Microcrystalline Wax/Pre-Mixture Liquid Sealant Composition, Method of Manufacture and Methods of Use

Abstract

A method and composition are shown for treating a variety of different substrates with a sealant coating composition which provides a long lasting protective barrier on a selected substrate. First a sealant composition is formulated by combining a micro-crystalline wax with an organic solvent pre-mixture blend. Next, the selected substrate is contacted with the sealant composition and the solvent blend is allowed to flash away, leaving behind a substantially solvent free micro-crystalline wax residue barrier. The solvent blend can be a mixture of hexane and xylene but is not limited to these two particular solvents.

Claims

1. A method for treating a substrate with a sealant composition comprising the steps of: formulating a sealant composition by combining a micro-crystalline wax with an organic solvent pre-mixture blend; contacting the substrate with the sealant composition and allowing the solvent blend to flash away, leaving a substantially solvent free micro-crystalline wax residue barrier; and wherein the solvent blend chosen is effective to keep the micro-crystalline wax emulsified in a liquid state at ambient temperatures prior to application.

2. The method of claim 1, wherein the sealant composition is sprayed onto the substrate.

3. The method of claim 1, wherein the organic solvent pre-mixture blend is a blend of xylene with other distillates which work together as a filler to create volume in the sealant composition.

4. The method of claim 3, wherein the combination of distillates has a lighter specific gravity than that of the microcrystalline wax so that the solvent blend keeps the wax from re-solidifying into a solid piece.

5. The method of claim 1, wherein the organic solvent blend is a blend of at least cyclohexane and xylene.

6. The method of claim 1, wherein the organic solvent blend is a solution of approximately 60% cyclohexane, 5% isohexane, 20% xylene, 7% ethylbenzene and 3% toluene, all percents being percents by volume, based upon the total volume of the sealant composition.

7. The method of claim 1, wherein the sealant composition is comprised of 5 to 10% by volume micro-crystalline wax, based upon the total volume of the sealant composition.

8. The method of claim 1, wherein the preferred micro-crystalline wax has a weight of about 570-750 g/mole.

9. A method for treating a substrate with a sealant composition, comprising the steps of: formulating a sealant composition which is comprised of a micro-crystalline wax in an organic solvent pre-mixture blend; wherein the sealant composition is prepared by adding the micro-crystalline wax to the solvent pre-mixture blend containing at least cyclohexane and xylene, the micro-crystalline wax being heated to its melting point and then added to the solvent pre-mixture blend at ambient temperature with frequent stirring until the micro-crystalline wax is completely dispersed throughout the solvent blend, thereby forming the sealant composition; wherein the solvent blend chosen is effective to keep the micro-crystalline wax emulsified in a liquid state at ambient temperatures prior to application; and thereafter, contacting the substrate with the sealant composition and allowing the solvent blend to flash away after initial curing, leaving a non-toxic and substantially solvent free micro-crystalline wax residue barrier.

10. The method of claim 9, wherein the sealant composition is sprayed onto the wood substrate.

11. The method of claim 9, wherein the sealant composition is brushed onto the wood substrate.

12. The method of claim 9, wherein the sealant composition is rolled on.

13. The method of claim 9, wherein the organic solvent pre-mixture blend is a blend of at least cyclohexane and xylene.

14. The method of claim 9, wherein the organic solvent pre-mixture blend is a solution of approximately 60% cyclohexane, 5% isohexane, 20% xylene, 7% ethylbenzene and 3% toluene, all percents being percents by volume, based upon the total volume of the sealant composition.

15. The method of claim 9, wherein the sealant composition is comprised of 5 to 10% by volume micro-crystalline wax, based upon the total volume of the sealant composition.

16. The method of claim 9, wherein the preferred micro-crystalline wax has a weight of about 570-750 g/mole.

17. A sealant composition for a variety of different substrates, the composition comprising: an initially liquid composition which is formulated by combining a micro-crystalline wax with an organic solvent pre-mixture blend; wherein the solvent blend chosen is effective to keep the micro-crystalline wax emulsified in a liquid state at ambient temperatures prior to application; and wherein the initially liquid composition is subsequently applied to the substrate with the solvent pre-mixture blend subsequently being allowed to flash away, leaving a substantially solvent free micro-crystalline wax residue barrier on the substrate.

18. The composition of claim 17, wherein the organic solvent blend is a blend of at least cyclohexane and xylene.

19. The composition of claim 17, wherein the organic solvent pre-mixture blend is a solution of approximately 60% cyclohexane, 5% isohexane, 20% xylene, 7% ethylbenzene and 3% toluene, all percents being percents by volume, based upon the total volume of the sealant composition.

