MASS AND PROCESS FOR PAPER MANUFACTURE, AND, PAPER

专利摘要:
dough and process for papermaking, and paper, this invention refers to a new method for preparing aqueous masses useful as a raw material in the manufacture of high mineral content products, in particular sheets of paper with a mineral filler content up to 90% that display the physical properties required for the intended applications. the dough comprises fibrillated long fibers / mineral fillers mixed with anionic and coadditive acrylic binders, in the presence or absence of cellulose fibers. the long fibrillated fibers and cellulose fibrils provide a high surface area for fixing a larger load and the reinforcing base network that joins all the product components together. anionic binders allow fast and strong fixation of charge particles on the surfaces of the fibrils, when the mixture is conducted at temperatures above the binder's glass transition temperature (tg). for the new aqueous formulation, other process and functional additives commonly used in the manufacture of paper and cardboard packaging can be added using individual, multiple and multiple papermaking processes. the aqueous formulation can also be used to manufacture items molded by known dough molding processes. aqueous formulations offer excellent load retention and drainage during product manufacture.
公开号:BR112013007704B1
申请号:R112013007704-2
申请日:2011-09-29
公开日:2020-09-29
发明作者:Makhlouf Laleg；Xujun Hua
申请人:Fpinnovations；
IPC主号:

专利说明:

TECHNICAL FIELD
[0001] The invention relates to pulp mass paper mass with a mineral filler content of 50 to 90% by weight, based on total solids, for papermaking; sheet of paper with a filler content of 40 to 90% by weight, and a papermaking process with filler from the pulp mass. TECHNICAL FOUNDATIONS
[0002] The cardboard, paper and plastic industries produce rigid and flexible sheets for a wide variety of uses. Plastic sheets are usually more flexible, tear resistant and stretchable, and more dense and slippery than paper sheets, while ordinary base sheets of paper are usually much more porous and water resistant. For processing and printing purposes, sheets of paper are usually much more attractive than plastic sheets. In order to check the plastic sheet, with some paper characteristics the addition of mineral fillers is necessary. The incorporation of inorganic fillers in thermoplastic polymers has been widely practiced in the industry to extend them and to improve certain properties, that is, opacity and gloss, and also to reduce the cost of the material. US patent 6,054,218 describes a method for producing a sheet made of plastic material and inorganic filler that has the feel and has at least some of the properties of the paper. The loaded plastic sheet according to the invention comprises a multilayer structure having an outer layer, an intermediate layer and an inner layer. The layers comprise different proportions of polyethylene, filler namely calcium carbonate, and pigments namely titanium dioxide and silicate adapted to give a paper feel to the multilayer sheet.
[0003] The process for producing the loaded plastic paper comprises the coextrusion and calendering steps of a thermoplastic polymer, such as polyethylene and inorganic fillers and pigments, at a temperature above the melting point of the thermoplastic polymer, which can be so high like 200 ° C. A product of this nature has been manufactured by A. Schulman Inc. and marketed under the trademark Papermatch®. The manufacturer claims that the process can be used for manufacturing in packaging applications, and for labels, envelopes, wallpaper, prospectuses and a variety of other products. Natural Source Printing, Inc. currently markets FiberStone® Paper, which is also referred to as mineral paper or calcium carbonate paper. According to this company's published sources, mineral paper made from polyethylene combined with up to 80% calcium carbonate filler can be used as a substitute for traditional papers used in the printing industry, such as paper and synthetic film, premium coated paper, recycled paper, PVC sheet, labels and tags. Being impermeable to water, mineral paper can also be very useful for outdoor applications.
[0004] While the above mineral papers have the advantages of being made without the use of ligocellulose fibers and water, they have some important disadvantages: high amounts of petroleum-based polymers, high density and low stiffness. They can be neither recycled nor biodegradable. The analysis of some commercial mineral papers revealed that the sheets are multilayered structures with 54 to 75% inorganic material and the rest is made of thermoplastic polymer, that is, high density polyethylene (HDPE) and coating material. Depending on the level of inorganic material used with thermoplastic, the density of the leaves is in the range of 0.9-1.4 g / cm3. In order to achieve the desired values of opacity, bulk, stiffness and strength, the sheets must be made with high base weights (200 to 300 g / m2 or more). The base weight or weight is the weight per unit area of the sheet. Bulkiness is a term used to indicate volume or thickness in relation to weight. It is the inverse of density (weight per unit volume). It is calculated from a caliper and base weight of the sheet: the volume (cm3 / g) = caliber (mm) * base weight (g / m2) * 1000. Decrease the volume in sheet or in other words, increase the density of the sheet. sheet makes it softer, brighter, more opaque, and lower in stiffness. However, in many applications, such as those used in copy printers, the most critical property is the stiffness of the sheet, which is greatly reduced, the density is increased.
[0005] Because of the general disadvantages of plastic-based mineral paper described above, there is a need for the production of supercharged sheets from renewable, recyclable, biodegradable and sustainable materials, which use the conventional papermaking process. Supercharged sheets must also have low density and the desired volume, opacity and strength properties, even when they are produced at half the basic weights of these commercially available plastic-based mineral paper sheets. Thin normal printing papers made with load contents up to 28% have specific densities ranging from 0.5 to 0.7 g / cm3, which are almost about half of plastic-based mineral papers. For some applications, overloaded sheets must have water resistant characteristics.
[0006] Inorganic (mineral) fillers are generally used in the manufacture of printing papers (copy, inkjet, flexography, offset, engraving) from aqueous dispersions of wood pulp fibers to improve gloss and opacity, and achieve improvements in the definition of printing sheet and dimensional stability. The term "thin" paper is used in the conventional sense of the industry and includes ream paper, bond paper, offset paper, coated printing paper, text and cover material, coated publication paper, book paper and cotton paper. Thin offset paper is sized on the surface with a formulation composed mainly of starch and hydrophobic polymer, such as maleic styrene anhydride, after the web has been dried. The internal load levels on normal thin papers can vary from 10 to 28%. Since fine paper suitable for gravure and offset printing must be strong enough to withstand the high speed printing operation, it has been found that existing papermaking technologies are not suitable for doing the same with a higher load level than 30%.
