HIGH CONCENTRATION WAX EMLESS FOR WOOD PANELS AND A PRODUCTION AND APPLICATION METHOD

Abstract

The invention relates to a method for the production of a high-concentration wax emulsion, comprising the mixing of an aqueous phase with wax under controlled pressure and temperature to achieve a dry matter content of at least 60%, whereby the wax phase is added in separate parts, each dispersed in water with a specific degree of shear. The wax emulsion produced has a lower viscosity than comparable processes, which leads to better applicability. Wax emulsions are used in wood panels as a water-repellent agent. Furthermore, the inventors demonstrate that dilution prior to use improves the water-repellent properties of the dispersed wax, which is particularly beneficial for the highly concentrated wax emulsion produced in accordance with the described production method which forms part of the present invention.

Description

2 moreeco-friendlyduetothehigherefficiencyofthewax,thereduceduseofemulsifiersand contributestoenvironmentalsustainability. DETAILEDDESCRIPTIONOFTHEINVENTION Theterm"high-concentrationwaxemulsion"refersinthepresentinventiontoawaxemulsion5 withadrymattercontentofatleast60%,whichisdesignedforuseinwood-basedpanels suchasOSB,particleboard,andMDF.ThedrymattercontentismeasuredusingtheISO1625 standard,whichspecifiesthedeterminationofnon-volatilematterinwaxemulsions. Thedrymattercontentisdeterminedbydryingasampleoftheemulsionat105°Cuntila10 constantweightisachievedandcalculatingthepercentageoftheremainingsolidmaterial relativetotheinitialsampleweight. Theterm"waxphases"refersinthepresentinventiontothemainwaxcomponentsofthe emulsion,whichcanincludemicrocrystallinewax,paraffinwax,syntheticwaxesandbiobased15 waxes.Thesewaxesarecharacterizedbytheirmeltingpointsandcrystallinestructures,with typicallyameltingpointrangeof30to90°C.Bytheterm"emulsifier"ismeantinthepresentinventionasubstanceusedtostabilizethe mixtureofwaxandwaterintheemulsion.Emulsifierscanbeusedinquantitieslowerthanin20 traditionalwaxemulsionsduetothehighconcentrationanddilutionprocessofthepresent invention.Theeffectivenessofemulsifiersinaspecificapplicationisdeterminedtoagreat extentbytheHLB(Hydrophilic-LipophilicBalance)system. Theterm"antifoamingagent"refersinthepresentinventiontoasubstanceusedtoprevent25 foamformationduringtheproductionandapplicationofthewaxemulsion.AntifoamSMIisan exampleofsuchanagent,whichistypicallyamineraloil-basedcompound. Theterm“shear”isashortertermfor“shearrate”andreferstothevelocitygradientgenerated invariousemulsifyingdevices.Velocitygradientscreateturbulenceleadingtowaxdroplet30 breakupandthuslowerparticlesizeandmorestableemulsions.Examplesofcommonshear creatingdevicesforemulsificationarehighpressurehomogenisers,rotor-statormixing devices,sonolators,colloidmillsandmicrofluidisers.Bytheterm"homogenizing"ismeantinthepresentinventiontheprocessofmixingthewater35 phaseandwaxcomponentsunderhighsheartocreateauniformemulsion.Thisprocessis typicallyperformedinahighpressurehomogenizeratapressurebetween20and500bar,to achievethedesiredviscosityandstability.Incaseofahomogenizer,theshearlevelis proportionaltothehomogenizationpressure. 40 BE2024 / 5795 3 Theterm"diluting"refersinthepresentinventiontotheprocessofaddingwatertothehigh- concentrationwaxemulsionoraddinghigh-concentrationwaxemulsiontowater,justbefore itsapplicationtoawoodpanel.Thisstepensuresthattheemulsionhastheappropriate consistencyandpropertiesforeffectiveapplicationandperformance. 5 Inanaspect,theinventionpertainstowaxemulsionswithdrymattercontenthigherthan 35%,designedforuseinwood-basedpanelssuchasOSB,particleboard,andMDF.These emulsionsareformulatedwithahigherpercentageofsolidwaxcomponents,reducingthe watercontent.Thesignificantreductioninwatercontenttranslatestolowertransportation volumesandenergyusage,therebyreducingcarbonemissionsandcontributingtomore10 sustainablemanufacturingprocesses. Thehigh-concentrationwaxemulsionsareproducedusingahigh-shearmixingprocessunder controlledpressureandtemperatureconditions.Thismethodresultsinalowerviscosityofthe waxemulsioncomparedtotraditionalmethods,evenwithahighersolidcontent.The15 emulsionsaredesignedtobedilutedjustbeforeapplication,whichreducestheneedfor emulsifiersandstabilizers,furtherloweringproductioncostsandimprovingtheoverall efficiencyofthewax. Usingalowershearleveltodisperseapartofthedispersedphasefurtherleadstolower20 energyuse,amoresustainableprocessandalowerproductioncost. Inafurtherembodiment,thewaxemulsionsmaycontainvaryingamountsofsolidcontent. Preferably,thedrymattercontentisbetween60%and75%.Thisflexibilityallowsfor customizationbasedonspecificapplicationrequirementsandmanufacturingconditions.25 Thecompositionofthehigh-concentrationwaxemulsionsincludesawaxphasethatcan consistofmorethanonewax,whichcanbemicrocrystallinewax,paraffin-based,biobased