20. The composition of claim 17, wherein the sealant composition is comprised of 5 to 10% by volume micro-crystalline wax, based upon the total volume of the sealant composition.

21. The composition of claim 17, wherein the preferred micro-crystalline wax has a weight of about 570-750 g/mole.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0023] The invention described herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting examples which are detailed in the following description. Descriptions of well-known components and processes and manufacturing techniques are omitted so as to not unnecessarily obscure the workings of the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention herein may be practiced and to further enable those of skill in the art to practice the invention. Accordingly, the examples should not be construed as limiting the scope of the claimed invention.

[0024] The sealant compositions of the invention are prepared by combining a hydrophobic component with a special organic solvent pre-mixture blend. The hydrophobic component is preferably a strong hydrophobe. Exemplary strong hydrophobes include waxes, such as petroleum waxes, natural waxes, synthetic waxes, or a combination of these. Exemplary petroleum waxes include slack wax or microcrystalline wax. Exemplary natural waxes include bees' wax or carnauba wax. Exemplary synthetic waxes include polyethylene wax or oxidized polyethylene wax. Preferred waxes have a melting point in the range from about 30-100 C., more preferably in the range from about 40 to 95 C. The most preferred wax is a microcrystalline wax having a melting point in the range from about 60 C. to about 87.78 C. Exemplary concentrations of the hydrophobic component are 2 to 30 weight %, more preferably about 5 to 15 weight %, most preferably about 10 weight %, based on the total weight of the stain/sealant formulation.

[0025] Microcrystalline waxes are a type of wax that can be produced, for example, by de-oiling petrolatum, as part of the petroleum refining process. In contrast to the more familiar paraffin wax which contains mostly unbranched alkanes, microcrystalline wax contains a higher percentage of isoparaffinic (branched) hydrocarbons and naphthenic hydrocarbons. It is characterized by the fineness of its crystals in contrast to the larger crystal of paraffin wax. It consists ofhigh molecular weight saturated aliphatic hydrocarbons. It is generally darker, more viscous, denser, tackier and more elastic than paraffin waxes, and has a higher molecular weight and melting point. However, the microcrystalline wax can be further processed to achieve greater purity levels at the refinery level. The elastic and adhesive characteristics of microcrystalline waxes are related to the non-straight chain components which they contain. Typical microcrystalline wax crystal structure is small and thin, making them more flexible than paraffin wax. They are commonly used in cosmetic formulations, as well as a food ingredient.

[0026] Microcrystalline waxes when produced by wax refiners are typically produced to meet a number of ASTM specifications. These include congeal point (ASTM D938), needle penetration (D1321), color (ASTM D6045), and viscosity (ASTM D445). Microcrystalline waxes can generally be put into two categories: laminating grades and hardening grades. The laminating grades typically have a melt point of 140-175 F. (60-80 C.) and needle penetration of 25 or above. The hardening grades will range from about 175-200 F. (80-93 C.), and have a needle penetration of 25 or below. Color in both grades can range from brown to white, depending on the degree of processing done at the refinery level.

[0027] One preferred micro-crystalline wax suitable for purposes of the present invention has the following measured characteristics:

[0028] Melting point: 60-95 C.

[0029] Initial boiling point: >572 C.

[0030] Flash point: >200 C.

[0031] Evaporation Rate: <0.01 (Butyl acetate=1)

[0032] Vapor Pressure: <0.01 mm Hg (25 C.)

[0033] Vapor density: >5 (air=1)

[0034] Relative density: 0.91 to 0.94 (25 C.)

[0035] Solubility: <0.1% (20 C.)

[0036] Partition coefficient (oil/water): <0.01

[0037] The liquid sealant barrier of the invention can be used to protect various subject substrates from water, salt, and any other corrosive or damaging influences in the surrounding environment. The present invention may conveniently be applied as a spray, for example by using high pressure airless sprayers, low pressure pump sprayers, hand sprayer bottles and aerosol canisters. Other applications techniques such as brushing on, rolling on and dipping a subject article into a container of the liquid sealant barrier are also possible, depending upon the particular end application.

[0038] In one aspect of the invention, a method is described for treating a substrate with a sealant composition comprising the steps of:

[0039] formulating a sealant composition by combining a micro-crystalline wax with an organic solvent pre-mixture blend;

[0040] contacting the substrate with the sealant composition and allowing the solvent blend to flash away, leaving a substantially solvent free micro-crystalline wax residue barrier.

[0041] By way of example, in one preferred embodiment, the sealant composition of the invention is prepared by adding a micro crystalline wax (wax) to a chemical pre-mixture containing cyclohexane (CAS #110-82-7) and xylene (1330-20-7). The wax is heated to the melting point and then added to the pre-mixture at ambient temperature stirring frequently and consistently until the wax has been completely disbursed throughout the chemical pre-mix. The visual results are a milky white to amber brown liquid, depending on the type of wax used.