[0007] Cardboard-based sheets are formed by one or more fibrous layers or sheets and, in general, without added filler. Depending on the end use; cardboard is classified as: 1) cardboard plates (various compositions used to make folding cardboard and assembled / rigid boxes), 2) food packaging plate (used for food and liquid packaging), and 3) corrugated cardboard (used for containers consisting of two or more types of lining plates separated by corrugated means glued to the lining). Depending on the application, the product's surface finish is often achieved by single or double coating using known formulations that can be composed of filler and inorganic pigments, bonding agents and barrier polymers. Some types of packaging have their surfaces covered with polymeric films to provide high barrier properties to gas, water vapor or liquids. Cardboard-based sheets are made almost exclusively from virgin and recycled fibers, and additives. For some multiple types of white tops a very limited amount of inorganic filler (about 5%) is sometimes introduced into the top layer sheet to improve opacity and print quality.
[0008] Manufacture of paper or cardboard, with high internal load levels similar to those of plastic-based mineral paper and with the required properties can be a means to make low-cost green products for a variety of applications, that is, from printing papers, flexible packaging, labels, stickers, maps, bags, wallpapers and other applications. The cost of papermaking fillers, such as precipitated calcium carbonate (PCC), ground calcium carbonate (GCC), kaolin clay, talc, precipitated calcium sulfate (PCS) or calcium sulfate (CS), it is generally less than the cost of cellulose fibers. The savings for the paper maker to produce a ton of paper can be substantial, if the load can be used to replace a large amount of expensive kraft fibers. Because the loaded sheet of paper is much easier to dry than the sheet of paper made without any load material, the drying energy is lower. Since the addition of high charge will substantially improve the opacity of the sheet, it may be possible to obtain this desired property on the basis of lower weight. In addition, a loaded paper base requires less coating material to achieve the required quality of normal coated types.
[0009] The common method of introducing charge for the paper sheet is by measuring the charge suspension to a pulp suspension of about 1 to 3% consistency in locations, such as in a machine box or at the entrance of the fan pump, before the paper machine arrival box. The charge particles normally have a negative charge similar to that of the fibers and thus have little propensity to adsorb on the surfaces of the fibers. As a result, the retention of filler particles with the pulp fibers during the sheet making process is difficult to achieve, especially in modern high-speed paper machines, where mass components experience great shear forces. Therefore, an auxiliary polymeric retention system is always added to the diluted papermaking mass, prior to the arrival box of the paper machine, to improve load retention by known agglomeration and flocculation mechanisms. However, with existing aid retention technologies, achieving high load retention without impairing sheet formation or structural uniformity is still a major challenge. For example, in a modern thin paper machine operating at a speed of 1400 m / min, the first pass through load material retention is about 40-50%. This means that only about half the amount of filler in the manufacturing composition is retained on the sheet during its formation and the remaining portion flows with process water, which is often referred to by the term white water. In many paper mills problems with machine operability, high sewage losses from loading material, holes in the sheet and increased costs of functional additives (sizing, optical brightener, starch), have been associated with poor load retention and load accumulation in the white water system.
[00010] In the papermaking technique once the wet web is formed it requires strength of the wet web suitable for the good progression speed in the paper machine. The dry sheet will require high strength in the Z direction, tensile strength and rigidity of operability in printing presses and copiers, and for other end uses. It is well known that the main obstacle to increasing the load content in types of printing to higher levels is limited by the deterioration of these strength properties. Because the load has no binding capacity, the inclusion of load in the paper prevents fiber-to-fiber bonding. When adding load to the sheet, tensile strength and modulus of elasticity are inevitably reduced by replacing fibers with load particles, not only are there fewer fibers in the sheet, which reduces the strength of fiber-fiber bonds, but also the presence of load decreases the contact area and prevents the occurrence of intimate connections between the fibers. As a result, the addition of filler dramatically reduces the strength of the wet web. A wet paper containing a high amount of load can break more easily in the open passes of a paper machine. Therefore, strong wet sheet is an important criterion for the good operability of the paper machine. Loads are denser than fibers, and thus their addition will also reduce the volume of the sheet, which is essential for flexural rigidity. Poor bonding of charge particles to the fibrous structure can also increase the powder surface in offset printing.
[00011] It is well known that the strength of the paper sheet is affected by the length and surface area of the fibers which influences the relative area bound in the fiber network. The bonded area can be increased by refining the fibers and consolidating the web in the press section of the paper machine. Increasing the bonding area by pressing and fiber refining can increase the internal bonding strength and tensile strength of the sheet, but at the expense of its mass. With a determined base weight, the decrease in sheet mass can reduce the flexural stiffness. However, despite these negative effects on mass and stiffness, in recent years, the development of good fiber by refining and better forming and printing techniques have improved the strength of sheets with fillers, and thinner paper manufacturers now have the possibility of increasing the load levels in their grades by a few percentage points ['' Practical ways to achieve a higher load content on paper ", CFBaker and B. Nazir, Use of minerals in papermaking, Pira Conference, Manchester, February 1997)].
[00012] Another well-known method for increasing the strength of the paper, but without changing the density of the sheet, is the addition of natural and synthetic polymers. They are usually added in small proportions, which can vary from 1 to 20 kg / ton (1 ton = 1.02 t) of paper, to the aqueous pulp mass, or applied to the sheet surface after the continuous sheet of paper be dry. The performance of cationic strength polymers is generally low when added to the mass of long fibers, such as kraft fibers due to their low negative charge and available surface area for the adsorption of the polymers. Performance can be totally impaired when cationic polymers are introduced to the aqueous pulp mass, providing unfavorable chemical conditions, such as high levels of colloidal anionic dissolved substances and high conductivity.