waxorsyntheticwax.Thesewaxesarecombinedwithaminimalamountofemulsifier,such ethoxylatedfattyalcoholorpolyethyleneglycolfattyacidesters,aligninderivedproduct,or30 long-chainfattyacidssuchasstearicacidtostabilizethewaxduringtheinitialmixingprocess. Analkalinecomponentsuchaspotassiumhydroxide,sodiumhydroxide,triethanolamine, diethanolamine,monoethanolamine,morpholineorammoniaoramixtureofbasesisincluded asapHcontrolagent,ensuringtheemulsionmaintainsoptimalpropertiesduringstorageand application.AdditivessuchasMergalV615andActicideMVareincorporatedaspreservatives35 toincreasetheshelf-lifeoftheemulsions,whileAntifoamSMIisusedtopreventfoam formationduringthemixingandapplicationprocesses.Thecombinationofthesecomponents resultsinahighlyefficientwaxemulsionthatprovidessuperiorwater-repellentpropertiesand enhancesthebondingstrengthofthewoodpanels.40 Inasecondaspect,presentinventionrelatestoamethodforproducingwaxemulsions comprising:dividingthewaxphaseintoatleasttwoseparatefractions;addingeachfraction BE2024 / 5795 4 ofthewaxphasetothebulkphaseinasequentialmanner;andmixingeachfractionunder shear,whereineachshearappliedtoeachsubsequentfractiondiffersfromthatappliedtothe precedingone. Inapreferredembodiment,thewaxandwaterphasearemixedusingahigh-shearmixing5 process.Thisprocessensuresthatthewaxparticlesareuniformlydispersedwithinthe emulsion,resultinginastablemixturewithreducedviscosity. Inanotherembodiment,theemulsionistypicallyproducedusingamulti-stepprocessapplying differentshearlevelsindifferentstepsoftheprocess.Thehigh-shearprocessmaybeahigh10 pressurehomogenizeroperatingatapressureof50to300bar,morepreferablybetween100 and250bar,andmostpreferablybetween150and200bar.Morepreferably,additional dispersedphaseisaddedbetweenatleastsomeofthestepsofthemulti-stepprocess,i.e.in betweenapplyingdifferentshearlevelsfurtheramountsofwaxphaseareaddedtothe mixture,whicharethendispersedundershear.15 Theoperatingtemperatureforthepreparationofthewaxemulsionispreferablybetween50 and100°C,morepreferablybetween60and90°C,morepreferablybetween70and80°C, mostpreferablyaround75°C.Thesetemperaturerangesareadvantageousastheyensure optimalmixingandstabilityoftheemulsioncomponents.20 Inoneembodiment,afirstfractionofthemassofwaxisaddedtothebulkphaseandmixed undershearinafirststep.Inapreferredembodiment,thefractionofthemassofwaxadded basedonmassoftheemulsioninthefirststepisatleast10%.Inamorepreferred,the fractionofthemassofwaxaddedbasedonmassoftheemulsioninthefirststepisatleast25 20%.Inanevenmorepreferred,thefractionofthemassofwaxaddedbasedonmassofthe emulsioninthefirststepisatleast30%.Inanevenmorepreferred,thefractionofthemass ofwaxaddedbasedonmassoftheemulsioninthefirststepisatleast40%.Inanevenmore preferred,thefractionofthemassofwaxaddedbasedonmassoftheemulsioninthefirst stepisatleast50%.Inanevenmorepreferred,thefractionofthemassofwaxaddedbased30 onmassoftheemulsioninthefirststepisatleast60%.Inanevenmorepreferred,the fractionofthemassofwaxaddedbasedonmassoftheemulsioninthefirststepisatleast 65%. Inoneembodiment,eachfractionofthemassofwaxisaddedtothebulkphaseandmixed undershearinsubsequentsequentialsteps.Inoneembodiment,thefractionofthemassof35 thewaxaddedineachsteprelativetothetotalmassofthewaxinthefinalemulsionisat least10%.Inamorepreferredembodiment,thefractionofthemassofthewaxaddedin eachsteprelativetothetotalmassofthewaxinthefinalemulsionisatleast20%.Inaneven morepreferredembodiment,thefractionofthemassofthewaxaddedineachsteprelative tothetotalmassofthewaxinthefinalemulsionisatleast30%.Inanevenmorepreferred40 embodiment,thefractionofthemassofthewaxaddedineachsteprelativetothetotalmass ofthewaxinthefinalemulsionisatleast40%.Inanotherorfurtherembodiment,partofthe BE2024 / 5795 5 additivescanbeaddedinanysubsequentstep.Inanotherorfurtherembodiment,partofthe additivescanbeaddedineverysubsequentstep. Inapreferredembodiment,thedifferencebetweenthelowestshearandthehighestshear appliedinthedifferentstepsisatleast10%,morepreferablyatleast20%,morepreferably5 atleast30%,morepreferablyatleast40%,morepreferablyatleast50%,morepreferablyat least60%,morepreferablyatleast70%,morepreferablyatleast80%,morepreferablyat least90%,morepreferablyatleast100%,morepreferablyatleast150%. Inanotherorafurtherpreferredembodiment,thedifferencebetweentheshearinsubsequent10 stepsisatleast10%,morepreferablyatleast20%,morepreferablyatleast30%,more preferablyatleast40%,morepreferablyatleast50%,morepreferablyatleast60%,more preferablyatleast70%,morepreferablyatleast80%,morepreferablyatleast90%,more preferablyatleast100%,morepreferablyatleast150%.15 Inanotherorfurtherpreferredembodiment,theshearinsubsequentstepsisreducedbyat least10%,morepreferablyatleast20%,morepreferablyatleast30%,morepreferablyat least40%,morepreferablyatleast50%,morepreferablyatleast60%,morepreferablyat