsion, the wax
emulsion can
comprise synthetic wax including polyethylene glycol or methoxypolyethylene
glycol, or both
polyethylene glycol and methoxypolyethylene glycol. In some embodiments, the
joint compound
can comprise synthetic wax at about 0.1% to about 8% of the joint compound dry
weight.
[0014] In some embodiments, the joint compound can comprise wax
emulsion
stabilized with polyvinyl alcohol. In some embodiments, the joint compound can
have a pH
below 9. In some embodiments, the joint compound can have a contact angle of
about 60 to
about 130 degrees. In some embodiments, the joint compound can be generally
hydrophobic and
can have a contact angle of about 110 to about 130 degrees. In some
embodiments, the joint
compound can have a Cobb value of about 1.0 to about 200 grams per square
meter. In some
embodiments, the joint compound can have a Cobb value of about 65 grams per
square meter.
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[0015] In some embodiments, the joint compound can comprise wax
emulsion and
silicones, or siloxanes, or siliconates, or fluorinated compounds, or
stearates, or combinations
thereof. In some embodiments, the joint compound can further comprise surface
micro-
roughened fillers.
[0016] Also disclosed herein is a method of making a water-resistant
joint compound
which can comprise mixing a combination of water, preservative, and wax
emulsion, or silicone,
or siliconate, or a fluorinated compound, or stearate, or combinations thereof
to form a water-
resistant joint compound.
[0017] In some embodiments, the joint compound can comprise a wax
emulsion and
can have a contact angle of about 90 to about 130 degrees, a pH below 9, and a
Cobb value of
about 5.0 to about 200 grams per square meter.
[0018] In some embodiments, the joint compound can further comprise
about 20 to
about 55 wt. % water, about 0.02 to about 1.0 wt. % preservatives, about 10 to
about 50 wt. %
calcium carbonate, about 0.0 to about 10 % mica, about 0.0 to about 10 wt. %
attapulgite clay,
about 0.0 to about 10 wt. % talc, about 0.0 to about 40 wt. % perlite, about
0.0 to about 10 wt. %
polyethylene oxide, about 0.0 to about 10 wt. % polyether siloxane, about 0.1
to about 20 wt. %
wax emulsion, about 0.5 to about 10 wt. % latex binder, and about 0.1 to about
8.0 wt. %
cellulose ether thickener.
[0019] In some embodiments, the joint compound can further comprise a
rheology
modifier, a binder, a thickener, and a filler. In some embodiments, the joint
compound can
further comprise calcium carbonate, or cristobalite, or a micro-roughened
filler, or gypsum, or
mica, or clay, or thickener, or a latex binder, or talc, or perlite, or
expanded perlite, or
combinations thereof. In some embodiments, the joint compound can comprise wax
emulsion
stabilized with polyvinyl alcohol. In some embodiments, the joint compound can
comprise wax
emulsion comprising synthetic wax. In some embodiments, the joint compound can
comprise
wax emulsion, the wax emulsion can comprise synthetic wax including
polyethylene glycol or
methoxypolyethylene glycol, or both polyethylene glycol and
methoxypolyethylene glycol.
[0020] In some embodiments, the joint compound can comprise synthetic
wax at
about 0.1% to about 8% of the joint compound dry weight.
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[0021] In some embodiments, the joint compound can comprise wax
emulsion and
silicones, or siloxanes, or siliconates, or fluorinated compounds, or
stearates, or combinations
thereof.
[0022] In some embodiments, the joint compound can comprise wax
emulsion, the
wax emulsion can be formed by mixing a combination of water, polyvinyl
alcohol, and paraffin
wax, or montan wax, or synthetic wax, or combinations thereof.
[0023] In some embodiments, an acid is not used in forming the water-
resistant joint
compound. In some embodiments, the joint compound can have a contact angle of
about 60 to
about 130 degrees
[0024] In some embodiments, the joint compound can further comprise
about 5.89
wt. % latex binder, about 34.60 wt. % water, about 7.36 wt. % wax emulsion,
about 1.84 wt. %
attapulgite clay, about 7.36 wt. % mica, about 33.86 wt. % calcium carbonate,
and about 8.47 wt.
% expanded perlite.
[0025] In some embodiments, the wax emulsion can further comprise
about 58 wt. %
water, about 2.70 wt. % polyvinyl alcohol, about 34.30 wt. % paraffin wax, and
about 3.50 wt. %
montan wax.
[0026] In some embodiments, the joint compound can comprise a wax
emulsion and
silicones, or siliconates, or fluorinated compounds, or stearates, or
combinations thereof In some
embodiments, the silicones, siliconates, fluorinated compounds, or stearates
can be selected from
the group consisting of metal siliconate salts, potassium siliconate, poly
hydrogen methyl
siloxane, polydimethyl siloxane, stearate-based salts, and combinations
thereof
In some embodiments, the joint compound can comprise the wax emulsion, and at
least one
siliconate and optionally at least one thickener, preferably a cellulose ether
based thickener.
BRIEF DESCRIPTION OF THE FIGURES
[0027] The disclosed aspects will hereinafter be described in
conjunction with the
appended drawings, provided to illustrate and not to limit the disclosed
aspects, wherein like
designations denote the elements.
[0028] FIG. 1 illustrates an example process of one embodiment of the
disclosure.
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[0029] FIG. 2 illustrates a wall having an example embodiment of the
disclosed
water-resistant joint compound applied thereon.
DETAILED DESCRIPTION
[0030] Embodiments of the present disclosure provide a water-resistant
joint
compound formed from a wax emulsion. The joint compound may optionally be used
to create a
water resistant barrier at wall joints, as well as at holes, such as nail
holes, through a wall,
thereby preventing moisture from passing through the walls. The joint compound
may optionally
be used, for example, in construction of houses or commercial buildings. The
joint compound
can contain, in some embodiments, a montan activated and polyvinyl alcohol
stabilized wax
emulsion. By doing so, the resulting dried joint compound surface can exhibit
a high contact
angle, which can lead to exceptional water repellency. Further, the disclosed
joint compound
formed from a wax emulsion can avoid deleterious effects on key desirable
performance
properties of the joint compound.
[0031] The joint compound can be used to create a moisture resistant
joint compound
that can, for example, complement and be used on moisture resistant gypsum
boards ("green"
boards). These boards, along with the joint compound, can be used in high
humidity areas, such
as bathrooms. The use of the moisture resistant boards and joint compounds can
help to reduce
the susceptibility of the walls, and the studs behind the walls, to mold
growth and structural
deformation caused through the absorption of water, reducing damage and health
risks.
[0032] Certain example embodiments of the joint compound can be
generally
prepared from an improved wax emulsion, among other materials and additives.
More details on
example embodiments of the different materials are disclosed herein.
Wax Emulsions Including Moisture Resistant Stabilizers
[0033] Embodiments of an improved wax emulsion for use in a water-
resistant joint
compound are now described in greater detail, as follows. An embodiment of the
wax emulsion
may comprise water, a base, one or more waxes optionally selected from the
group consisting of
slack wax, paraffin wax, and a polymeric stabilizer, such as ethylene-vinyl
alcohol-vinyl acetate
terpolymer or polyvinyl alcohol. Further, montan wax, carnauba wax, sunflower
wax, tall oil,
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tallow wax, rice wax, and any other natural or synthetic wax or emulsifiers
containing organic
acids (such as, for example, stearic acid) and/or esters can be used to form
the wax emulsion..