[00013] Despite advances in papermaking and chemical products, the current charge content on all uncoated thin sheets of paper is generally less than 30% of the paper's weight. Using conventional technologies, attempts to increase the load content in these grades to higher levels resulted in insufficient load retention, continuous sheet-to-sheet strength, tensile strength and stiffness, and lower surface strength. Adequate surface strength is required to prevent dust and build-up when operating on a high-speed printing press, that is, during offset printing.
[00014] In recent years, several patents have been granted for making paper with a load. US 4,445,970 teaches a method for making fine paper printing suitable for high speed gravure and offset printing and containing high load levels for a wide variety of base weights. High load levels have been achieved with high base weight sheets, for example, more than 120 g / m2. These highly loaded thin papers were produced in a low speed Fourdrinier paper machine from a mass containing large amounts of filler, preferably a mixture of clay and talc, and including 3-7% of a cationic latex that is selected to provide good retention and good resistance without leaving a residue on the screen. Sheet of fine paper of 120 g / m2 made for this invention, with load of 46% has a tensile strength of 0.665 km. This tensile strength is considered to be very low when compared to that of a normal 73 g / m2 thin paper made with 20% load which has a tensile strength of about 6.0 km. Despite the addition of very high dosages of cationic latex, the paper load content achieved by the invention of this US patent 4,445,970 is still less than 50%.
[00015] A number of previous patents reveal the general idea that the strength of paper can be increased by adding cationic latex to the papermaking mass. Because of the basic electrochemical properties of anionic mass components, cationic latex interacts with fiber surfaces to provide additional fiber bonding and, consequently, resistance to the resulting paper. These patents mainly refer to so-called "high-strength" papers that are largely devoid of filler materials, or at best contain only very small amounts of filler. For example, US 4,178,205 Wessling et al discusses the use of cationic latex, but pigment is not essential. US 4,187,142 Pickleman et al, describes the use of an anionic polymer cations with cationic latex, with the use of a sufficient amount of latex to make the entire papermaking system cationic, the use of charge is not mentioned in any example. Foster et al US 4,189,345 describes extremely high levels of cationic latex.
[00016] US 4,181,567 Riddell et al refers to papermaking, using an agglomerate of ionic polymer and relatively large amounts of filler material. The patent holders indicate that either anionic or cationic polymers can be used, and the fillers mentioned are calcium carbonate, clay, talc, titanium dioxide and mixtures. In example 1, a paper weight of 80 g / m2 with a 29% load is produced using calcium carbonate as the filler. This patent discusses, in essence, the precipitation of the pigment, with an auxiliary retention system before its addition to the composition of the dough.
[00017] It is known in the paper industry that the addition of anionic latex to the wet end of the paper machine, combined with the cationic chemical substance, such as alum, causes the anionic latex to precipitate in the presence of fibers and fillers and thus , gives the paper increased resistance. This procedure is normally used in the manufacture of certain so-called "high-strength" products, such as joint material, saturated cardboard, roofing felt, floor felt, etc. No similar technique has been suggested for making sheets of paper that have loading amounts of up to 90%.
[00018] It has been proposed noting McReynolds US 4,225,383 in the manufacture of relatively thick paper products, similar to the manufacture of felt papers for roofs and floors, using the combination of a cationic polymer with anionic latex, and substantial amounts of mineral filler. However, the product is not designed for printing papers, and the strength requirements are therefore relatively low. In addition, because of the substantial weight of the paper produced by such a technique, the additional strength is created only through its mass.
[00019] Several other patents, including US 4,115,187, US 5,514,212, GB 2,016,498, US 4,710,270, and GB 1,505,641, describe the benefits of treatment with filler additives on the retention properties and of the leaf. It is known that since most particles of common inorganic charges in suspension carry a negative charge, the cationic additive adsorbs on their surfaces, through electrostatic interactions, causing them to agglomerate or flocculate. For anionic additives to promote the flocculation of the charge particles, a positive charge would be necessary to allow the adsorption of the anionic additive. The aggregation of filler particles improves retention during sheet manufacture and can also decrease the negative effect of the filler on the strength of the sheet, but the aggregation of excess load can impair the uniformity of the paper and also decrease the gain in optical properties expected from the addition of charge. The load content obtained by these patents is below 40%.
[00020] In US 7,074,845 from Laleg, anionic latex has been used in combination with bloated starch for the preparation of treated cargo suspensions to be added internally in papermaking. Bloated latex / starch compositions are prepared by premixing the latex with suspension of starch granules in a batch or jet cooker, or by adding hot water to the mixture under controlled conditions to make the starch granules swollen sufficiently to improve its properties as a load additive, but avoid excess swelling leading to breakage. The anionic latex interacts with the swollen cationic starch granules forming an active matrix. The composition is rapidly mixed with the load suspension, the load aggregation increased. The treated filler is then added to the papermaking mass before the sheet is manufactured. The retention of the treated load prepared by this process on the web during papermaking has been improved and the loaded sheets have a higher bond and resistance to internal tension than the loaded sheets produced using the conventional addition of cooked starch to the raw material.
[00021] International publication number WO 2008/148204, Laleg et al, describes a method for increasing the strength of the loaded paper sheet by the continuous treatment of load suspension to improve the fixation of anionic latex in precipitated calcium carbonate particles in a short period of time. In this process, anionic latex is added to the charge suspension at room temperature and then mixed with water at a temperature higher than the glass transition temperature (Tg) of the latex used. In order to effectively fix the latex, the temperature of the filler / latex mixture must be 20-60 ° C higher than the Tg of the latex used. The anionic latex applied by this process is totally and irreversibly fixed or bonded on the charge particles and the aggregate charge suspension is stable over time. In the present invention, the latex-treated cargo suspension is designed for addition to papermaking masses, at any point, prior to the arrival box of the paper machine or stored for later use. Latex-treated load suspension improved load retention, loss of strength greatly impeded sheet strength and better performance of internal sizing agents.
