As demonstrated in the formulation of Gilsonite lignosulphonate, asphalt and various other bituminous polymer emulsion compound are effective for surface pavement and for producing coatings, insulation board materials, etc. Although these agents are useful, the instability of emulsions makes it difficult to use these products after their shelf life. Shelf life of the prepared emulsion and the ability of the composition to protect it from deterioration after long-term use. These earlier compositions are formed at high temperatures and are typically used or must be used at high temperatures. The compositions of the present invention are still further developed formulations of Gilsonite emulsions with better properties, as well as many other applications. Until now, gilsonite formulations used heat to soften the gilsonite and aromatic and aliphatic organic solvents to melt the gilsonite. The use of these solvents is now restricted by laws such as the Clean Air Act. Water-based paints and other products are needed to replace VOC-containing products such as solvents and compounds. It was also found that prior art bituminous water emulsions were not capable of producing suitable wood stains and printing inks when greatly reduced by the addition of water. 
The unique properties of gelsonite present unique problems in the formation of stable aqueous emulsions, unlike bitumen in general. Pre-emulsion formulations tend to break down and separate when diluted with water, making them less valuable as wood stains and printing inks. Prior art emulsions were formed at high temperatures. The need to provide a system and method for stable and safe emulsification of gelsonite is due in part to the unique properties of this type of bitumen. Other unmodified asphalt mixtures using pre-emulsifiers and surfactants are brittle. In particular, because emulsion application in printing inks requires relatively high elasticity, these compositions cannot be effectively used as printing inks. Chemicals added to asphalt emulsions so far include a variety of emulsifiers and dispersants, such as polymers to improve flexibility, extensibility, and strength, emulsifiers to help stabilize the emulsion, dispersants, clays, fillers, pigments, and other specialty additives. Conventional mixing or mixing techniques are used to incorporate the chemical into the asphalt emulsion. Previously known emulsified asphalts were used as road slurry sealants but could not be used as wood stains or printer inks because they were incompatible with the components required to produce such products.
To date, none of the prior art emulsions have been found to be effective for use in purified, stable emulsions of gelsonite as wood stains, printing inks, automotive paint emulsions, or similar applications. Aqueous bitumen emulsions known to date usually consist of emulsions in clay form or combinations of cationic, nonionic or anionic emulsifiers combined with bitumen at high temperatures. Surfactants are needed to stabilize emulsions. After the emulsion molecules are combined, the presence of surfactants reduces the repulsive properties of water. Addition of polymer emulsion to asphalt emulsion improves the properties of the resulting coating material. However, the resulting film may be water-soluble, so the water resistance of the processed material is adversely affected. Therefore, the main objective of the present invention is to create gelsonite-based bitumen emulsions in which purified lignin-based emulsifiers are combined to form a stable aqueous emulsion. Another object of the present invention is to provide gilsonite-lignosulfonate emulsions particularly useful in the formulation of wood stains, water-based printing inks, adhesives, modified asphalt compositions, oil drilling muds, and the like.
A further object of the present invention is to provide a gilsonite-lignosulfonate emulsion which can be readily formed by known processing techniques at or near room temperature. The gilsonite emulsion composition of the present invention consists of a base stock consisting of a mixture of gelsonite, water and purified lignosulfonate. Preferred lignosulfonates for use in the present invention have been found to include sodium, ammonium or calcium lignosulfonates with anionic surfactants such as fractionated sodium or calcium salts of oxylignin. The acrylic polymer emulsion can be added to a mixture of purified gelsonite, water and lignosulfonate after appropriate grinding, for example in a gravel or ball mill, to help ensure a uniform distribution of the components. In addition to the refined lignosulfonate used to form the gilsonite emulsion, it has been discovered that carbon black can be incorporated into the emulsion using a selective lignosulfonate to further influence the latent and pigmentation properties of the emulsions of the present invention. Effective in the formation of carbon black emulsion. Gelsonite is suitable for emulsification with fractionated sodium lignosulfonate such as LIGNOSRM 823 manufactured by Georgia-Pacific Corp. Emulsions involving carbon black and gilsonite were not successful until it was discovered that various lignosulfonates could be usefully used to emulsify carbon black and gilsonite.
Lignosulfonate agents useful in the present invention include various purified sodium, calcium, and ammonium lignosulfonates and various xylenes. Lignin is the main non-carbohydrate component of wood and is a natural binder and support polymer for the cellulose fibers of wood and plants. Spruce-derived xylenes with molecular weights between 1,000 and 15,000 exhibit the most desirable dispersion and stability properties when used with gelsonite emulsions. The most useful oxylines in this process are surfactant chemicals characterized as anionic dispersants. Oxygenate is produced from oxidized lignin in a process where the sulfur content of the gnosulfonate feedstock is reduced and the sulfone number is reduced as a result of oxidation-induced condensation, decomposition, and rearrangement reactions. and the number of methoxy groups, phenolic and carboxyl functional hydroxyl groups increases. Waste sulfite liquors without purification and separation into the specific groups of lignosulfonates mentioned above are insufficient to form the gilsonite emulsions of this invention. The preparation of the gilsonite-lignosulfonate dispersion described herein consists of grinding the gelsonite and lignosulfonate in water at approximately room temperature (60-100°F) for an extended period of time to achieve the desired particle size in the dispersant.
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