[0034] Water may be provided to the emulsion, for example in amounts
of about 30%
to about 60% by weight of the emulsion. The solids content of the wax emulsion
can be about
40% to about 70% by weight of the emulsion. Other amounts may be used.
[0035] In some embodiments, a dispersant and/or a surfactant may be
employed in
the improved wax emulsions. Optional dispersants, include, but are not limited
to those having a
sulfur or a sulfur-containing group(s) in the compound such as sulfonic acids
(R-S(=0)2-0H)
and their salts, wherein the R groups may be otherwise functionalized with
hydroxyl, carboxyl or
other useful bonding groups. In some embodiments, higher molecular weight
sulfonic acid
compounds such as lignosulfonate, lignosulfonic acid, naphthalene sulfonic
acid, the sulfonate
salts of these acids and derivatized or functionalized versions of these
materials are used in
addition or instead. An example lignosulfonic acid salt is Polyfong H
available from
MeadWestvaco Corporation, Charleston, SC. Other dispersants may be used, such
as magnesium
sulfate, polycarboxylate technology, ammonium hepta molybdate/starch
combinations, non-ionic
surfactants, ionic surfactants, zwitterionic surfactants and mixtures thereof,
alkyl quaternary
ammonium montmorillonite clay, etc. Similar materials may also be used, where
such materials
may be compatible with and perform well with the formulation components. For
example, other
materials may be used such that the edge swell, water absorption, internal
bonding and/or
flexural strength properties of the resultant boards are not materially
affected and the resultant
boards are acceptable for use as industry acceptable wallboard. If used, a
dispersant and/or
surfactant may comprise about 0.01% to about 5.0% by weight of the improved
wax emulsion
formulation composition, preferably about 0.1% to about 2.0% by weight of the
improved wax
emulsion formulation composition. Other concentrations may be used.
[0036] The wax component of the emulsion may include at least one wax
which may
be slack wax. The total wax content may be about 30% to about 60%, more
preferably about
30% to about 40% by weight of the emulsion. Slack wax may be any suitable
slack wax known
or to be developed which incorporates a material that is a higher petroleum
refining fraction of
generally up to about 20% by weight oil. In addition to, or as an alternative
to slack wax,
paraffin waxes of a more refined fraction are also useful within the scope of
the disclosure.
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[0037] Suitable paraffin waxes may be any suitable paraffin wax, and
preferably
paraffins of melting points of from about 40 C to about 110 C, although
lower or higher
melting points may be used if drying conditions are altered accordingly using
any techniques
known or yet to be developed in the composite board manufacturing arts or
otherwise. Thus,
petroleum fraction waxes, either paraffin or microcrystalline, and which may
be either in the
form of varying levels of refined paraffins, or less refined slack wax may be
used. Optionally,
synthetic waxes such as ethylenic polymers or hydrocarbon types derived via
Fischer-Tropsch
synthesis may be included in addition or instead, however paraffins or slack
waxes are preferred
in certain embodiments. By way of further example, synthetic waxes, such as
polyethylene
glycol, methoxypolyethylene glycol, or combinations thereof may be included.
An example of a
polyethylene glycol is PEG 1500, while an example of methoxypolyethylene
glycol is MPEG
750 LD, both manufactured by Clariant International Ltd.
[0038] Montan wax, which is also known in the art as lignite wax, is a
hard, naturally
occurring wax that is typically dark to amber in color (although lighter, more
refined montan
waxes are also commercially available). Montan is insoluble in water, but is
soluble in solvents
such as carbon tetrachloride, benzene and chloroform. In addition to naturally
derived montan
wax, alkyl acids and/or alkyl esters which are derived from high molecular
weight fatty acids of
synthetic or natural sources with chain lengths preferably of over 18 carbons,
more preferably
from 26 to 46 carbons that function in a manner similar to naturally derived
montan wax are also
within the scope of the disclosure and are included within the scope of
"montan wax" as that
term is used herein unless the context indicates otherwise (e.g., "naturally
occurring montan
wax"). Such alkyl acids are generally described as being of formula R¨COOH,
where R is an
alkyl non-polar group which is lipophilic and can be from 18 to more than 200
carbons. An
example of such a material is octacosanoic acid and its corresponding ester
which is, for
example, a di-ester of that acid with ethylene glycol. The COOH group forms
hydrophilic polar
salts in the presence of alkali metals such as sodium or potassium in the
emulsion. While the
alkyl portion of the molecule gets embedded within the paraffin, the acid
portion is at the
paraffin/aqueous medium interface, providing stability to the emulsion. Other
components which
may be added include esterified products of the alkyl acids with alcohols or
glycols.
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[0039] In some embodiments, the at least one wax component of the
emulsion
includes primarily and, preferably completely a slack wax component. In some
embodiments, the
at least one wax component is made up of a combination of paraffin wax and
montan wax or of
slack wax and montan wax. Although it should be understood that varying
combinations of such
waxes can be used, and the combinations are not limiting. When using montan
wax in
combination with one or more of the other suitable wax components, it is
preferred that montan
be present in an amount of about 0.1% to about 10%, more preferably about 1%
to about 4% by
weight of the wax emulsion with the remaining wax or waxes present in amounts
of from about
30% to about 50%, more preferably about 30% to about 35% by weight of the wax
emulsion.
[0040] In some embodiments, the wax emulsion can include polyvinyl
alcohol
(PVOH) of any suitable grade which is at least partially hydrolyzed. The
preferred polyvinyl
alcohol is at least 80%, and more preferably at least 90%, and most preferably
about 97-100%
hydrolyzed polyvinyl acetate. Suitably, the polyvinyl alcohol is soluble in
water at elevated
temperatures of about 60 C to about 95 C, but insoluble in cold water. The
hydrolyzed
polyvinyl alcohol is preferably included in the emulsion in an amount of up to
about 5% by
weight, preferably 0.1% to about 5% by weight of the emulsion, and most
preferably about 2%
to about 3% by weight of the wax emulsion.
[0041] In some embodiments, the stabilizer comprises a polymer that is
capable of
hydrogen bonding to the carboxylate or similar moieties at the water/paraffin
interface. Polymers
that fit the hydrogen-bonding requirement would have such groups as hydroxyl,
amine, and/or
thiol, amongst others, along the polymer chain. Reducing the polymer's
affinity for water (and
thus, its water solubility) could be achieved by inserting hydrophobic groups
such as alkyl,
alkoxy silanes, or alkyl halide groups into the polymer chain. The result may
be a polymer such
as ethylene-vinyl acetate-vinyl alcohol terpolymer (where the vinyl acetate
has been
substantially hydrolyzed). The vinyl acetate content may be between 0% to 15%.