[00022] In US 5,824,364, calcium carbonate crystals are disclosed as being directly formed on fiber fibrils by a precipitation process of calcium hydroxide and carbon dioxide, without the addition of fixing agents. The calcium carbonate load contained in the sheet is limited to the available surface area of the fiber fibrils, as specified by the inventors, in the range of 3-200 m2 / g. The objective of the present method of the prior art was to achieve high load retention, focusing on individual sections of fibers, such as the lumen, cell wall, or fibrils. The paper load content achieved by the present invention was less than 30%. In this patent, no latex or other chemical agents have been used to help fix the charge on the surface of the fibrils and to improve the bond.
[00023] FI 100729 (CA 2,223,955) discloses filler for use in papermaking, the filler comprising porous aggregates formed from particles of calcium carbonate deposited on the surface of fines. According to the patent report, this filler material of a new type is characterized in that the fines are formed by fine fibers prepared by beating cellulose fibers from mechanical or chemical pulp. The size distribution of the fines fraction essentially corresponds to the PI 00 wire mesh fraction. The paper load content achieved by this approach, or by a similar approach described in US 5,824,364 and US 2003/0051837, was about 30% and the strength properties were only slightly higher than the measurements on sheets produced by conventional filler methods.
[00024] Although the aforementioned methods are claimed to help produce sheets with a high load material content and acceptable strength, any attempt to increase the load material to high levels of up to 50% or more has never been done on a conventional paper machine or commercially. Poor load retention, weak dry and wet web resistance and low paper stiffness remain the biggest obstacles for paper manufacturers. Obviously, there is still a need for a technology to manufacture fibrous sheets of supercharged pulp, without the aforementioned papermaking problems. It would be very useful if a simple composition could be designed to allow the attachment of large portions of filler particles to fibrous surfaces and to act as glue or bonding and charge transfer agent between the materials that form the final paper product. It would be more practical, for some applications, if the final product has some barrier and water resistance characteristics. DESCRIPTION OF THE INVENTION
[00025] The present invention aims to provide a pulp mass for paper making comprising: fibrillated long fibers and filler particles, in an amount of up to 90% by weight, based on total solids, for use in the production of paper sheets with high load.
[00026] This invention further seeks to provide a process for making paper with a filler content of up to 90% by weight.
[00027] This invention further seeks to provide a paper having a filler content of up to 90% by weight.
[00028] In one aspect of the invention, a pulp mass for papermaking is provided comprising: fibrillated long fibers, filler particles and an anionic binder, in an aqueous vehicle, said filler particles being in an amount of up to 90% by weight, based on total solids.
[00029] In another aspect of the invention, a papermaking process is provided which comprises a) forming an aqueous pulp mass for papermaking which comprises providing long fibrillated fibers, filler particles and an anionic binder, in a vehicle aqueous, said filler particles in an amount of up to 90% by weight, based on the total solids, b) mixing the pulp mass and subjecting the paper mass mixture to a higher temperature than the Tg of the binder anionic to fix the particles of charge and binder on the fibers, c) draining the pulp mass through a screen to form a leaf, and d) drying the leaf.
[00030] In a particular embodiment, the usual papermaking additives can be added to the pulp mass in a) or b).
[00031] In yet another aspect of the invention, a paper is provided comprising a matrix of fibrillated long fibers, filler particles and an anionic binder, said filler particles, being in an amount of up to 90% by weight, of the paper , and said particles of filler material and the binder being fixed on surfaces of said fibrillated long fibers.
[00032] In preferred embodiments, long fibrillated fibers / loaded dough and the supercharged paper of the invention further comprise high surface area cellulose fibrils such as cellulose nanofilaments (CNF), microfibrillated cellulose (MFC), and / or nanofibril cellulose (NFC). The introduction of CNF, MFC or NFC to pulp mass provides a high surface area for fixing the larger load material and improves the consolidation of the paper structure. The preferred cellulose fibrils for this invention are those made from wood fibers or plant fibers and are long and thin in diameter. DETAILED DESCRIPTION OF THE INVENTION
[00033] The present invention provides a new method for preparing aqueous composite formulations of fibrillated long fibers / mineral filler mixed with anionic binder and, optionally, papermaking additives, in the absence or presence of cellulosic fibrils (CNF, MFC or CNF) , at a mixing temperature above the Tg of the anionic binder and useful for making paper products with mineral fillers up to 80% and the physical properties necessary for the intended applications. Aqueous composite formulations can also be used to manufacture, in existing conventional equipment, cardboard, packaging and shaped molded articles.
[00034] At no time do any of the prior art patents or publications in the open literature disclose or discuss aqueous compositions of fibrillated long fibers and fillers mixed with specific binders at a higher mixing temperature than the Tg of the optionally used binder. cellulosic fibrils with elevated surface areas such as CNF, MFC or NFC, to make products, namely sheet, mat, paper, cardboard packaging and molded articles, containing up to 90% of loading material and with the required physical properties for the applications intended.
[00035] The present invention overcomes the disadvantages described above of the prior art through a method that satisfies the conditions for the production in existing machines, supercharged products with a load content of up to 90% by weight of the total solids. The present invention provides the technology to produce these supercharged products from aqueous compositions, in which the attachment of a large amount of filler particles to high-surface fibrous materials is carried out in order to increase the retention of filler material and to reduce the loss of strength when adding high load. Conventional surface treatment techniques, namely tank finishing press, metering finishing press or coaters can be used successfully to further increase resistance and provide water resistance.
[00036] In general, the invention aims to explore high charge content, mainly up to 90% by weight of total solids charge in the manufacturing composition, or up to 90% based on the dry weight of sheet or paper. However, the invention can also be used for lower load levels.
[00037] The present invention in specific embodiments and in particular is based on average consistency of the mixture of filler material, for example precipitated calcium carbonate or calcium sulfate, with fibrillated long fibers, preferably combined with CNF, MFC or NFC with or followed by the addition of an anionic binder and optionally other functional and process additives used in papermaking, including starch, sizing agent, cationic agent, and drainage and retention aids. Aqueous compositions prepared to total consistencies of up to 10% solids are sheared in a mixing tank, mixing in the pump or, preferably in a refiner at temperatures higher than the Tg of the binder.