least70%,morepreferablyatleast80%,morepreferablyatleast90%,morepreferablyat least100%,morepreferablyatleast150%.20 Theadvantagesofthesehigh-concentrationwaxemulsionsaremanifold. Theimprovedwaterrepellencyimpartedbythewaxemulsionsmanufacturebytheuseofthe twostepprocessisadvantageousforOSBandotherwood-basedpanelsthatareexposedto25 moisture.Theenhancedmechanicalstrengthalsocontributestothedurabilityandlongevity ofthefinalproduct.Additionally,thereducedneedforemulsifiersintheformulationlowers productioncostsandminimizesanyadverseeffectsonthebondingstrengthofthewood panels.30 Thelowertransportationcosts,duetothereducedwatercontentduringtransport,andthe improvedperformanceoftheemulsionsintermsofwaterrepellencyandbondingstrength makethisinventionhighlycompetitiveinthewoodpanelindustry.Moreover,thereduced carbonemissionscontributetoamoresustainablemanufacturingprocess,aligningwithglobal effortstoreduceenvironmentalimpact.35 Insummary,thehigh-concentrationwaxemulsionsofferacost-effective,efficient,and environmentallyfriendlysolutionforthewoodpanelindustry.Theinnovativeformulationand productionmethodsensurethattheemulsionsmaintainstabilityandperformance,providing enhancedwaterrepellencyandbondingpropertiesinthefinalwoodproducts.40 BE2024 / 5795 6 Inapreferredembodiment,thewaxemulsionformulationalsoincludesadditivessuchas stabilizers,pHcontrolagents,preservatives,andantifoamingagents.Theseadditivesare preferablypresentinsmallquantitiestomaintaintheoveralleco-friendlinessoftheproduct. Thestabilizersmayincludeelectrolytes,preferablyintherangeof0.05%to0.5%byweight, morepreferablybetween0.1%and0.4%,morepreferablybetween0.15%and0.35%,more5 preferablybetween0.17%and0.3%,andmostpreferablyaround0.25%byweight. Inapreferredembodiment,thewaxemulsionformulationispreparedusingahigh-shear mixingprocesswithcontrolledpressureandtemperature.Inanevenmorepreferred embodiment,thehighshearmixingprocessinvolvesatleast2differentstepswithdifferent10 levelsofhighshear.Thisprocessresultsinalowerviscosityofthewaxemulsion,makingit easiertohandleandapply,evenwiththehighersolidcontent.Thewaxphasemaybe subdividedandeachpartmaybeaddedinadifferentstepoftheprocesswherebythelevelof shearvariesbetweensteps. 15 Inanevenmorepreferredembodiment,themixingprocessisperformedunderhighshear. Morepreferably,themixingprocessisperformedunderhighshearbyhighpressure homogenization.Inanevenmorepreferredembodiment,themixingprocessishighpressurehomogenization andhomogenizationpressurevariesindifferentstepsbetween0and1000bar,more20 preferablybetween0and500bar,evenmorepreferablybetween0and300bar,most preferablybetween0and250bar,wherebythewaxphaseissubdividedandeachpartis addedinadifferentstepwherebyalsothehomogenizationpressurevariesbetweenthe differentsteps. 25 Inanotherpreferredembodiment,themixingprocessishighpressurehomogenizationand homogenizationpressurevariesindifferentstepsbetween25and1000bar,morepreferably between25and500bar,evenmorepreferablybetween25and300bar,mostpreferably between25and250bar,wherebythewaxphaseissubdividedandeachpartisaddedina differentstepwherebyalsothehomogenizationpressurevariesbetweenthedifferentsteps.30 Inapreferredembodiment,thewaxemulsionincludesanelectrolyteasastabilizer,preferably toincreasethelong-termstabilityofthewaxemulsionandtomaintainthehomogeneityof thewaxemulsionoverextendedstorageperiods.Thisstabilizationismorepreferablyachieved bymitigatingissuesrelatedtoseparationandaggregationofthewaxparticleswithinthe35 emulsion.Thisisparticularlybeneficialwhentheemulsionissubjectedtovaryingtemperature conditionsduringstorageandtransport.Bypreventingtheseparationofthewaxphasefrom theaqueousphase,theelectrolytemorepreferablyensuresthattheemulsionremainsina usablestateevenafterprolongedperiodsofinactivity.Inafurtherpreferredembodiment,the additionoftheelectrolytemayalsoenhancethecompatibilityofthewaxemulsionwithother40 additives,suchasbiocides,antifoams,andpHcontrolagents.Thiscompatibilityispreferably crucialinmaintainingtheoverallperformancecharacteristicsoftheemulsion.Morepreferably, BE2024 / 5795 7 theelectrolytedoesnotinterferewiththeefficacyoftheseadditives,therebypreservingthe intendedpropertiesofthefinalwood-basedproduct.Theelectrolyteisawatersolublesaltsuchasthecombinationofanammoniumderivativeor analkaliorearth-alkalimetalionwithahalogenanion,acarbonate,acarbonicacidderivative5 ortheanionofanoxidatedsulphurornitrogenatomcontainingmolecule.Typicalexamples areNaClorKCL.Theconcentrationofelectrolyteispreferablybetween0.1%and0.01%by weightofthetotalemulsioncomposition,morepreferablybetween0.05%and0.01%.This rangeensuresoptimalstabilizationwithoutnegativelyimpactingotherpropertiesofthe emulsion.10 Thepreferredmethodofincorporatingtheelectrolyteintothewaxemulsioninvolvesits additionduringtheinitialmixingstage.Thisstagepreferablyincludesthecombinationofthe