In some
embodiments, the vinyl acetate content is between 0% and 3% of the terpolymer
chain. The
ethylene-vinyl alcohol-vinyl acetate terpolymer may be included in the
emulsion in an amount of
up to about 10.0% by weight, preferably 0.1% to about 5.0% by weight of the
emulsion. In some
embodiments, ethylene-vinyl alcohol-vinyl acetate terpolymer may be included
in the emulsion
in an amount of about 2% to about 3% by weight of the wax emulsion. An example
ethylene-
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vinyl alcohol-vinyl acetate terpolymer that is available is the Exceval
AQ41O4TM, available from
Kuraray Chemical Company.
[0042] The wax emulsion may include a stabilizer material (e.g., PVOH,
ethylene-
vinyl alcohol-vinyl acetate terpolymer as described above). The stabilizer may
be soluble in
water at elevated temperatures similar to those disclosed with reference to
PVOH (e.g., about
60 C up to about 95 C), but insoluble in cold water. The active species in
the wax component
(e.g., montan wax) may be the carboxylic acids and esters, which may comprise
as much as 90%
of the wax. These chemical groups may be converted into carboxylate moieties
upon hydrolysis
in a high pH environment (e.g., in an environment including aqueous KOH). The
carboxylate
moieties may act as a hydrophilic portion or "head" of the molecule. The
hydrophilic portions
can directly interface with the surrounding aqueous environment, while the
rest of the molecule,
which may be a lipophilic portion or "tail", may be embedded in the wax.
[0043] A stabilizer capable of hydrogen bonding to carboxylate
moieties (e.g., PVOH
or ethylene-vinyl alcohol-vinyl acetate terpolymer as described above) may be
used in the wax
emulsion. The polar nature of the carboxylate moiety may offer an optimal
anchoring point for a
stabilizer chain through hydrogen bonding. When stabilizer chains are firmly
anchored to the
carboxylate moieties as described above, the stabilizer may provide emulsion
stabilization
through steric hindrance. In embodiments where the wax emulsion is
subsequently dispersed in a
wallboard (e.g., gypsum board) system, all the water may be evaporated away
during wallboard
manufacture. The stabilizer may then function as a gate-keeper for repelling
moisture.
Decreasing the solubility of the stabilizer in water may improve the moisture
resistance of the
wax emulsion and the wallboard. For example, fully hydrolyzed PVOH may only
dissolve in
heated, and not cool, water. For another example, ethylene-vinyl alcohol-vinyl
acetate
terpolymer may be even less water soluble than PVOH. The ethylene repeating
units may reduce
the overall water solubility. Other stabilizer materials are also possible.
For example, polymers
with hydrogen bonding capability such as those containing specific functional
groups, such as
alcohols, amines, and thiols, may also be used. For another example, vinyl
alcohol-vinyl acetate-
silyl ether terpolymer can be used. An example vinyl alcohol-vinyl acetate-
silyl ether terpolymer
is Exceval R-2015, available from Kuraray Chemical Company. In some
embodiments,
combinations of stabilizers are used.
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[0044] In some embodiments, the wax emulsion comprises a base. For
example, the
wax emulsion may comprise an alkali metal hydroxide, such as potassium
hydroxide or other
suitable metallic hydroxide, such as aluminum, barium, calcium, lithium,
magnesium, sodium, r
zinc hydroxide, and/or metal siliconates. These materials may serve as
saponifying agents. Non-
metallic bases such as derivatives of ammonia as well as amines (e.g.,
monoethanoline, diethanol
or triethanol amine) can also be used. In some embodiments, potassium
siliconate or imidazole
could be used as a base. Combinations of the above-mentioned materials are
also possible. If
included in the wax emulsion, potassium hydroxide is preferably present in an
amount of 0% to
1%, more preferably about 0.1% to about 0.5% by weight of the wax emulsion.
[0045] In some embodiments, an exemplary wax emulsion comprises: about
30% to
about 60% by weight of water; about 0.1% to about 5% by weight of a
lignosulfonic acid or a
salt thereof; about 0% to about 1% by weight of potassium hydroxide; about 30%
to about 50%
by weight of wax selected from the group consisting of paraffin wax, slack wax
and
combinations thereof; and about 0.1% to about 10% montan wax, and about 0.1 to
5% by weight
of ethylene-vinyl alcohol-vinyl acetate terpolymer.
[0046] The wax emulsion may further include other additives, including
without
limitation additional emulsifiers and stabilizers typically used in wax
emulsions, flame
retardants, lignocellulosic preserving agents, fungicides, insecticides,
biocides, waxes, sizing
agents, fillers, binders, additional adhesives and/or catalysts. Such
additives are preferably
present in minor amounts and are provided in amounts which will not materially
affect the
resulting composite board properties. Preferably no more than 30% by weight,
more preferably
no more than 10%, and most preferably no more than 5% by weight of such
additives are present
in the wax emulsion.
[0047] Shown in the below Table I is an example embodiments of a wax
emulsion,
although other quantities in weight percent may be used.
Table I: Example Wax Emulsion Composition
Raw Material Quantity in Weight Percent
Water 58
Polyvinyl alcohol 2.70
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Dispersant (Optional) 1.50
Paraffin Wax 34.30
Montan Wax 3.50
Biocide 0.02
[0048] Table II below shows another example of a wax emulsion. In this
embodiment, stearic acid is used in place of montan wax.
Table II: Example Wax Emulsion Composition
Raw Material Quantity in Weight Percent
Water 50.48%
Polyvinyl alcohol 3.06%
Monoethanol amine 0.08%
Paraffin Wax 44.96%
Stearic Acid 0.08%
Biocide 0.02%
[0049] The wax emulsion may be prepared using any acceptable
techniques known in
the art or to be developed for formulating wax emulsions, for example, the
wax(es) are
preferably heated to a molten state and blended together (if blending is
required). A hot aqueous
solution is prepared which includes any additives such as emulsifiers,
stabilizers, etc., ethylene-
vinyl alcohol-vinyl acetate terpolymer (if present), potassium hydroxide (if
present) and
lignosulfonic acid or any salt thereof The wax is then metered together with
the aqueous
solution in appropriate proportions through a colloid mill or similar
apparatus to form a wax
emulsion, which may then be cooled to ambient conditions if desired.
In some embodiments, the improved wax emulsion may be incorporated with or
coated on
various surfaces and substrates. For example, the improved wax emulsion may be
mixed with
gypsum to form a gypsum wallboard having improved moisture resistance
properties.
[0050] For a general understanding of an example embodiment of the
method of
making the composition of the disclosure, reference is made to the flow
diagram in FIG. 1. As
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shown in 101, first the wax components may be mixed in an appropriate mixer
device. Then, as
shown in 102, the wax component mixture may be pumped to a colloid mill or
homogenizer. As
demonstrated in 103, in a separate step, water, and any emulsifiers,
stabilizers, or additives (e.g.,
ethylene-vinyl alcohol-vinyl acetate terpolymer) are mixed. Then the aqueous
solution is
pumped into a colloid mill or homogenizer in 104. Steps 101 and 103 may be
performed
simultaneously, or they may be performed at different times. Steps 102 and 104
may be
performed at the same time, so as to ensure proper formation of droplets in
the emulsion. In
some embodiments, steps 101 and 102 may be performed before step 103 is
started. Finally, as
shown in 105, the two mixtures from 102 and 104 are milled or homogenized to
form an aqueous
wax emulsion.
