# US 10,370,566 B2 · Low-dust products using microcrystalline wax emulsion

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- Number: US 10,370,566 B2
- Document ID: US10370566B2
- Status: Granted
- Kind: B2
- Application number: 15/274,258
- Filed: 2016-09-23
- Published: 2017-03-30
- Granted: 2019-08-06
- Earliest claimed: 2015-09-24
- Assignees: Henry Company, LLC
- Applicants: Henry Company, LLC
- Inventors: Amba Ayambem; Daniel Kent
- Web page: https://patentgrep.com/patent/US10370566B2

## CPC

- C09J 9/00: Adhesives characterised by their physical nature or the effects produced, e.g. glue sticks (C09J7/00 takes precedence)
- B32B 37/12: characterised by using adhesives
- C08K 5/01: Hydrocarbons {(C08K5/0091 takes precedence)}
- C09D 5/34: Filling pastes (materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12)
- C09J 5/00: Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
- C09J 11/06: organic
- C09J 11/08: Macromolecular additives
- C09J 129/04: Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
- C09K 3/10: {Materials in mouldable or extrudable form} for sealing or packing joints or covers (filling pastes C09D5/34)
- C09K 3/22: for dust-laying or dust-absorbing
- B32B 2607/00: Walls, panels
- C09J 2301/408: additives as essential feature of the adhesive layer
- C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE

## Abstract

The present invention relates generally to wall repair compounds such as joint compounds, spackling compounds, and the like used to repair imperfections in walls or fill joints between adjacent wallboard panels. Particularly, the present invention relates to such a wall repair compound comprising a dust reducing additive that reduces the quantity of airborne dust generated when the hardened compound is sanded. The dust reducing additive also imparts adhesion to the wall repair compounds to which it is added, for example to a joint compound. The dust reducing additive comprises microcrystalline-wax based emulsion.

## Claims

### Claim 1

A low-dust joint compound composition comprising:
(i) a dust reduction additive emulsion comprising colloidally-protected microcrystalline-wax-based (CMWB) microstructures; and
(ii) a first water, wherein said CMWB microstructures comprise:
(A) a wax core,
wherein said wax core comprises a microcrystalline-wax component and a non-microcrystalline-wax component,
wherein said microcrystalline-wax component comprises at least one linear alkane wax defined by the general formula CnH2n+2, where n ranges from 13-80,
wherein said non-microcrystalline-wax component comprises at least one wax selected from the group consisting of animal-based wax, plant-based wax, mineral wax, synthetic wax, a wax containing organic acids and/or esters, anhydrides, an emulsifier containing a mixture of organic acids and/or esters, and combinations thereof; and
(B) a polymeric shell,
wherein said polymeric shell comprises at least one polymer selected from the group consisting of polyvinyl alcohol, polyvinyl alcohol copolymers, polyvinyl alcohol terpolymers, polyvinyl acetate, polyvinyl acetate copolymers, polyvinyl acetate terpolymers, cellulose ethers, polyethylene oxide, polyethylene imine s, polyvinylpyrrolidone, polyvinylpyrrolidone copolymers, polyethylene glycol, polyacrylamides polyethylene glycol, polyacrylamides and poly(N-iso-propylamides), pullulan, sodium alginate, gelatin, starches, and combinations thereof.

### Claim 2 (depends on 1)

The low-dust joint compound composition as recited in claim 1, wherein said polymeric shell comprises polyvinyl alcohol.

### Claim 3 (depends on 1)

The low-dust joint compound composition as recited in claim 1, wherein the composition further comprises at least one component selected from the group consisting of a filler; a binder; a thickener; a non-leveling agent; a preservative; a rheology modifier; and a surfactant.

### Claim 4 (depends on 3)

The low-dust joint compound composition as recited in claim 3, wherein:
said filler is selected from the group consisting of calcium carbonate (CaCO3), calcium sulfate dihydrate (CaSO4 2H2O), calcium sulfate hemihydrate (CaSO4-½H2O), glass micro bubbles, mica, perlite, talc, limestone, pyrophyllite, silica, diatomaceous earth, and combinations thereof;
said binder is selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, ethylene vinyl acetate co-polymer, vinylacrylic copolymer, styrene-butadiene, polyacrylamide, acrylic polymers, latex, natural starch, synthetic starch, casein, and combinations thereof;
said thickener is selected from the group consisting of methyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl cellulose, hydroxyethyl methyl cellulose, hydroxyethyl hydroxypropyl cellulose, ethylhydroxyethyl cellulose, sodium carboxymethyl cellulose, and combinations thereof; and
said non-leveling agent is selected from the group consisting of attapulgite clay, bentonite, illite, kaolin, sepiolite, clays mixed with starches, and combinations thereof.

### Claim 5 (depends on 3)

The low-dust joint compound composition as recited in claim 3, wherein the composition further comprises at least one of cristobalite, a micro-roughened filler, clay, expanded perlite, and combinations thereof.

### Claim 6 (depends on 1)

The low-dust joint compound composition as recited in claim 1, wherein said dust-reduction additive emulsion further comprises a second water; a base; and a dispersant.

### Claim 7 (depends on 6)

The low-dust joint compound composition as recited in claim 6, wherein said dispersant is selected from a dispersant having sulfur; a dispersant having a sulfur-containing group in the compound; sulfonic acid (R—S(═O)2—OH); sulfonic acid salts, wherein the R group is functionalized with hydroxyl, or carboxyl; lignosulfonate; lignosulfonic acid; naphthalene sulfonic acid; sulfonate salt of lignosulfonic acid; sulfonate salt of naphthalene sulfonic acid; derivatized lignosulfonic acid; derivatized naphthalene sulfonic acid; functionalized lignosulfonic acid; functionalized naphthalene sulfonic acid; magnesium sulfate; polycarboxylate; ammonium hepta molybdate; combination of ammonium hepta molyb-date and starch; alkyl quaternary ammonium; montmorillonite clay; non-ionic surfactants; ionic surfactants; zwitterionic surfactants; and mixtures thereof.

### Claim 8 (depends on 6)

The low-dust joint compound composition as recited in claim 6, wherein said base is selected from the group consisting of monoethanol amine; diethanol amine; triethanol amine; imidazole; potassium siliconate; and combinations thereof.

### Claim 9 (depends on 1)

The low-dust joint compound composition as recited in claim 1, wherein the weight of said dust reduction additive emulsion is in the range of from about 0.1% to about 20% by weight of said low-dust joint compound composition.

### Claim 10 (depends on 9)

The low-dust joint compound composition as recited in claim 9, wherein the weight of said dust reduction additive emulsion is in the range of from about 0.1% to about 10% by weight of said low-dust joint compound composition.

### Claim 11 (depends on 1)

The low-dust joint compound composition as recited in claim 1, wherein the peak air-borne dust generation of said low-dust joint compound composition is less than 100 mg/m3.

### Claim 12 (depends on 1)

The low-dust joint compound composition as recited in claim 1, wherein the composition further comprises at least one component selected from the group consisting of a silicone, a siliconate, a fluorinated compound, a stearate, or a combination thereof.

### Claim 13 (depends on 12)

The low-dust joint compound of claim 12, wherein the silicones, siliconates, fluorinated compounds, or stearates are selected from the group consisting of metal siliconate salts, potassium siliconate, poly hydrogen methyl siloxane, polydimethyl siloxane, stearate-based salts, and combinations thereof.