waterphaseandwaxcomponentsundercontrolledpressureandtemperatureconditions.The electrolytepowderismorepreferablydissolvedinthewaterphasebeforetheadditionofthe15 waxcomponents.Thisapproachensuresthattheelectrolytestabilizerisuniformlydistributed throughouttheemulsion,therebymaximizingitsstabilizingeffect.Overall,theinclusionofelectrolytepowderasastabilizerinthewaxemulsionpreferably resultsinamorestable,homogeneousproductthatislesspronetoseparationand20 aggregation.Thisstabilizationismorepreferablyachievedwithoutcompromisingthe performancecharacteristicsoftheemulsion,ultimatelyleadingtoimprovedefficiencyand cost-effectivenessinwoodpanelapplications. TheamountofpHcontrolagentispreferablybetween0.5%and1.5%byweight,more25 preferablybetween0.6%and1.4%,morepreferablybetween0.7%and1.3%,more preferablybetween0.8%and1.2%,andmostpreferablybetween0.9%and1.1%byweight. Inapreferredembodiment,thewaxemulsionincludesaalkalinecomponentasapHcontrol agent.30 TheinclusionofthealkalinecomponentisespeciallybeneficialforstabilizingthepHlevelwithin thewaxemulsion,whichensuresconsistentperformanceandextendstheshelflifeofthe product.ThepHstabilizationprovidedbythealkalinecomponentiscrucialformaintainingthe emulsion'sstabilityduringstorageandapplication,therebypreventingpHfluctuationsthat35 couldleadtodestabilization.BymaintainingastablepH,thewaxemulsionremains homogenousandeffectiveoverextendedperiods,reducingtheneedforadditionalstabilizers andpreservatives. Inanotherpreferredembodiment,theuseofthealkalinecomponentnotonlystabilizesthe40 pHbutalsointeractssynergisticallywithothercomponentsoftheemulsion,suchasemulsifiers andwaxes,toenhancetheoverallstabilityandperformanceoftheproduct.Thisinteraction BE2024 / 5795 8 canleadtoimprovedwaterrepellencyandbondingpropertieswhentheemulsionisappliedto wood-basedproducts.TheenhancedperformanceisparticularlynoticeableinOSB, particleboard,andMDFapplications,whereconsistentqualityanddurabilityarecritical.The combinationofthesestabilizersensuresthattheemulsionremainseffectiveundervarying storageconditionsandduringthedilutionprocesspriortoapplication.Thisdual-stabilizer5 approachprovidesarobustsolutionformaintainingtheintegrityofhigh-concentrationwax emulsions,makingthemmorereliableandcost-effectiveforindustrialuse. ThepHcontrolagentisreferredtoasalkalinecomponentandispreferablyastrongbasesuch aspotassiumhydroxideorsodiumhydroxide,awater-solubleamineoracombinationof10 differentwater-solubleamines.Inamorepreferredembodimentthealkalinecomponentisa amine.Inanevenmorepreferredembodimentthealkalinecomponentisanethoxylatedamine suchasethanolamine,diethanolamine,triethanolamineorammonia. Preferably,thealkalinecomponentisaddedinaquantityabletoneutralize30to200%ofall15 acidicgroupspresentinthewaxemulsion.Morepreferably,thealkalinecomponentisadded inaquantityabletoneutralize40to150%ofallacidicgroupspresentintheemulsion.Even morepreferablethealkalinecomponentisaddedinaquantityabletoneutralize50to100% ofallacidicgroupspresentinthewaxemulsion.Mostpreferablythealkalinecomponentis addedinaquantityabletoneutralize50to85%ofallacidicgroupspresentintheemulsion.20 Inapreferredembodiment,thewaxemulsioncompositionincludesbiocides.Theinclusionof thesebiocidespreventmicrobialgrowthwhichcouldotherwisedegradetheemulsion,and ensuresthatthewaxemulsionmaintainsitseffectivenessoveraprolongedduration. Preferably,thebiocidecontainsaformaldehydereleasingcomponent.Morepreferablythe25 biocidecontainsbothaformaldehydereleasingcomponentsandisothiazolines.Evenmore preferablythebiocidecontainsaformaldehydereleasingcomponentandacombinationof chloromethyl-andmethyl-isothiazolines.Preferably,theconcentrationofbiocidesinthewax emulsionrangesfrom0.05%to0.3%byweight.Morepreferably,theconcentrationisbetween 0.07%and0.15%,evenmorepreferablybetween0.08%and0.12%,andmostpreferably30 around0.1%byweight.Thecombineduseofformaldehydereleasingcomponentsandisothiazolinesinthesepreferred concentrationsensuresthatthewaxemulsionremainsstableandeffectiveforalongerperiod, whichisparticularlybeneficialforindustrialapplicationswhereprolongedstoragemaybe35 required.Theextendedshelflifeprovidedbythesepreservativesreducestheneedforfrequent productionbatches,therebyloweringoverallproductioncostsandimprovingoperational efficiency.Overall,theinclusionofacombinationofaformaldehydereleasingcomponentand isothiazolinesinthewaxemulsioncompositionnotonlyextendsitsshelflifebutalsoensures thattheemulsionretainsitswater-repellentpropertiesandeffectivenessovertime.This40 makesthewaxemulsionhighlysuitableforuseintheproductionofOSBandotherwood- basedpanels,wherelong-termstabilityandperformancearecritical. BE2024 / 5795 9 AnexampleofaisothiazolinecompoundisMergalV615,whichisabroad-spectrumbiocide effectiveagainstbacteria,yeasts,andfungi.Anexampleofaformaldehydereleasingbiocide isBodoxinAE.Inapreferredembodiment,thewaxemulsioncomprisesanantifoamingagent.Theinclusion5 oftheantifoamingagentisoptionallyaimedatensuringauniformapplicationofthewax emulsiontothewoodpanelsurfaces.Theantifoamingagentmaypreferablyrelateto substancesthatreduceorpreventtheformationoffoamduringthemixingandapplication processes.Morepreferably,theantifoamingagentisselectedfromagroupconsistingof silicone-basedantifoams,non-siliconeorganicantifoams,andmineraloil-basedantifoams.In10 oneembodiment,theantifoamingagentusedisasilicone-basedantifoamduetoitshigh efficiencyinfoamsuppressionandstabilityunderawiderangeoftemperatures. Inanotherembodiment,theantifoamingagentisamineraloilbasedantifoamduetoitshigh costefficiency. 