[0051] Some or all steps of the above method may be performed in open
vessels.
However, the homogenizer, if used, may use pressure in its application.
[0052] Advantageously in some embodiments, the emulsion, once formed,
is cooled
quickly. By cooling the emulsion quickly, agglomeration and coalescence of the
wax particles
may be avoided.
[0053] In some embodiments the wax mixture and the aqueous solution
are combined
in a pre-mix tank before they are pumped into the colloid mill or homogenizer.
In other
embodiments, the wax mixture and the aqueous solution may be combined for the
first time in
the colloid mill or homogenizer. When the wax mixture and the aqueous solution
are combined
in the colloid mill or homogenizer without first being combined in a pre-mix
tank, the two
mixtures may advantageously be combined under equivalent or nearly equivalent
pressure or
flow rate to ensure sufficient mixing.
[0054] In some embodiments, once melted, the wax emulsion is quickly
combined
with the aqueous solution. While not wishing to be bound by any theory, this
expedited
combination may beneficially prevent oxidation of the wax mixture.
Water-Resistant Joint Compound
[0055] Embodiments of the disclosed wax emulsion can be used to form a
water-
resistant joint compound. The joint compound can be used to cover, smooth, or
finish gaps in
boards, such as joints between adjacent boards, screw holes, and nail holes.
The joint compound
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can also be used for repairing surface defects on walls and applying texture
to walls and ceilings
amongst numerous other applications. The joint compound can also be specially
formulated to
serve as a cover coat on cement and concrete surfaces. The joint compound can
be particularly
useful in locations where there is high humidity, such as bathrooms, to
prevent molding or other
deleterious effects.
[0056] Wax emulsions can be particularly advantageous for use in a
joint compound
as compared to, for example, non-emulsified and/or non-stabilized waxes such
as melted PEG
M750. These non-emulsified waxes can impart severe deleterious effects on the
adhesion
properties of a joint compound. Therefore, if the non-emulsified wax is to be
used at all, it must
be added in very low levels. On the other hand, wax emulsions, such as those
described herein,
can advantageously increase the adhesion properties of a joint compound, at
least due to the
adhesive effects of the stabilizer, and thus can be added at higher dosage
levels. The wax
emulsions can then be useful as they can provide both low dust properties as
well as water
repellency to the joint compound. In some embodiments, the wax emulsion can
act as a
dedusting agent. The wax emulsion can soften or melt when friction is applied,
such as during
cutting or sanding. Accordingly, dust can be agglomerated by the softened wax
emulsion, where
it can be securely held.
[0057] Embodiments of the joint compound can be applied in thin layers
to a surface.
The joint compound can be applied by, for example, using a trowel or other
straight edged tool.
However, the application and thickness of the layers of joint compounds is not
limiting. Further,
multiple layers may be applied in order to obtain a smooth, attractive
finished wall. The number
or layers applied is not limiting. In some embodiments, each layer can be
allowed to dry prior to
application of the next layer. In some embodiments, a second layer can be
applied when the first
layer is only partially dried. In some embodiments, the joint compound can be
spread over mesh
or tape used to connect wallboards. In some embodiments, the joint compound
may also be used
to patch and texture interior walls. In some embodiments, the joint compound
can be made of
water, preservative, calcium carbonate, mica, clay, thickener, binder (e.g.,
latex binder), and a
wax emulsion. In addition to a latex binder, other water soluble binders, such
as polyvinyl
alcohol, can be used as well. Other materials, such as talc, binders, fillers,
thickening agents,
preservatives, limestone, perlite, urea, defoaming agents, gypsum latex,
glycol, and humectants
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can be incorporated into the joint compound as well or can substitute for
certain ingredients (e.g.,
talc can be used in place of, or in addition to mica; gypsum can be used in
place of, or in addition
to calcium carbonate, etc.). In some embodiments, the calcium carbonate can be
replaced either
wholly or partially with a surface micro-roughened filler that can further
enhance the joint
compound's hydrophobicity. In some embodiments, CalcimattTM, manufactured by
Omya AG,
can be used. In some embodiments, cristobalite (silicon dioxide) such as
Sibelite M3000,
manufactured by Quarzwekre, can be used. These fillers can be used alone or in
combination.
[0058] In some embodiments, the joint compound can be mixed in water.
This
mixture can then be applied to a surface, e.g., hole or joint, and can be
allowed to dry. Once the
water evaporates from the mixture, a dry, relatively hard cementitious
material can remain. In
some embodiments, shrinkage may occur upon drying.
[0059] FIG. 2 shows an example of a wall system incorporating an
embodiment of a
water-resistant joint compound. As shown, the wall system can be made of a
plurality of boards
202. There is no limit to the amount of boards or the positioning of boards
next to one another.
Where two boards 202 are adjacent to one another, a gap, or joint, can be
formed. While the
boards 202 themselves may be water-resistant, the joints may allow for
moisture to pass through.
Therefore, embodiments of the water-resistant joint compound 204 can be spread
across the
joints. The compound 204 can be spread on the joint to completely cover the
joint. In some
embodiments, the boards 202 can also contain holes. These holes can be formed
by nailing the
boards 202 into studs, or other attachment means. Regardless of the reason for
the hole, the
compound 206 can also be used to cover the holes. The compound 206 can insert
partial through
the holes, or can cover the top of the holes, or both. The compound 206 can
cover any fastener,
e.g. a screw or nail, that is located in the hole. In some embodiments,
compound 206 and 204 are
the same compound. The application and thickness of the compound 204/206 on
the boards 202
is not limiting, and common methods of application can be used.
[0060] An example formula range of an embodiment of a water-resistant
joint
compound using the above disclosed wax is shown in the below Table III:
Table III: Example Composition of a Water-Resistant Joint Compound
Component Range
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Water 20 ¨ 55%
Preservatives 0.02¨ 1.0%
Calcium Carbonate 10 ¨ 50%
Mica 0.5 ¨ 10%
Attapulgite Clay 0.2 ¨ 10%
Talc 0.0 ¨ 10%
Perlite 0.0 ¨ 40%
Polyethylene oxide 0.0 ¨ 10%
Polyether siloxane 0.0 ¨ 10%
Wax emulsion 0.1 ¨ 20%
Latex binder 0.5 ¨ 10%
Cellulose ether thickener 0.1 ¨ 8.0%
[0061] Further, an example of a specific formulation for a water-
resistant joint
compound can is shown in the below Table IV, although other weight percentages
may be used:
Table IV: Example Composition of a Water-Resistant Joint Compound
Compound Wt. %
Preservative 0.01
Wetting Agent 0.05
Latex Binder 5.89
Water 34.60
Wax emulsion 7.36
Cellulose ether 0.55
Attapulgite clay 1.84
Mica 7.36
Calcium Carbonate 33.86
Expanded Perlite 8.47
[0062] Another embodiment of a water-resistant ready-mix joint
compound formula
is shown in the below Table V. In this embodiment, an optional potassium
siliconate additive is
incorporated.