[00038] In the shear mixture, at a temperature higher than the Tg of the anionic binder, a simultaneous action of aggregation of charge particles and their fixation or attachment of the fibrous surfaces takes place, removing the charge particles and the binder of the aqueous vehicle of the manufacturing composition. Conventional papermaking coadditives are added to the dough comprising fibrillated long fibers, cellulose fibrils (CNF, MFC or CNF), fillers and anionic binder before product formation. The resulting supercharged sheets can also be treated on the surface in conventional coating or sizing equipment for product development, such as composites and packaging materials with functional properties suitable for the intended applications. At the same load content, the supercharged sheets produced by the present invention can have tweezers similar to those of plastic-based mineral papers at much lower base weights, and yet have higher values of opacity, gloss, tensile strength and rigidity .
[00039] The long fibrillated fibers to be used in the production of the supercharged sheets of this invention can be those treated from wood, similar to those used conventionally in the manufacture of paper and cardboard materials. Long fibrillated fibers made from softwood trees are more preferred for the present invention.
[00040] Some plant fibers, such as hemp, flax, sisal, kenaf and jute, and regenerated cotton and cellulose fibers, can also be used to reinforce overloaded leaves. Regenerated cellulose fibers, such as rayon fibers, can be made in dimensions similar to cotton fibers, and can also be used for long fibrillated fibers. However, optimization and refining of these long coarse fibers is necessary for efficient application and maximizing performance.
[00041] The performance of cellulose fibers to make strong sheets of paper can be substantially improved if their surface area is increased and length preserved, exposing more fibrils on the surface of long fibers during thermo-mechanical refining or pulping of cellulose fibers.
[00042] In the papermaking technique, it is well known that refining pulp fibers causes a variety of simultaneous changes in fiber structure, such as internal and external fibrillation, generation of fines, shortening of the fiber, and curling of the fiber. External fibrillation is defined as interruption and peeling of the fiber surface that leads to the generation of fibrils associated with the fiber surface. External fibrillation also leads to a large increase in surface area (Gary A. Smook, Handbook for Pulp and Paper Technologists, 3rd edition, Angus Wilde Publication Inc., Vancouver, 2002.). Paper made from highly fibrillated fibers has high tensile strength, while shortening the fiber would impair tear resistance, and drainage behavior of the web in the paper machine, so paper producers often carefully refine the pulp for a characteristic drainage system that is more favorable to the operability of the paper machine (Colin F. Baker, Tappi Journal, vol. 78, N0.2-ppl47-153). However, in the present invention, these well-developed fibers have been found to present an excellent opportunity for the manufacture of supercharged paper when the drainage problem is overcome by the addition of high charge and the charge particles were essentially well fixed on the fibrous surfaces through introduction of an anionic binder with a Tg lower than the mass temperature.
[00043] Microfibrillated cellulose (MFC), first introduced by Turbak et al. in 1983 (US 4,374,702), it was produced in homogenizers or microfluidizers by various research organizations and is also commercially manufactured on a small scale. Japanese patents (JP 58197400 and JP 62033360) also claimed that microfibrillated cellulose produced in a homogenizer improves the tensile strength of the paper. More information on microfibrillated cellulose and cellulose nanofibrils can also be found in these two references: "Microfibrillated cellulose, a new cellulose product: properties, uses and commercial potential" J. Appl. Polym. Sci .: Appl. Polym. Symp, 37, 813) and "Cellulose nanofibrils produced by Marielle Henriksson (Doctoral Thesis 2008 - KTH, Stockholm, Sweden: Cellulose nanofibrils and Composites, Preparation, Structure and Properties) from a pre-pulp dissolution treated with 0.5% enzymes, then homogenized in the Microfluidizer had a DP 580.)
[00044] The aforementioned product, MFC is composed of branched fibrils of low aspect ratio of relatively small particles compared to the original cellulose fibers from which they were produced. They are usually much smaller than 1 micrometer, although some can be up to a few micrometers in length.
[00045] Microfibrillated cellulose or nanofibril cellulose described in the patents mentioned above and below can be used in the present invention, for reinforcing supercharged sheets: US 4,374,702, US 6,183,596, US 6,214,163, US 7,381,294, JP 58197400, JP 62033360, US 6,183,596, US 6,214,163. US 7,381,294, WO 2004/009902, and W02007 / 091942. However, the most preferred reinforcement component is cellulose nanofilaments (CNF), produced according to USSN 61/333, 509, deposited on May 1, 2010, Hua et al. The CNF are composed of thin individual filaments (a mixture of micro- and nano-materials), and are much longer than CNF and MFC as disclosed in the aforementioned patents. CNF lengths are typically about 100 micrometers, and even millimeters, but they can have very narrow widths, around 30-500 nanometers, and thus have an extremely high aspect ratio. These materials have been found to be extraordinarily efficient for reinforcing paper (to improve the strength of dry paper and wet web). The introduction of a small amount of this CNF, such as 1 to 5%, in the paper pulp greatly improved the inter-fiber cohesion resistance, the tensile strength, the stretching, and the stiffness of the sheet. Therefore, the application of long fiber fibrillation and high surface area cellulose fibrils, especially CNF, can be very useful for the reinforcement of overloaded papers.
[00046] The level of leaf load to be achieved by the present invention, depends significantly on the proportions of fibrillated long fibers and cellulose fibrils, the type of binder, its dosage and mode of administration. The preferred fibrillated long fibers for use in the present invention can be softwood kraft pulp, softwood thermomechanical pulp or mixtures thereof. A small fraction of other optimized long fibers, such as hemp, kenaf, cotton, rayon or synthetic polymer fibers, which need to be processed for proper length and fibrillation levels, can also be added, along with wood pulp fibers soft, to confer certain functional characteristics of supercharged products. The most preferred fibrillated long fibers are those well developed, readily available fibers, such as bleached softwood thermomechanical pulp commonly used in the manufacture of supercalendered paper types and bleached softwood kraft fibers produced using known papermaking refining conditions who develop external fibrillation without shortening the fiber, either by a high consistency or a low consistency refiner. Highly fibrillated thermomechanical pulp produced by low intensity refining, as described in US patent 6 336 602 (Miles) allows the application of more energy than the conventional refining method to promote fiber evolution instead of cutting fibers.