15 Theantifoamingagentispreferablyincludedinthewaxemulsioninanamountrangingfrom 0.05%to2%byweightofthetotalemulsion.Morepreferably,theamountrangesfrom0.1% to0.8%byweight,evenmorepreferablyfrom0.1%to0.5%byweight,andevenmore preferablyfrom0.1%to0.3%byweightandmostpreferablyaround0.2%,byweight.The preciseamountoftheantifoamingagentmaybeadjustedbasedonthespecificformulationof20 thewaxemulsionandtheintendedapplicationprocess,ensuringoptimalperformanceand cost-efficiency. Inafurtherpreferredembodiment,theuseoftheantifoamingagentenhancesthewater- repellentpropertiesofthewoodpanels.Thisenhancementisoptionallyachievedbypromoting25 amoreuniformdistributionofthewaxemulsionacrossthewoodsurface,therebyensuring consistentcoverageandpenetration.Theantifoamingagentmayalsocontributetotheoverall qualityofthewoodpanelsbyminimizingdefectssuchasbubblesorvoidsthatcould compromisethestructuralintegrityandaestheticappearanceofthefinalproduct. 30 Additionally,inanotherpreferredembodiment,theantifoamingagentmayfacilitatethe handlingandapplicationofthewaxemulsion.Thisfacilitationisoptionallyachievedby reducingtheviscosityoftheemulsion,makingiteasiertopump,spray,orotherwiseapplyto thewoodpanels.Thereducedviscositymayalsoenablemoreprecisecontroloverthe applicationprocess,leadingtomoreefficientuseofthewaxemulsionandpotentiallyreducing35 waste. Insummary,theinclusionofanantifoamingagentinthewaxemulsionispreferablyaimedat improvingtheuniformityofapplication,enhancingthewater-repellentproperties,andoverall qualityofthewoodpanels,whilealsofacilitatingthehandlingandapplicationprocess.40 BE2024 / 5795 10 Inapreferredembodiment,thehigh-concentrationwaxemulsionincludewaxasawaxphase. Theinclusionofwaxintheemulsionpreferablyenhancesthewater-repellentpropertiesof wood-basedpanels,providingbetterprotectionagainstmoistureandextendingtheproduct's lifespan. 5 Inoneembodimentthewaxisaparaffinwax.Inamorepreferredembodiment,theparaffin waxcontainsbetween0and40%oilasitismeasuredusingmethodASTMD721.Inamore preferredembodiment,theparaffinwaxcontainsbetween5and35%oilasitismeasured usingmethodASTMD721.Inanevenmorepreferredembodiment,theparaffinwaxcontains between5and25%oilasitismeasuredusingmethodASTMD721.Inapreferred10 embodiment,theparaffinwaxisapetroleumslackwax. Inanotherembodimentthewaxisasyntheticwax.Inamorepreferredembodimentthewax isawaxobtainedfromsyngasthroughtheFisherTropschprocess.ExamplesofFisherTropsch waxesareSarawaxSX50andSarawaxSX70,producedbyShell.15 Inanothermorepreferredembodimentthewaxisaalpha-olefinwax.Examplesofalpha olefinewaxesareNAOCPChemC24-28orNAOCPChemC30+,producedbyChevronPhillips Chemical. Injetanotherembodiment,thewaxisawaxobtainedfromtherecyclingofplasticsusingthe20 pyrolysisprocess.Inamorepreferredembodiment,thewaxisawaxobtainedfromthe recyclingofpolyethyleneusingthepyrolysisprocess. Instillanotherembodiment,thewaxisapartlyorfullybiobased.Thewaxcanbeafullyor partiallyhydrogenatedtriglycerideorthewaxcanbeanesterbasedonfattyacid.Triglycerides andfattyacidscanbefromplantoranimalorigin.25 Theconcentrationofwaxintheemulsionispreferablybetween20%and70%,morepreferably between30%and65%,morepreferablybetween40%and65%,mostpreferablybetween 45%and65%.Thisrangeensuresoptimalwater-repellencywhilemaintainingthestabilityof theemulsion.30 Thewaxusedintheemulsionpreferablyhasameltingpointbetween30°Cand70°C,more preferablybetween45°Cand65°C,morepreferablybetween50°Cand65°C,andmost preferablyaround60°C.Thismeltingpointrangeispreferredtoensurethatthewaxremains solidatroomtemperaturebutmeltsduringtheapplicationprocess,allowingforuniform35 coverageandpenetrationintothewoodfibers. Insummary,theinclusionofwaxinthehigh-concentrationwaxemulsionpreferablyenhances water-repellency,extendsthelifespanofwood-basedpanels,therebyimprovingtheoverall efficiencyandcost-effectivenessoftheseproducts.40 BE2024 / 5795 11 Inapreferredembodiment,theformulationreducesenvironmentalimpactbyminimizingthe useofchemicalemulsifiers.Inapreferredembodiment,thewaxemulsionformulationincludes areducedamountofemulsifiers,whichresultsinamoreeco-friendlyproduct,minimizingthe environmentalfootprint.Theratioofthemassofemulsifieronthemassofwaxinthe