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Table V
Raw Material Wt. %
Preservative 0.20%
Latex (CPS 716) 6.50%
Water 36.70%
Wax Emulsion 3.80%
Potassium Siliconate (Silres BS 16) 0.20%
Cellulose Ether 0.60%
Clay (Attagel 30) 1.90%
Mica 6.10%
Limestone (MW 100) 35.20%
SilCel 43-34 8.80%
[0063] The wax emulsion used in the joint compound can be formed from
slack wax,
montan wax, paraffin wax, carnauba wax, tall oil, sunflower wax, rice wax, and
any other natural
or synthetic wax containing organic acids and/or esters, or combinations
thereof. For example,
synthetic wax used in the joint compound may comprise ethylenic polymers or
hydrocarbon
types, optionally derived via Fischer-Tropsch synthesis, or combinations
thereof. By way of
further example, synthetic wax used in the joint compound may comprise
polyethylene glycol,
methoxypolyethylene glycol, or combinations thereof Optionally, the synthetic
waxes can be
added in concentrations ranging from about 0.1% to about 8% of the dry weight
of the joint
compound or from about 0.5% to about 4.0% of the dry weight of the joint
compound. In some
embodiments, the wax emulsion is stabilized by polyvinyl alcohol.
[0064] In some embodiments, perlite can be used in a joint compound
to, for
example, control the density, shrinkage, and crack resistance of the joint
compound. In some
embodiments, perlite need not be used (e.g., where weight is not as much of a
factor).
[0065] In some embodiments, mica can be used in a compound as well.
Mica, which
is a low bulk density mineral, may be used as a filler or extender, and may
also improve crack
resistance of the joint compound.
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[0066] In some embodiments of the joint compound gypsum (calcium
sulfate
dihydrate) can also be used. Gypsum can be used to replace calcium carbonate,
or can be used in
conjunction with calcium carbonate. In some embodiments, talc can be included
in a joint
compound to, for example, enhance application properties and can also be used
as a white
extender pigment.
[0067] In some embodiments, clay can be used in a joint compound as,
for example,
a non-leveling agent and/or a thickening agent that can control the viscosity
or rheology of the
final product. Clay can also help enhance or create the water-holding
properties of the joint
compound.
[0068] In some embodiments, thickeners can be used to control the
viscosity, affect
the rheology, and affect the water holding characteristics of a joint
compound. For example,
cellulose ether can be used as a thickener.
[0069] In some embodiments, binders can be used in a joint compound
to, for
example, improve bonding to the substrate such as wallboard.
[0070] In some embodiments, a glycol can be used in a joint compound
to provide
functional properties to the joint compound such as wet edge, open time,
controlling drying time,
and freeze/thaw stability.
[0071] In some embodiments, other rheology modifiers can also be used
in
conjunction with, or instead of, some of the above described compositions.
[0072] In some embodiments, fillers can be used in the joint compound.
For example,
calcium carbonate, calcium sulfate hemihydrate, or calcium sulfate dehydrate
can all be used as
fillers, though other materials can be used as well. Further, thickeners,
preservatives, binders,
and other additives can be incorporated into the joint compound.
[0073] Other additives can also be added to the described joint
compound in addition
to the wax emulsion. In some embodiments, metal siliconate salts such as, for
example,
potassium siliconate, as well as silicone based compounds such as, for
example, poly hydrogen
methyl siloxane and polydimethyl siloxane, could provide advantageous water
resistance to a
joint compound. In some embodiments, fluorinated compounds and stearate-based
salts could
also be used to provide advantageous water resistance.
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Any suitable siliconate may be used. Suitable examples of siliconates include,
but are not
necessarily limited to, Na0Si(OH)2(CH2)3NH2,
Na0(OH)Si(CH3)(CH2)3NE12,
1(00.5(-10)1.5Si(CH3)(CH2)3NH2, KOSi(OH)2(CH2)3NH2, LiO(OH)Si(CH3)(CH2)3NH2,
and
KO(HO)Si(CH3)(CH2)3NH2. Such siliconates are discussed in U.S. Pat. App. No.
20070028809
to Wacker et al, which is incorporated fully by reference herein.
In at least one embodiment, the siliconate is provided in an aqueous solution
which is then mixed
into the joint compound formulation. The siliconate solids in such aqueous
solution is from
about 10-70% by weight. In these embodiments, the siliconate may be present in
the joint
compound formulation in an amount of 0.010% to about 5%, based on the total
weight of the
joint compound formulation (on a dry basis, that is after the joint compound
has been applied
and dried). Stated another way, the siliconate may be present in the joint
compound in an
amount defined by any one of following numbers, by weight of the dried joint
compound:
0.01, 0.02, 0.03, 0.04, 0.05, ..Ø10,... , 0.20, .. , 1.0, .. , 2.0, ...,
5Ø
The siliconate can also be in an amount within a range defined by any two
numbers above,
including the endpoints.
In one embodiment, the latex binder used in the joint compound ranges from
about 0.5 to about
wt.%. Stated another way, the latex binder may be present in the joint
compound in an
amount defined by any one of following numbers, by weight of the joint
compound:
0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9,
2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6,
2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1,
4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8,
4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3,
6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0,
7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5,
8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2,
9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, and 10Ø
The latex binder can also be in an amount within a range defined by any two
numbers above,
including the endpoints. With the joint compound preparation above, this
invention allows for a
very small amount of latex binder being included in the joint compound but
without any adverse
impact to the physical characteristics of the joint compound. For example, the
water repellency
in fact improved for a joint compound in which the latex binder content was
reduced. For
example, in sample 3 (Table 1), 5.8% latex binder was used with 0.2% potassium
siliconate, the
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contact angle was 91 and the Cobb value was 69. When the binder content was
reduced to 4.0%
by weight of the joint compound, the contact angle improved 20%, to 110, and
the Cobb value
by more than 95%. In one embodiment, the present invention envisions reducing
the latex
binder content progressively to achieve the desired contact angle as well as
the Cobb value.
In at least one embodiment, the joint compound may comprise a cellulose ether,
for example, a
hydroxy-based cellulose ether. In at least one embodiment, the cellulose ether
is present in the
joint compound in an amount of 0.050 to 3.0 weight percent, based on the total
weight of the
joint compound. Stated another way, the cellulose ether may be present in the
joint compound in
an amount defined by any one of following numbers, by weight of the dried
joint compound:
0.05,. . Ø10,. . . , 0.20, . . , 1.0,. . , 2.0, . . ., 3Ø
The cellulose ether can also be in an amount within a range defined by any two
numbers above,
including the endpoints.
Any suitable cellulose ether may be used. Suitable examples of hydroxy-based
cellulose ethers
include, but are not necessarily limited to, hydroxyethyl cellulose ether,
hydroxypropyl cellulose
ether, hydroxyethyl methyl cellulose ether, hydroxypropyl methyl cellulose
ether, carboxymethyl
cellulose ether, methyl hydroxy cellulose ether, hydroxymethyl cellulose
ether, and
methylhydroxyethyl cellulose ether.