[0042] There are several distillates that can be used in substitution of the above mixture. For example, one preferred combination of the present invention is a solution comprising 60% cyclohexane, 5% isohexane, 5% hexane, 20% xylene, 7% ethylbenzene, 3% toluene. It should also be noted that rexene (CAS #64742-49-0) is a preferred alternate.

[0043] The preferred embodiment is comprised of 5%-10% by volume micro crystalline wax (570-750 g/mole), based upon the total volume of solvent blend.

[0044] The exact nature of the solvent blend may vary to some extent, depending upon the end application. In every case, the particular combination of solvents with micro crystalline wax allows the wax to remain liquid at temperatures below the cooling point of the wax. The combination of distillates used in the solvent blend will always have a lighter specific gravity than that of the microcrystalline wax component. Of the solvents used in the solvent blend, the most notable is xylene. Xylene's primary function is to prepare the exposed surface of an object to be sealed.

[0045] The other solvents in the exemplary blends basically work together as filler to create volume in the solution to allow for a wide and thinly dispersed application. The solvents also are more cost effective and make the product more affordable, allowing for more uses in applications generally served by oil based products.

[0046] The combination of distillates having a lighter specific gravity than that of the wax performs the function of keeping the wax from re-solidifying into a solid piece, as well as keeping the wax in a liquid form which can be applied in a variety of methods including but not limited to brushing, rolling and spraying. In other words, the preferred solvent blends perform a critical task of keeping the micro-crystalline wax, which is normally a solid, in liquid form at ambient temperatures. This function is vital in order to use and apply the present invention in the field on a variety of different products that could be harmed by the elements.

[0047] The wax used in the mixture of the present invention can vary in molecular weight, however the use of a wax with a high tensile strength is recommended for its ability to adhere without losing its bonding affinity to the item being sealed.

[0048] An invention has been provided with several advantages. There are many thousands of potential uses of the present invention, both commercial and industrial. To name a few, the sealant composition of the invention can be applied to:

[0049] Fresh and salt water marine vessels above and below the water displacement line

[0050] Fishing equipment

[0051] Exposed Electronic Connections

[0052] Metal Components, Propellers, Outdrives

[0053] Firearms: Metal and Wood Surfaces

[0054] Printed Circuit Boards

[0055] Industrial: Metal and Steel components for the oil and gas industry

[0056] Communication Antennas

[0057] Outdoor garden and pool copings, retaining walls, fire places, railing fences (wood and metal)

[0058] Rail and transit, multiple static surfaces

[0059] Vehicles: battery terminals, trailer light plugs, wheel wells, fuse boxes, wheels and tires.

[0060] Construction: faux tile roofs, wood, cement and rock decks, wood and metal fences; multiple surfaces from rough-in stage to completion of trim stages in any project

[0061] Municipalities in graffiti abatement programs

[0062] General: clothing, camping equipment, hats, leather shoes, gloves, flashlights, exposed wood, power tools, hand tools.

[0063] The sealant composition of the invention can be used with any product where exposure to moisture, salt, or other environmental influences may be harmful to the functioning of the product. The sealant composition can be applied as a spray in a liquid form, making it easy to apply to any of the aforementioned products.

[0064] In order to illustrate the effectiveness of the protective coating compositions of the invention, two different marine vessels, both dual outboard engines, approximately 30-50 feet length were coated up to the approximate water displacement line with the coating composition of the invention. One vessel was left docked for a year. The other vessel was used on a normal daily basis. Coating each vessel took less than 40 minutes using a hand sprayer.

[0065] The docked vessel was pulled from the salt water after approximately one year and was covered in barnacles and marine fouling up to the water displacement line. A high pressure sprayer using simple water was used to remove the barnacles in less than two hours. This type of removal usually requires chiseling, grinding wheels and even other toxic dissolving chemicals. Generally, the process follows:

[0066] One day to remove the barnacles;

[0067] One day to prime coat and cure; and

[0068] A third day to apply Epaint or a similar coating and cure.

[0069] The entire process is expensive, time consuming and takes the vessel out of service during the maintenance period. Applicant's process is economical, time saving and eliminates the need for recoating. The vessel can be put directly back into service.

[0070] The results on the vessel which was in daily use were even more surprising. After a year of use, the vessel was essentially clean. It appears that contaminants do not adhere to the coated surfaces of the vessel long enough to overcome the drag of the water while in use. They are literally sheared off.

[0071] While the invention has been shown in several of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof, as described in the claims which follow.