formulationispreferablybetweenand1%and10%byweight,morepreferablybetween1%5 and8byweight,morepreferablybetween2and5%byweight,andmostpreferablybetween 2.5%and4%byweight.Thisreductioninemulsifiercontentisachievedwithout compromisingthestabilityandperformanceofthewaxemulsion.Typicalemulsifiersusedare ethoxyltedfattyalcohols,polyalkyleneglycolestersoffattyacids,sulphonatedsurfactantssuch assodiumdodecylsulphate,fattyacidssuchasstearicacidandsaltsthereof,Kraftligninor10 sulfonatedlignin,orothernaturalemulsifiers,whichfurtherenhancetheeco-friendlynature oftheproduct. Preferably,theformulationincludesnaturalorbiodegradableemulsifiers,suchasfattyacids salts,polysaccharidesandproteins,thatreplacetraditionalchemicalemulsifiers.More15 preferably,theconcentrationofthesenaturalemulsifiersrangesbetween0.1%and5.0%by weightofthetotalformulation,morepreferablybetween0.5%and3%,morepreferably between2%and3%,mostpreferablyaround2.5%.Byusingthesealternativeemulsifiers, theformulationnotonlymaintainsthestabilityandperformanceofthewaxemulsionbutalso significantlyreducestheenvironmentalfootprintassociatedwithitsproductionanduse.20 Moreover,inanotherpreferredembodiment,thewaxemulsionmayoptionallybeformulated tohaveapHrangethatisfavorableforthestabilityofthenaturalemulsifiersandadditional stabilizingagents.Preferably,thepHoftheformulationisbetween5and10,morepreferably between7and9,morepreferablybetween8and9,mostpreferablyaround8,5.ThispHrange25 ensuresoptimalperformanceandstabilityofthewaxemulsionwhileminimizinganypotential environmentalimpact.Overall,thesepreferredembodimentsoftheformulationnotonlyreducetheenvironmental impactbyminimizingtheuseofchemicalemulsifiersbutalsomaintainorenhancethe30 performanceandstabilityofthewaxemulsion.Theuseofnaturalorbiodegradable componentsensuresthattheformulationismoresustainableandenvironmentallyfriendly, aligningwithcurrenttrendsandregulationsaimedatreducingtheenvironmentalfootprintof industrialproducts. 35 Inapreferredembodiment,thehigh-concentrationwaxemulsionwithdrymattercontentof atleast60%isdesignedforuseinwood-basedpanels.Theformulationpreferablyincludesa lowerwatercontent,whichresultsinalightershipmentweightandreducedcontainervolume. Thisreductioninweightandvolumeisadvantageousasitcontributestodecreasedcarbon emissionsduringtransportation,aligningwithsustainabilitygoalsintheindustry.40 BE2024 / 5795 12 Thewaxemulsionisoptionallypreparedusingahigh-shearmixingprocess,whichispreferably conductedundercontrolledpressureandtemperatureconditions.Thisprocessmorepreferably resultsinalowerviscosityofthewaxemulsion,evenwiththehighersolidcontent.Thelower viscosityisbeneficialasitmakestheemulsioneasiertohandleandapply,thusimprovingthe efficiencyoftheapplicationprocess.5 Inafurtherpreferredembodiment,thewaxemulsionisdilutedjustbeforeapplicationtothe woodpanel.Thisdilutionstepisoptionalbutpreferableasitreducestheneedforemulsifiers, whichcanimpactboththecostandthebondingstrengthofthewoodpanel.Thediluted emulsionpreferablydemonstratesenhancedwater-repellentpropertiesandimprovedbonding10 withadhesives,leadingtoahigherqualityfinalwoodproduct. Insummary,thepreferredembodimentsofthehigh-concentrationwaxemulsionprovide significantadvantagesintermsofcostreduction,improvedperformance,andsustainability. Thelowerwatercontent,reducedneedforemulsifiers,andenhancedapplicationefficiency15 makethisinventionahighlycompetitivesolutionforthewoodpanelindustry.Inanaspect,theinventionpertainstoahigh-concentrationwaxemulsionwithatleast60% drymattercontent,designedforuseinwood-basedpanelssuchasOSB,particleboard,and MDF.Thehigh-concentrationwaxemulsionischaracterizedbyitsabilitytobedilutedjust20 beforeapplication,whichsignificantlyenhancesitsutilityandefficiencyinindustrial applications.Thisinnovativeapproachinvolvesauniqueformulationandproductionmethod thatreducestheneedforemulsifiers,therebyloweringproductioncostsandimprovingthe environmentalfootprintofthemanufacturingprocess. 25 Thecoreofthisinventionliesinitsabilitytomaintainahighdrymattercontent,specifically atleast60%,whichisasignificantimprovementovertraditionalwaxemulsionsthattypically containaround50-60%drymattercontent.Thereductioninwatercontentnotonlydecreases transportationcostsbutalsominimizespackagingwaste,contributingtoenvironmental sustainability.Thehighdrymattercontentensuresthatthewaxemulsionismore30 concentrated,leadingtobetterwaterrepellencyandenhancedbondingpropertieswhen appliedtowood-basedpanels. Theproductionmethodofthehigh-concentrationwaxemulsioninvolvesamulti-stephigh- shearmixingprocess,typicallyusingahighpressurehomogenizer.Thismethodwherethe35 emulsionissubjectedtodifferentlevelsofshearresultsinawaxemulsionwithlowerviscosity despiteitshighersolidcontent.Inapreferredembodiment,onlypartofthewaxisshearedat