In at least one embodiment, suitable cellulose ether, for example, hydroxy-
based cellulose ethers
have a molecular weight of from 50,000 to 500,000, and preferably from 75,000
to 150,000, with
a chain length of from 300 to 1500 repeating units, and more preferably from
400 to 700. Stated
another way, the molecular weight of the cellulose ether can be any one of the
following
numbers:
50,000; 60,000; 70,000; 80,000; 90,000; 100,000; 110,000; 120,000; 130,000;
140,000; 150,000;
160,000; 170,000; 180,000; 190,000; 200,000; 210,000; 220,000; 230,000;
240,000; 250,000;
260,000; 270,000; 280,000; 290,000; 300,000; 310,000; 320,000; 330,000;
340,000; 350,000;
360,000; 370,000; 380,000; 390,000; 400,000; 410,000; 420,000; 430,000;
440,000; 450,000;
460,000; 470,000; 480,000; 490,000; and 500,000.
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The molecular weight of the cellulose ether can also be within a range defined
by any two
numbers above, including the endpoints.
The cellulose ethers, for example, hydroxy-based cellulose ethers should also
have a viscosity
range of from 1000 to 100,000 cps, and more preferably from 2000 to 10,000
cps, as measured
by 2% solution in water at 20 C, according to ASTM D 2363. Stated another way,
the viscosity
of the cellulose ether can be any one of the following numbers, measured in cp
units:
1,000; 2,000; 3,000; 4,000; 5,000; 6,000; 7,000; 8,000; 9,000; 10,000; 11,000;
12,000; 13,000;
14,000; 15,000; 16,000; 17,000; 18,000; 19,000; 20,000; 21,000; 22,000;
23,000; 24,000;
25,000; 26,000; 27,000; 28,000; 29,000; 30,000; 31,000; 32,000; 33,000;
34,000; 35,000;
36,000; 37,000; 38,000; 39,000; 40,000; 41,000; 42,000; 43,000; 44,000;
450,000; 46,000;
47,000; 48,000; 49,000; 50,000; 51,000; 52,000; 53,000; 54,000; 55,000;
56,000; 57,000;
58,000; 59,000; 60,000; 61,000; 62,000; 63,000; 64,000; 65,000; 66,000;
67,000; 68,000;
69,000; 70,000; 71,000; 72,000; 73,000; 74,000; 75,000; 76,000; 77,000;
78,000; 79,000;
80,000; 81,000; 82,000; 83,000; 84,000; 85,000; 86,000; 87,000; 88,000;
89,000; 90,000;
91,000; 92,000; 93,000; 94,000; 950,000; 96,000; 97,000; 98,000; 99,000; and
100,000.
The molecular weight of the cellulose ether can also be within a range defined
by any two
numbers above, including the endpoints.
Hydroxy-based cellulose ethers such as these are normally identified by their
viscosity rather
than molecular weight.
In at least one embodiment, the cellulose ether is methyl cellulose ether, for
example Methocel
manufactured by Dow Chemical Co. Methocel products are available in two basic
types:
methylcellulose and hydroxypropyl methyl cellulose ether. Both types of
Methocel have the
polymeric backbone of cellulose, a natural carbohydrate that contains basic
repeating structure of
anhydroglucose units. Methylcellulose ether is made using only methyl
chloride.
Hydroxypropyl methylcellulose ether uses propylene oxide in addition to methyl
chloride to
obtain hydroxypropyl substitution on the anhydroglucose units. This
substituent group, -
OCH2CH(OH)CH3-, contains a secondary hydroxyl on the number two carbon and may
be
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considered to form a propylene glycol ether of cellulose. These products
possess varying ratios
of hydroxypropyl and methyl substitution. The amount of substituent groups on
the
anhydroglucose units of cellulose can be designated by weight percent or by
the average number
of substituent groups attached to the ring, a concept known to cellulose
chemists as "degree of
substitution" (DS).
If all three available positions on each unit are substituted, the DS is
designated as 3; if an
average of two on each ring are reacted, the DS is designated as 2, etc. The
number of
substituent groups on the ring determines the properties of the various
products. For example,
Methocel A cellulose ether contains 27.5 to 31.5% methoxyl, or a methoxyl DS
of 1.64 to
1.92, a range that yields maximum water solubility. A lower degree of
substitution gives
products having lower water solubility, leading to products that are only
soluble in caustic
solutions. Higher degrees of substation produce methylcellulose products that
are soluble only
in organic solvents. In the Methocel E, F and K cellulose ether products, the
methoxy
substitution is still the major constituent. The molar substitution (MS)
reports the number of
moles of hydroxypropyl groups per mole of anhydroglucose. In the Methocel J
and 310 series
products, the hydroxypropyl substitution is about 50% of the total
substitution. All these soluble
methyl cellulose ethers can be used in embodiments of the present invention.
Table 1
Siliconate containing water resistant joint
compound formulas
Batch ID Control 1 2 3 4
Acticide CBM2 0.1 0.1 0.1 0.1 0.1
Fungitrol 404DS 0.11 0.1 0.1 0.1 0.1
Latex CPS 716 8.2 5.9 5.8 4.7 4.0
Water 40.8 40.4 37.3 37.7 38.0
Wax Emulsion ---- 3.1 3.1 3.1
AQ484
Potassium 1 0.2 0.2 0.2
siliconate (Silres
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BS 16)
Cellulose ether 0.5 0.6 0.4 0.4 0.4
(MOT 60000
YP4)
Cellulose ether ---- 0.2 0.2 0.2
(Methocel 240S)
Attagel 30 1.8 1.9 1.9 2.0 2.0
4K Mica 7.2 7.4 6.2 6.3 6.3
Calcium 33 34.1 35.7 36.1 36.4
carbonate (Imerys
MW 100)
Expanded perlite 8.2 8.5 8.9 9.0 9.1
(SilCel 43-34)
Total wt. 100 100 100 100 100
Total solids 54.9 55.6 56.3 56.5 56.5
% Solids 54.91% 55.55% 56.30% 56.45% 56.50%
Active 0 0.34% 0.07% 0.07% 0.07%
siliconate in wet
compound
Active 0 0.61% 0.12% 0.12% 0.12%
siliconate in dry
compound
Wt. fraction of 0 0 2.2% 2.2% 2.2%
wax solids in dry
compound
Joint compound 0 86 91 98 110
contact angle
Cobb values 69 7 3
(unsanded, 30
mins.)
Cobb values 482 24 8 1
(sanded, 30
mins.)
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[0074] In some embodiments, the wax emulsion can be replaced by other
materials
(or used in combination with other materials) which may also increase the
water repellency of
the joint compound. For example, metal siliconate salts such as, for example,
potassium
siliconate, as well as silicone based compounds such as, for example, poly
hydrogen methyl
siloxane and polydimethyl siloxane, could be used in place of the wax emulsion
(or in
combination with the wax emulsion). In some embodiments, fluorinated compounds
and
stearate-based salts could also be used instead of the wax emulsion or in
combination with the
wax emulsion. The compounds described in this paragraph can be used alone as a
replacement
for wax emulsion, or can be used in combination with each other.
[0075] In some embodiments, the disclosed joint compound can cover a
joint or hole
and provide resistance to water penetration. Further, the joint compound is
formulated to
properly adhere to any boards that the compound is placed onto. With regards
to adhesion,
embodiments of the joint compound can have at least about 90%, 95%, 99%, or
100% bond
according to an ASTM C474 peel test, hereby incorporated by reference in its
entirety. Further,
the joint compound can have adequate sag resistance, compatibility, and
contact angle.
