# US 2023/0265016 A1 · Wax dispersion composition containing lignin for imparting water resistance to gypsum > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0265016 A1 - Document ID: US20230265016A1 - Status: Published application - Kind: A1 - Application number: 18/142,163 - Filed: 2023-05-02 - Published: 2023-08-24 - Earliest claimed: 2019-08-26 - Assignees: Walker Industries Holdings Limited - Applicants: Walker Industries Holdings Limited - Inventors: Laurence Anthony SINNIGE; Niels Mathieu Barbara SMEETS; Rebecca Katie HUM - Web page: https://patentgrep.com/patent/US20230265016A1 ## CPC - C04B 24/38: Polysaccharides or derivatives thereof {(C04B24/243 takes precedence)} - C08L 97/005: {Lignin} - C04B 22/062: {of the alkali or alkaline-earth metals} - C04B 24/08: Fats; Fatty oils; Ester type waxes; Higher fatty acids, i.e. having at least seven carbon atoms in an unbroken chain bound to a carboxyl group; Oxidised oils or fats - C04B 24/34: Natural resins, e.g. rosin {(C04B24/243 takes precedence)} - C04B 28/14: containing calcium sulfate cements {(gypsum-paper plates E04C)} - C04B 40/0039: {Premixtures of ingredients} - C08L 91/06: Waxes - C09D 191/06: Waxes - C09D 197/005: {Lignin} - C04B 2103/65: Water proofers or repellants - C04B 2111/0062: {Gypsum-paper board like materials} - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - 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) ## Abstract Aqueous water repellency dispersions for use in the manufacture of gypsum wallboard, comprising a wax phase including a wax and a functionalized wax, an aqueous phase including a Kraft lignin and a water soluble base in an amount sufficient to solubilize the Kraft lignin. ## Claims ### Claim 1 An aqueous water repellency dispersion for use in the manufacture of gypsum wallboard comprising: a wax, a functionalized wax, a Kraft lignin, and a water soluble base in an amount sufficient to solubilize the Kraft lignin, wherein the amount of base is determined based on a minimum equivalent base mass ratio (β) plus sufficient base to neutralize the acid value (AV) of the functionalized wax, and wherein, when the base has a pKa≥9.4, a minimum β is about 0.07 and when the base has a pKa<9.4 a minimum β is in the range of 0.17 to greater than 0.07. ### Claim 2 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein Kraft lignin is a purified Kraft lignin. ### Claim 3 (depends on 2) The aqueous water repellency dispersion for use according to claim 2 wherein the purified Kraft lignin is Kraft lignin which has been using a LignoBoost process or a LignoForce process, or other similar purification process. ### Claim 4 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the Kraft lignin is one or more of Amallin™, Indulin™, or BioChoice™. ### Claim 5 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the water soluble base is potassium hydroxide. ### Claim 6 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the amount of base is determined by the amount of base required to achieve β, wherein β is greater than or equal to 0.10, plus the amount of base required to neutralize the AV of the functionalized wax ### Claim 7 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein, the wax is one or more of a naturally occurring wax derived from petroleum, vegetable oil, animal fat, or synthetic wax. ### Claim 8 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the wax is paraffin wax or synthetic wax. ### Claim 9 (depends on 8) The aqueous water repellency dispersion for use according to claim 8 wherein the synthetic wax is alphaolefin wax or Fischer Tropsch wax or a blend thereof. ### Claim 10 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the functionalized wax is a hydrocarbon wax that contains carboxylic acid functionality. ### Claim 11 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the functionalized wax is an oxidized synthetic wax, a maleic anhydride containing wax, Carnauba wax, Montan wax or a mixture thereof. ### Claim 12 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the functionalized wax comprises two or more types of waxes, wherein at least one is an oxidized synthetic wax or a maleic anhydride containing wax, and the other is an oxidized synthetic wax, a maleic anhydride containing wax or a Montan wax. ### Claim 13 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the functionalized wax is a blend of oxidized polyethylene wax and olefinic succinic anhydride wax. ### Claim 14 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein a wax phase, comprising the wax and the functionalized wax is 30 to 45 w/w % of the total aqueous water repellency dispersion. ### Claim 15 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein a wax phase, comprising the wax and the functionalized wax is 32-35 w/w % of the total aqueous water repellency dispersion. ### Claim 16 (depends on 14) The aqueous water repellency dispersion for use according to claim 14 wherein the wax phase contains 3-14 w/w % functionalized wax relative to the total amount of wax. ### Claim 17 (depends on 14) The aqueous water repellency dispersion for use according to claim 14 wherein the wax phase contains 5-7 w/w % functionalized wax relative to the total amount of wax. ### Claim 18 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the kraft lignin is 2-10 w/w % of the total aqueous water repellency dispersion. ### Claim 19 (depends on 1) The aqueous water repellency dispersion for use according to claim 1 wherein the kraft lignin is 4-8 w/w % of the total aqueous water repellency dispersion. ### Claim 20 (depends on 1) A method of preparing an aqueous water repellency dispersion according to claim 1 comprising: i) preparing an aqueous phase containing the Kraft lignin and the water-soluble base; ii) preparing a molten wax blend containing the wax and the functionalized wax; iii) emulsifying the molten wax blend with the aqueous phase and iv) cooling to below the wax melting temperature to form the aqueous water repellency dispersion. ### Claim 21 (depends on 20) The method according to claim 20 wherein the emulsifying step comprises, first, emulsifying under high shear to form a coarse emulsion and second, passing the coarse emulsion through a high shear homogenizer to form a fine emulsion. ### Claim 22 (depends on 21) The method according to claim 21 wherein the emulsion is homogenized at a minimum of 1000/100 psi of pressure. ### Claim 23 (depends on 22) The method according to claim 22 wherein the emulsion is homogenized at about 2500/250 psi of pressure. ### Claim 24 (depends on 21) The method according to claim 21 wherein the high shear homogenization step results in a dispersion that comprises particles having an average particle size that is smaller than the average particle size for corresponding aqueous water repellency dispersions comprising PVA. ### Claim 25 (depends on 1) Use of an aqueous wax dispersion according to claim 1 in the manufacture of gypsum wallboard.