thehighestshearlevel.Thismethodensuresthattheemulsioniseasiertohandleandapply, whichisparticularlybeneficialforindustrialapplicationswhereefficiencyandeaseofuseare critical.40 BE2024 / 5795 13 Thehigh-concentrationwaxemulsioncanbedilutedjustbeforeapplication,whichfurther reducestheneedforemulsifiers.Thisaspectoftheinventionisparticularlyadvantageousas itlowersproductioncostsandenhancestheoverallperformanceofthewaxemulsion.The dilutedemulsionsdemonstrateimprovedwaterrepellencyandbondingproperties,thereby increasingtheefficiencyofboththewaxandadhesivesusedinthefinalwoodproduct.5 Insummary,thepreferredembodimentsofthewaxemulsionformulationandproduction methodoffersignificantadvantages,includingimproveddurability,enhancedwater-repellent properties,reducedproductioncosts,andbetterhandlingcharacteristics.Thesebenefitsmake thewaxemulsionparticularlysuitableforuseinOrientedStrandBoard(OSB),particleboard,10 MediumDensityFiberboard(MDF)andotherwood-basedproducts,wherewaterrepellency andbondingstrengtharecriticalperformancefactors. Overall,thecontrolledhomogenizationandpumpingpressures,combinedwiththeoptimized useofemulsifiersandstabilizers,preferablyresultinawaxemulsionthatismoreefficient,15 cost-effective,andstable.Thisimprovedemulsionisoptionallyeasiertohandleandapply, leadingtoenhancedperformanceinwood-basedproducts.Inapreferredembodiment,thedilutionmethodensuresaconsistentandevencoatingacross thewoodpanel,enhancingtheoverallqualityandreliabilityofwaterrepellencyperformance.20 Thismethodpreferablyinvolvesdilutingthehigh-concentrationwaxemulsionjustbefore applicationtoachieveanoptimalbalancebetweenviscosityandcoverage.Theemulsion:water dilutionratioispreferablybetween1:0.2and1:5,morepreferablybetween1:0.2and1:4, evenmorepreferablybetween1:0.2and1:3,evenmorepreferablybetween1:0.2and1:2, evenmorepreferablybetween1:0.5and1:1.5andmostpreferablyaround1:1.Thisensures25 thatthewaxemulsionmaintainsitsstabilitywhileprovidingauniformcoatingonthewood surface. Inafurtherpreferredembodiment,thedilutionprocessmayinvolvetheuseofdehardened water,whichispreferredforitsabilitytomaintaintheemulsion'sstabilityandperformance30 characteristics.Thewatertemperatureduringdilutionispreferablybetween5°Cand40°C, morepreferablybetween10°Cand35°C,evenmorepreferablybetween15°Cand30°C,and mostpreferablyaround20°C.Thistemperaturerangeensuresthatthewaxemulsionremains inaliquidstate,facilitatingeasyapplicationandpenetrationintothewoodfibers. 35 Additionally,inanotherpreferredembodiment,themethodofapplicationmayinvolvefirsta mixingprocessoftheconcentratedemulsionandwatertomakesurethatthedilutedemulsion ishomogeneous,resultinginauniformandconsistentcoatingofthewoodparticlesinthe woodpanel.Inanevenmorepreferredembodiment,thismixingprocessoftheconcentrated emulsioninwaterisdoneusinganin-linestaticmixer.40 BE2024 / 5795 14 Inyetanotherpreferredembodiment,theapplicationmethodmayincludesprayingthediluted emulsionontothewoodpanelusingaspraynozzle.Thespraypressureispreferablybetween 0.5barand6bar,morepreferablybetween0.5barand5bar,evenmorepreferablybetween 0.5barand4bar,evenmorepreferablybetween0.5and3barandmostpreferablyaround2 bar.Thispressurerangeensuresthattheemulsionisappliedevenlyacrossthesurface,5 providingauniformwater-repellentlayer.Insummary,thepreferredembodimentsofthedilutionmethodandapplicationprocessensure thatthehigh-concentrationwaxemulsionprovidesaconsistent,evencoatingonwoodpanels. Thisenhancesthewaterrepellencyperformanceandoverallqualityofthefinalproduct,10 makingitmorereliableandcost-effectiveforindustrialapplications. EXAMPLES Thepresentinventionwillnowbefurtherexemplifiedwithreferencetothefollowingexamples. Thepresentinventionisinnowaylimitedtothegivenexamplesortotheembodiments presentedinthefigures.15 Twowater-basedemulsionsofaparaffinslackwax,Prowax540fromExxon,wereproduced accordingtothecompositionintable1.Theemulsifierwascomposedofacombinationofa biobasedemulsifier,afattyacidnamedRadiacid0444andanethoxylatedfattyalcohol, LutensolTO8ofBASF.TheLutensolTO8wasfirstdilutedto80%inwaterbeforeuse.25% ammoniasolutioninwaterwasusedasanalkalinecomponent.Inbothformulations,abiocide,20 PreventolD9producedbyLanxess,wasaddedforpreservationagainstmicrobialgrowthand anantifoamingagent,AntifoamSMIproducedbyGOVI,wasaddedtopreventapplication problemsduetoexcessivefoaming. Table1.compositionofparaffinwaxemulsions 25 Further,2differentmethodswereusedtoproducetheparaffinwaxemulsionswiththe compositionshownintable1. Inthefirstproductionmethod,first,thesoftwater,LutensolTO8solution,Radiacid0444and 25%ammoniaweremixedtogetherinthesoftenedwateratatemperaturebetween70and BE2024 / 5795 15 80°Ctoproduceanaqueousphase.Inasecondstep,Prowax540atatemperaturebetween 70and80°Cwasadded.BothfractionsofProwax540indicatedinTable1wereaddedatthe sametimeinthefirstproductionmethod.Bothaqueousandwaxphaseweremixedtogether