[0076] In some embodiments, the joint compound can provide water
repellency. One
indication of water repellency is the contact angle of a water droplet on the
surface of the dried
joint compound. A water droplet surface that has a contact angle of less than
90 degrees would
generally be considered hydrophilic (the smaller the contact angle the greater
the hydrophilicity).
Conversely, surfaces that cause a water droplet to have a contact angle
greater than 90 degrees
are generally considered hydrophobic. Commercially available ready mix joint
compound have
contact angles of about zero degrees, meaning that a drop of water placed on
such a surface will
rapidly spread and wet out on the surface. Embodiments of the disclosed joint
compound can
have a contact angle greater than about 60, 70, 80, 90, 100, 110, 120, or 130.
In some
embodiments, the joint compound can have a contact angle between about 60 and
130, about 115
and 130, or about 118-120. Embodiments of the disclosed joint compound,
containing a wax
emulsion, can have an average contact angle of about 98 degrees (based on an
average of six
measurements), or greater than about 98 degrees, indicating a hydrophobic
surface.
In some embodiments, the contact angle can be between about 60 to about 110
degrees, or about
60, about 70, about 80, about 90, about 100, or about 110 degrees.
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In some embodiments, the contact angel can be any number selected from the
following numbers
in degrees:
60, 61, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79,
80, 81, 82, 83, 84, 85, 86,
87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104,
105, 106, 107, 108,
109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123,
124, 125, 126, 127,
128, 129, and 130.
The contact angle can also be within a range defined by any two numbers above,
including the
endpoints.
This contact angle value can be modified, higher or lower, by adjusting the
dosage level of the
wax emulsion in the joint compound formula.
[0077] In some embodiments, the disclosed joint compound can be
resistant to
seepage of water into itself This attribute can be generally determined by
measuring the Cobb
value of the compound. A Cobb value is a quantitative determination of how
much water a
substrate absorbs in a predetermined timeframe. For example, a leveled surface
of an
embodiment of the disclosed joint compound was applied on to a piece of
commercially
available regular 1/2" gypsum wallboard. When dried, the joint compound was
sanded to a
uniform 1/4" thickness above the wallboard. A 100 cm2 Cobb testing ring was
then fitted on top of
the joint compound and the ring filled with 100 grams of water to begin the
test. After two hours,
the water was discarded and the Cobb ring disassembled. The wallboard/joint
compound combo
was then weighed to determine how much water was absorbed. This gram weight of
water was
multiplied by 100 to give the Cobb value of water absorbed per square meter.
For a control joint
compound (standard commercially available lightweight joint compound), the 30
minute Cobb
value was 1406 grams of water per square meter. Commercially available
lightweight joint
compounds can have 30 minute Cobb values as high as 1600 grams per square
meter. For
comparison, the moisture resistant wallboard ("Green Board") upon which the
joint compound is
applied has a 30 minute Cobb value of less than 100. Hence, filling a joint
with a joint
compound with a Cobb value several times higher than that of the corresponding
wallboard can
effectively create a weak link. For more satisfactory protection of the wall
system, the Cobb
value of the joint compound can formulated to be similar to that of the
wallboard.
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[0078] For further comparison, a joint compound formula containing
6.7% of the wax
emulsion had a 30 minute Cobb value of about 65 grams per square meter, which
is significantly
less absorbing. In some embodiments the disclosed joint compound can have a 30
minute Cobb
value range of between about 5.0 to about 200 grams per square meter, or about
5.0, about 10,
about 20, about 30, about 40, about 50, about 100, about 150, or about 200
grams per square
meter. In some embodiments, the disclosed joint compound can have a 30 minute
Cobb value
range of less than about 200, less than about 150, less than about 100, less
than about 50, less
than about 40, less than about 30, or less than about 20 grams per square
meter. In some
embodiments, the disclosed joint compound can have a 30 minute Cobb value of
about 50, about
100, about 150, about 200, about 300, about 400, or about 500 grams per square
meter.
[0079] Water resistance of the joint compounds was also evaluated via
an
adapted/modified version of ASTM C473, hereby incorporated by reference in its
entirety. In
this method, a weighed sample is submerged in water for 2 hours after which it
is taken out,
excess water dabbed off and then weighed again. The increase in weight after
submersion
represents the amount of water absorbed by the sample. The less water that is
absorbed, the more
water resistant the compound would be.
[0080] A metal ring of 2.5" internal diameter (and 2/5" internal
height) was placed on
a silicone coated paper (for non-stick). A sample of conventional ready-mixed
joint compound
was then applied inside the ring such that it occupied the entire open volume
of the ring. The
conventional joint compound was allowed to dry on a lab bench overnight, then
transferred into
a forced air oven at 50 C where drying was continued for another 5 hours
(until constant
weight) to form a patty. The same procedure was performed with the disclosed
wax emulsion
joint compound, forming a second patty. The patties were then lightly sanded
all around (to
ensure patty smoothness), weighed, and then submerged in a water bath in a
manner similar to
ASTM Method C473. To prevent sample flotation when in the water, a 100 gram
weight was
placed on each sample through the duration of the test. As in ASTM C473, the
joint compound
patties were removed from the water bath after 2 hours, excess water patted
off, and weighed.
The results of the testing are shown in the below Table VI.
Table VI: Testing Results
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Joint compound % Water absorption Sample condition
Sheetrock Lightweight Dust Control 32% Broke apart
Disclosed Joint Compound with 6.7% 5.2% Maintained structural and
Wax Emulsion dimensional integrity
[0081]
While the commercial joint compound crumbled at the end of the test and
could not be reused or retested, the patty containing the disclosed wax
emulsion joint compound
retained its structural and dimensional integrity. The patty containing the
disclosed wax
emulsion was in fact dried and then re-submerged to repeat the test. The
second test gave a value
of 5.4% and a third submersion test on the same sample gave a value of 4.0%.
In some
embodiments, the wax emulsion joint compound can have a % water absorbance
from about 4 to
about 6. In some embodiments, the wax emulsion joint compound can have a %
water
absorbance of about 6 or less, about 5.4 or less, about 5.2 or less, or about
4 or less. The
structural and dimensional integrity of the wax emulsion containing patty
remained intact and
unchanged through the third testing cycle, suggesting that it could continue
to survive multiple
cycles of submersion and retesting. By contrast, the standard commercially
available joint
compound could not survive a single test cycle.
[0082]
Standard joint compounds typically have a pH of 8 ¨ 9, primarily as a result
of
the high calcium carbonate content. However, it can be undesirable for the pH
of j oint compound
to be much higher than 9.0 because of the corrosive effects such high pH would
have on
worker's finishing tools as well as on the skin. Advantageously, the wax
emulsion used in
embodiments of the disclosed joint compound can have a pH of between 7.0 and
8.0, meaning
that adding it as a component in a joint compound formulation does not result
in an overall
increase in the pH of the joint compound. This can advantageously be done
without the addition
of an acid. In some embodiments, an acid can be used. Accordingly, the pH of
the joint
compound can be about 7.0 or about 8.0, or below about 9.0 or below about 8Ø
[0083]
In some embodiments, once the joint compound is applied, the compound
may be sanded. This sanding can be generally done to smooth out the finish of
the compound, or
can be used to remove excess material. However, sanding of the joint compound
can have an
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additional benefit in that the sanding can increase the overall adherence of
paint, or other
coating, onto the joint compound.