[00047] The procedure of the invention can be applied commercially by performing the following steps. For suspension mixtures of long fibrillated fibers / cellulose fibers (such as CNF) with a consistency of 2-4% and temperature 20-60 ° C, an amount of filler material, ie precipitated calcium carbonate or plaster, preferably made without an anionic chemical dispersant, is added, and mixing continued. Some filler particles tend to adsorb onto fibril surfaces, but a large part of the filler material remains dispersed in the water. The mixture is then treated with the anionic binder, at a temperature higher than its Tg to complete the fixation of the load on fibrous surfaces. In addition to the anionic binder at a higher temperature than its Tg, the process water becomes free of filler material and binder particles, indicating that the filler and binder are both well fixed on the cellulose surfaces. Preferred binders are anionic acrylate resins commercially available from companies such as BASF with a particle size of 30 to 200 nm or more and Tg ranging from -3 to 50 ° C (US 2008/0202496 Al, Laleg et al) . For the aqueous composition treated with some conventional coadditives or functional additives, cationic starch, chitosan, polyvinylamine, carboxymethylcellulose, sizing agents, and paints or dyes can be added. Other common functional additives, such as wet strength and thickening agents (for example, thermoplastic microspheres made by Eka Chemicals) can also be added to control the strength of the sheet when in contact with polar liquids, and gauge, respectively.
[00048] Depending on the end use, supercharged sheets can be surface treated using conventional presses, such as a size press, or conventional coaters to develop some specific properties. The surface treatment of supercharged paper imparts high surface resistance and hydrophobicity, and also presents more of a load for the final product.
[00049] The aqueous compositions prepared by this invention can be used to produce loaded sheets of base weight ranging from 80 to 400 g / m2, preferably from 100 to 300 g / m2 and more preferably from 150 to 200 g / m2, using conventional papermaking processes. When the aqueous treated binder composition of the present invention is transferred to the paper machine box, a conventional papermaking process additive, namely an auxiliary retention system, is added to improve charge retention during forming. of the leaf. The auxiliary retention system may suitably consist of cationic starch, a cationic polyacrylamide or double component system, such as cationic starch or cationic polyacrylamide and anionic microparticles. The microparticle may be colloidal silica or bentonite, or preferably anionic organic micropolymers. These retention aids are added to the grease before the delivery box, and preferably for the fan pump inlet or the paper machine pressure screen inlet. The addition of coadditives to the dough compositions of this invention followed by the introduction of the auxiliary retention system has been found to be an effective means to achieve very high load retention and strength development. Using the complete procedure of this invention good load retention and improved drainage during sheet manufacture are well achieved in order to manufacture papers with a load content as high as 90%, for example, as high as 80%, or more, than total weight of the leaf mass. Thus, a characteristic paper of the invention can have a loading content of 40 to 80% by weight.
[00050] As discussed above, when precipitated calcium carbonate is added to the fibrillated long fibers / cellulose fibrils, some particles tend to adsorb onto these high area fibrous surfaces, but a large part of the particles remain dispersed in the water. When the anionic binder is added it initially adsorbes onto the charge particles (which are in an aqueous solution or already fixed on fibrous surfaces) by electrostatic or hydrophobic interactions, or by hydrogen bonds and, simultaneously, causing their fixation on fibrous surfaces. When heating the mixture to temperatures above the Tg of the binder, the particles of the binder spread over the surfaces of the charge particles causing their complete fixation on fibrous cellulosic surfaces. The binder adsorbed from latex or scatters and binds strongly to the charge particles, along with the fibrous surfaces, thus reinforcing the paper composite and increasing its strength and other physical properties. Surface strength, paper porosity and smoothness are all improved. The degree of load and fixation of the binder on cellulosic fibrous surfaces was found to be greatly dependent on the consistency of the mass, the dosage rate of binding agent and its Tg and temperature.
[00051] When a Tg binder ranging between -3 and 50 ° C, such as those in the resin series made by BASF under the Acronal® trademark, is mixed, either alone or in combination with an Acrodur® dispersion that develops rigid film at room temperature and above 50 ° C, with an aqueous composition of fibrillated long fibers / cellulose fibrils / filler in mass consistencies of 3 to 10% or more and the temperature above the Tg of Acronal binder all particles of fillers, such as PCC, tend to deposit quickly on the fibrous cellulosic surface of the high surface area. This adsorption or fast fixation of load and binder is irreversible, even under high shear mixture of the treated load suspension for prolonged periods of time. This type of particle fixation on fibrous cellulosic surfaces is very different than that achieved with polymeric flocculants, which tend to flocculate all components in bulk in large flakes and the flakes are generally very sensitive to shear and dependent on time or deterioration with mixing time. The level of anionic adsorption binding agent induced under the conditions used can be as high as 100 kg / ton (1 ton = 1.02 t) of the amount of solid material of the mass (filler and cellulose) used, especially for the masses made with the addition of PCC, PCS or their mixtures, both made without anionic chemical dispersant. It was found that the greater the consistency of the mass composition, the better the adsorption of binder and a load fixation on fibrous cellulosic surfaces. Such adsorption of induced binder and load fixation caused very high load retention and better water drainage during the sheet manufacturing process.
[00052] For example, the filtered water collected during the manufacture of the sheet is very clear, indicating that the binder and filler are well retained in the sheet.