toproduceahomogeneousemulsionwithcoarseparticlesize.Thiscoarseemulsionwasthen homogenizedusingaAPV1000lab-scalehighpressurehomogenizer(producedbyAPV)at1805 barfirstinaclosedcircuitforatimesufficienttohavetheemulsionvolumepassedonceon averageoverthehomogenizerandthenhomogenizedoncemorewherebytheemulsionwas nowdirectedtowardsthetube-in-shellcooler.Thetemperatureduringhomogenizationwas alwayskeptbetween70and80°C.Inthetube-in-shellcoolertheemulsioniscooleddownto atemperaturebetween20and30°C,beforetheAntifoamSMIandthePreventolD9+are10 addedundergentlemixing. Inthesecondproductionmethod,33,33%oftheProwax540wasaddedbeforethestartof thehomogenizationinclosedloopat180barandtheremaining66.67%wasonlyaddedjust beforethesecondhomogenizationsteptowardsthetube-in-shellcooler.Thissecond homogenizationstepwasperformedat50barinthesecondproductionmethod.Exceptfor15 theabovementioneddifferences,thesecondproductionmethodfollowstheprocedure describedforthefirstproductionmethod.EmulsionpropertiesareshowninTable2.The “viscosity”ismeasuredusingaBrookfieldviscometerDV / Eusingaspindle3at5rpm.ThepH ismeasuredusingaglasselectrode. Table2.propertiesofparaffinwaxemulsions20 Table2showsthepropertiesofthedifferentemulsionsproduced.Productionmethod2gave largerparticles,abroaderparticlesizedistributionandalowerviscositythananemulsion madeaccordingtothesameformulationwithmethod1. Theemulsionswerethentestedashydrophobingagentintheproductionofwoodpanels.First25 about387gofwoodchipsweremixedduring4minutesinanLGB100labblender(IMALPal) withaparaffinemulsionwithcompositionaccordingtooneofbothformulasinTable1and BE2024 / 5795 16 producedaccordingtooneofbothproductionmethodsdescribedabove.Intheexamples‘Ex. 1diluted’and‘Ex.2diluted’,theparaffinwaxemulsionwasfirstdilutedto33%(m / m)solid contentbeforeapplicationwhereasintheexamples‘Ex.1’and‘Ex.2’comparativeexample ‘C.Ex.1’theemulsionwasappliedundiluted.Thefinalwaxconcentrationintheparticleboard was0,7weightpercentondrywood.Then,thetreatedwoodchipsweremixedduring45 minutesintheLGB100labblenderwitha65%aqueoussolutionofanE1ureumformaldehyde glue.Thefinalconcentrationis9mass%dryglueondrywood. ThecodesusedinTable2,Table3,Fig.1andFig.2consistof3partsseparatedby underscores.Inthefirstpart,theuseofformula1(highwaxconcentration)isindicatedby ‘Form1’whereastheuseoftheformula2(standardwaxconcentration)isindicatedby‘Form2’.10 Inthesecondpart,thefirstproductionmethodisindicatedby‘PM1’,whereasthesecond productionmethodisindicatedby‘PM2’.Inthethirdpart‘UNDIL’meanswedidnotdilute beforeusewhereas‘DIL’meanswedilutedtheemulsionto33%(m / m)drymattercontent justapplicationtothegluedwoodchips. Thewoodchipmasscontainingtheglueandthewaxemulsionisthenformedintoa26x2215 cmmatwithathicknessasevenaspossible.Thismatisthenpressedfor150secondsusing alabpress(ModelGEM40TproducedbyJBTEngineering).Thefinalboardthicknesswas determinedby12mmmetalspacersandthepressplatetemperatureswereboth200°C.Boardswereequilibratedfor1weekinambientconditions.Four5x5cmpieceswerecutout oreachboardandsubjectedtowateruptakeandswellingtestaccordingtoNBNEN317:1993.20 Alinearregressionofbothswellingandwateruptakeversusboarddensitywasperformedin ordertocorrectforvariationintroducedbyvaryingboarddensities.Thecalculatedvalueson thelinearregressioncurveat575kg / m³arereportedintable3.InFig.1andFig.2the referencevalueoftheboardmadewiththeundiluted65%waxemulsionproducedwiththe firstproductionmethodwasalwayssubstracted.SotheFig.1andFig.2ratherindicatethe25 changeinswellingandwateruptakerespectivelycomparedathereferenceemulsion. Table3.Wateruptakeandswellingresultsat0,63%drymatterfromemulsionintheboard. ThedatainTable3andFig.1&2showthatemulsionaddedatalowerwaxconcentrationin theemulsiongivesalowerwateruptake.Thisissurprisingsincetheamountofdrymatter30 fromemulsionandthusthecompositionoftheboardsarebasicallythesame.BE2024 / 5795 17 Comparingtheemulsionsproducedaccordingtoformula1,thesampleproducedwith productionmethod2gaveclearlyalowerviscositythantheoneproducedwithproduction method1,asindicatedinTable2.Thisresultedinabetterapplicabilityoftheemulsioninthe woodpanelproductionprocessandultimatelyalsoalowerwateruptakeandswellingresult (Table3andFigs.1&2).5 Itissupposedthatthepresentinventionisnotrestrictedtoanyformofrealizationdescribed previouslyandthatsomemodificationscanbeaddedtothepresentedexampleoffabrication withoutreappraisaloftheappendedclaims.Forexample,thepresentinventionhasbeen describedreferringtoOSB,particleboard,andMDF,butitisclearthattheinventioncanbe appliedtootherwood-basedproductsrequiringwaterrepellency,forinstanceortoother10 industrialapplicationsrequiringhigh-concentrationemulsions. Itisclearthatthemethodaccordingtotheinvention,anditsapplications,arenotlimitedto thepresentedexamples. Thepresentinventionisinnowaylimitedtotheembodimentsdescribedintheexamples15 and / orshowninth.