Water-Resistant Products
[0084] Embodiments of the disclosed wax emulsion can be used to form
many
different water-resistant products. For example, embodiments of the wax
emulsion can be
incorporated into building materials such as asphalt (e.g., comprising a
viscous liquid or semi-
solid form of petroleum), concrete (e.g., comprising aggregate or filler,
cement, water, various
chemical and/or mineral admixtures, etc.), stucco, cement (e.g., formed from
or comprising
calcium carbonate, clay, gypsum, fly ash, ground granulated blast furnace
slag, lime and/or other
alkalis, air entrainers, retarders, and/or coloring agents) or other binders.
In some embodiments,
the wax emulsion can be incorporated into concrete cover coat formulations,
such as those used
for filling, smoothing, and/or finishing interior concrete surfaces, drywall
tape, bead embedment,
skimcoating, and texturing drywall. Further, embodiments of the wax emulsion
can be
incorporated into concrete and/or cement mixtures as a water repellent
additive. Therefore,
embodiments of the wax emulsion can be incorporated into pourable concrete
and/or cement that
can be used, for example, for foundations in home constructions. Additionally,
embodiments of
the wax emulsion can be used in cinder blocks as well as other similar
concrete or cement based
products. In some embodiments, a water-resistant building material can be
formed with cement,
and wax emulsion, or silicone, or siloxane, or siliconate, or fluorinated
compound, or stearate, or
combinations thereof.
[0085] Embodiments of the wax emulsion can also be incorporated into
boards, such
as cement boards (e.g., a relatively thin board, comprising cement bonded
particle boards and
cement fiber (e.g., comprising cement, fillers, cellulose, mica, etc.), which
may be 0.25-0.5 inch
thick or which may be thicker or thinner), and/or cement board formulations.
Therefore, the wax
emulsion can be used to provide additional water resistance of the boards, and
potentially
prevent water or water vapor from penetrating the boards. In some embodiments,
a water-
resistant cement board can be formed with cement, and wax emulsion, or
silicone, or siloxane, or
siliconate, or fluorinated compound, or stearate, or combinations thereof,
wherein the
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combination of cement and wax emulsion, or silicone, or siloxane, or
siliconate, or fluorinated
compound, or stearate, or combinations thereof is formed into the shape of a
board.
[0086] Additionally, embodiments of the wax emulsion can be
incorporated into
paint and/or paint formulations (e.g. a liquid, liquefiable, or mastic
composition that, after
application to a substrate in a thin layer, converts to a solid film), such as
paint that may be used
to protect, color, or provide texture to a substrate. This can be done to
impart water repellency,
or water resistance, to the paint. The type of paint is not limiting, and
embodiments of the wax
emulsion can be incorporated into oil, water, acrylic, or latex based paints,
including paints that
may be pigmented to add color to the substrate on which the paint is applied.
This water resistant
paint can then be used on exterior and interior surfaces of buildings, as well
as other products
such as vehicles (e.g. cars, boats, and planes), toys, furniture. In some
embodiments, a water-
resistant paint can be formed comprising paint and wax emulsion, or silicone,
or siloxane, or
siliconate, or fluorinated compound, or stearate, or combinations thereof
[0087] From the foregoing description, it will be appreciated that
inventive devices
and approaches for water resistant products and wax emulsions have been
disclosed. While
several components, techniques and aspects have been described with a certain
degree of
particularity, it is manifest that many changes can be made in the specific
designs, constructions
and methodology herein above described without departing from the spirit and
scope of this
disclosure.
[0088] Certain features that are described in this disclosure in the context
of separate
implementations can also be implemented in combination in a single
implementation.
Conversely, various features that are described in the context of a single
implementation can also
be implemented in multiple implementations separately or in any suitable
subcombination.
Moreover, although features may be described above as acting in certain
combinations, one or
more features from a claimed combination can, in some cases, be excised from
the combination,
and the combination may be claimed as any subcombination or variation of any
subcombination.
[0089] Moreover, while methods may be depicted in the drawings or
described in the
specification in a particular order, such methods need not be performed in the
particular order
shown or in sequential order, and that all methods need not be performed, to
achieve desirable
results. Other methods that are not depicted or described can be incorporated
in the example
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methods and processes. For example, one or more additional methods can be
performed before,
after, simultaneously, or between any of the described methods. Further, the
methods may be
rearranged or reordered in other implementations. Also, the separation of
various system
components in the implementations described above should not be understood as
requiring such
separation in all implementations, and it should be understood that the
described components and
systems can generally be integrated together in a single product or packaged
into multiple
products. Additionally, other implementations are within the scope of this
disclosure.
[0090] Conditional language, such as "can," "could," "might," or
"may," unless
specifically stated otherwise, or otherwise understood within the context as
used, is generally
intended to convey that certain embodiments include or do not include, certain
features,
elements, and/or steps. Thus, such conditional language is not generally
intended to imply that
features, elements, and/or steps are in any way required for one or more
embodiments.
[0091] Conjunctive language such as the phrase "at least one of X, Y,
and Z," unless
specifically stated otherwise, is otherwise understood with the context as
used in general to
convey that an item, term, etc. may be either X, Y, or Z. Thus, such
conjunctive language is not
generally intended to imply that certain embodiments require the presence of
at least one of X, at
least one of Y, and at least one of Z.
[0092] Language of degree used herein, such as the terms
"approximately," "about,"
"generally," and "substantially" as used herein represent a value, amount, or
characteristic close
to the stated value, amount, or characteristic that still performs a desired
function or achieves a
desired result. For example, the terms "approximately", "about", "generally,"
and "substantially"
may refer to an amount that is within less than or equal to 10% of, within
less than or equal to
5% of, within less than or equal to 1% of, within less than or equal to 0.1%
of, and within less
than or equal to 0.01% of the stated amount.
[0093] Some embodiments have been described in connection with the
accompanying drawings. The figures are drawn to scale, but such scale should
not be limiting,
since dimensions and proportions other than what are shown are contemplated
and are within the
scope of the disclosed inventions. Distances, angles, etc. are merely
illustrative and do not
necessarily bear an exact relationship to actual dimensions and layout of the
devices illustrated.
Components can be added, removed, and/or rearranged. Further, the disclosure
herein of any
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particular feature, aspect, method, property, characteristic, quality,
attribute, element, or the like
in connection with various embodiments can be used in all other embodiments
set forth herein.
Additionally, it will be recognized that any methods described herein may be
practiced using any
device suitable for performing the recited steps.
[0094] While a number of embodiments and variations thereof have been
described
in detail, other modifications and methods of using and medical applications
for the same will be
apparent to those of skill in the art. Accordingly, it should be understood
that various
applications, modifications, materials, and substitutions can be made of
equivalents without
departing from the unique and inventive disclosure herein or the scope of the
claims.
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