[00053] Although the fixation of the anionic binder according to the present invention is complete when used with PCC, PCS and cationic talc or other cationic charge and pigment suspensions, for anionically dispersed charge suspensions, such as GCC, clays, talc, TiCL, cationic agents, such as calcium chloride, zirconium compounds (ammonium and zirconium carbonate, zirconium hydroxychloride, chitosan, polyvinylamine, polyethyleneimine, poly (dadmac), organic or inorganic microparticles, can also be pre-mixed with these loads to initiate the fixation of the anionic binder on its surface causing them to stick to fibrous surfaces and allow for greater binder fixation.
[00054] Below is a description of the ingredients that form the aqueous pulp dough compositions of the present invention:
[00055] Fibrillated long fibers'. The preferred fibrillated long fibers for use in the manufacture of supercharged sheets or articles of the present invention may be conventional externally fibrillated softwood kraft fibers, bleached thermomechanical softwood pulps, bleached chemo-thermomechanical softwood pulps, or mixtures thereof. The preferred softwood kraft pulp are those refined by Canadian Standard Freedom value - Canadian Standard Freeness value (CSF) as low as 50-400 ml, and as an example 200-400 ml using a high disc refiner consistency or a low consistency disc refiner, under conditions that favor external and blunt fiber fibrillation (Colin F. Baker, Tappi Journal, vol. 78, N ° .2-ppl47-153, whose teachings are incorporated here by reference). CSF is used as an industry index to predict the drainage rate of the pulp during the sheet making process. The lower the number, the more refined the fibers are and thus the slower the drainage rate. The other preferred pulps are the well developed bleached thermomechanical pulps similar to the pulps processed for the manufacture of supercalendered papers and have CSF values as low as 30-60 ml (US patent 6,336,602 to Miles, the teachings of which are incorporated by reference here ). A small fraction of non-wood fibers such as cotton, rayon or some annuals can also be used in the composition to improve some special properties of the final product. In order to efficiently use these long fibers in the compositions of the present invention they are suitably processed to reduce their length to a range of 5 to 10 mm and, preferably, refined according to Colin F. Baker (Tappi Journal, vol. 78, No. 2-ppl47-153), the teachings of which are incorporated herein by reference, to develop external fibrillation.
[00056] Cellulose fibrils'. Any cellulose-based fibers, such as CNF, MFC or NFC, can be used in the present invention. However, the preferred ones are the CNF fibrils described in the aforementioned USSN 61 / 333,509, Hua et al. and MFC described in J. Appl. Polym. Know. Appl. Polym. Symp., 37. 813, the teachings of both being incorporated herein by reference. The proportion of cellulose fibrils to the fibrillated long fiber fraction can vary from 0 to 50%. The fibrillated long fibers and cellulose fibrils to be used in the present invention can be improved by modifying their surfaces with chemical agents, especially polymers or resins that have cationic or anionic functional groups. Examples of such chemical agents are chitosan, polyvinylamine, cationic starch, cationic polyvinyl alcohol, cationic maleic anhydride, cationic latex, carboxymethylcellulose and polyacrylic acid.
[00057] Loads'. Loads for use in the present invention are typically inorganic materials with an average particle size ranging from 0.1 to 30 pm, more usually from 1 to 10 microns, such as usual loads for making paper such as clay, ground calcium carbonate (GCC), chalk, PCC, PCS, talc and mixtures. Preferred fillers are those made without or with a low level of anionic chemical dispersants. The most preferred inorganic fillers for use with anionic binders are those that are naturally carrying a positive charge in their application of commercial suspension, such as PCCs processed without anionic chemical dispersants. The load ratio for the fibrous cellulose fraction can vary from 50 to 90%. The charge will typically be in an amount of 50 to 90% or more, by weight of dry solids, of the mass, and in an amount of 40 to 90%, such as 40 to 80% by weight, of the dry paper. Typical papers of the present invention can contain 50 to 70%, or 60 to 80%, or 50 to 80% or 60 to 70% by weight, of the dry paper.
[00058] Binders: The binders to be used in the present invention are generally produced by emulsion polymerization of the appropriate monomers in the presence of a surfactant and the surfactant becomes adsorbed on the polymerized resin particles. The surfactant, which forms a shell in the resin particles (latex), often gives a charge. An important embodiment of the present invention involves the use of anionic latex, zwitterionic or amphoteric latex (containing both anionic and cationic sites). Preferred binder dispersions include acrylic polymers, styrene / butyl acrylate polymers, n-butyl acrylate polymers, styrene acrylonitrile and carboxylated styrene / butadiene polymers. The preferred Tg of the binders used in the present invention varies between -3 and 50 ° C and their average particle size ranges between 30 and 300 nm. The most preferred anionic binders of the present invention are acrylic-based products with Tg ranging from 0 to 40 ° C and particle size between 60 and 200 nm. However, another water-based resin / higher film binder system, such as that marketed by BASF under the Acrodur® trade name, can be combined with low Tg Acronal® binders to achieve paper with stronger and more rigid load. Anionic dispersions of Acrodur® are one component binder systems consisting of a modified polyacrylic acid and a polyalcohol crosslinking agent. The dosage of the binder (based on the solids content) of long fibrillated fibers / cellulose fibers / filler can vary from 0.5 to 100 kg / ton (1 ton = 1.02 t) of paper, but the dosage ranges preferred for the addition of high load are between 10 and 20 kg / ton (1 ton = 1.02 t). of paper. The most preferred dosage level for Acrodur dispersion is in the range of 2 to 4 kg / ton (1 ton = 1.02 t). . The dosage of the binder is governed by the requirement that substantially all particles of the binder become bound to filler particles and the fibrous surfaces. In particular, the charge particles are irreversibly bound by the binder to the fibrous surfaces, or clusters of charge particles are irreversibly bound by the binder to the fibrous surfaces and, in the case of agglomerates, the particles that form the agglomerates can be irreversibly bound in agglomerated by the ligand.
[00059] Coadditives'. For aqueous compositions produced by the present invention conventional and coadditive papermaking agents can be added to improve fixation, retention, drainage, hydrophobicity, color, volume, and binding, for example, polyvinylamine marketed by BASF, any cationic starch or amphoteric starch, cationic emulsions of sizing agent, such as alkyl ketene dimer, alkenyl succinic anhydride, maleic styrene anhydride, and pitch, wet strength agents, dyes, optical brightening agents, bulking agent, such as thermally expandable thermoplastic microspheres marketed by Eka Nobel. The grease can include a conventional auxiliary retention system that can be a chemical, such as an anionic microparticle (colloidal silicic acid, bentonite), anionic polyacrylamide, a cationic polymer (cationic polyacrylamide, cationic starch), or dual chemical systems (polymer cationic / anionic microparticle, cationic polymer / anionic polymer). The preferred auxiliary retention system is similar to those marketed by Kemira and BASF (and Ciba), where the combination of cationic polyacrylamide and anionic microparticle is used.
[00060] The aqueous composition made by the method of the present invention can be used to make sheets using conventional papermaking techniques or molding techniques, that is, products formed on forming fabric or a canvas from the drained aqueous composition, dry and eventually calendered. Dry supercharged paper can be surface treated on conventional size presses or coaters to provide additional surface characteristics.
[00061] The reference to% quantities here should be understood as% by weight, unless otherwise indicated. BRIEF DESCRIPTION OF THE DRAWINGS
[00062] Figure 1 is an electron scanning microscopy (SEM) image showing typical fibrillated softwood kraft fibers (250 ml CSF) and bleached softwood thermomechanical pulp fibers (50 ml) CSF) used in accordance with the present invention produced by refining softwood kraft pulp and softwood thermomechanical pulp; Figure 2 shows a SEM image of CNF composed of the thin and long fibrils, produced according to USSN 61 / 333.509, Hua et al; Figure 3 schematically illustrates the process for applying the aqueous compositions of the present invention, in a particular embodiment; Figure 4 shows a SEM image of PCC particles, aggregated and fixed to the surfaces of fibrillated fibers made from bleached thermomechanical pulp with 50 ml of freedom; Figure 5 shows a SEM image of PCC particles, aggregated and fixed to the fibrillated fiber surfaces made of bleached thermomechanical pulp with 50 ml of freedom in figure 4, but, afterwards, the sample was subjected to shear mixture for 1 minute in a dynamic drain bottle at 750 rpm; Figure 6a shows SEM images at two magnification levels, 500pm and 100pm of the surface of a sheet with a high load (81% PCC) made by this invention. The images of the leaf surface indicate the distribution of the fibrous component and the load component. Figure 6b shows SEM images at two levels of magnification of a cross section of the highly loaded sheet of Figure 6a. The cross-sectional images show that the PCC particles, aggregated and fixed by Acronal binder on surfaces of a mixture of fibrillated long fibers of softwood kraft pulp and cellulose fibers; CNF; and Figure 7 graphically illustrates the wet strength of the never-loaded supercharged sheets of the invention with a 50% wet solids content. These sheets were produced produced in the pilot paper machine at 800 m / min. DETAILED DESCRIPTION OF THE DRAWINGS
[00063] With additional reference to figures 1 and 2, the thin width of long fibrillated fibers and cellulose fibrils allows for high flexibility and a greater bonding area per unit mass of the material. The high length and high surface area allows for the development of better entanglement and connection sites with high tensile strength and rigidity of loaded paper composites. The high ratio of surface area to the weight of the fibrillated long fiber and cellulose fibrils of the present invention has been found to be very useful for making strong supercharged sheets.
[00064] Still with reference to figure 3, sheets or other elements of different base weight and load content can be produced from the aqueous compositions according to the following procedure. To the fibrillated long fibers / filler compositions, in the absence or presence of cellulose fibrils namely CNF, MFC, or NFC, dispersions of anionic binders (Acronal and / or Acrodur) and conventional coadditives are added. CNF cellulose fibrils produced according to the invention of USSN 61/333, 509 Hua et al mentioned above or MFC or NFC produced by the aforementioned references can be used as such or modified with cationic or anionic components. Before producing a sheet an auxiliary retention system of cationic polyacrylamide compound and anionic micropolymer is added. Loaded formed products can still be surface treated using conventional methods.
[00065] Figure 3 shows an apparatus 10, having a mass tank 12, a machine chamber 14, and a paper machine 16. Providing mass tank 10 has an entry line 18 for long fibrillated fibers, a line of inlet 20 for the suspension of cargo material and an inlet line 22 for the anionic binder, as well as an optional inlet line 24 of fibrils such as CNF. Line 26 communicates the mass tank 12 with the machine chamber 14. A dilution line 28 for white water from the machine communicates with line 26. Line 30 communicates the machine chamber 14 with the paper machine 16. A line optional input line 32 for coadditives communicates with the machine chamber 14. An optional line 34 for conventional functional papermaking additives communicates with line 30. An optional line 36 for a conventional auxiliary retention system communicates with the machine of paper 16. An overloaded sheet 38 leaves the paper machine 16 and can undergo an optional surface treatment 40.
[00066] The dough is formed in the dough tank 12 and fed to the machine chamber 14 where the coadditives can be introduced into the manufacturing composition, and from there to the paper machine 16 for the papermaking to produce the supercharged sheet38.
[00067] With additional reference to figures 4 and 5, the addition of an Acronal binder (resin) of Tg = 3 ° C for the aqueous composition of externally fibrillated bleached softwood pulp / PCC cellulose filler, in the absence of fibrils of CNF cellulose allowed excellent fixation of the load material, which resulted in retention with high load during sheet manufacture. Using this approach, pulps with extremely high levels of fixed PCC charge particles, for example a 2: 1 load: fiber ratio, were produced. The supercharged sheet made from this aqueous formulation has good strength, stiffness, porosity and load distribution in the Z direction
[00068] With additional reference to the SEM images of figures 6a and 6b (surface and a cross section b), the sheets were produced with 81% PCC load. The addition of an Acronal binder (resin) of Tg = 3 ° C for the aqueous composition of the 50/50 blend of fibrillated long fibers of softwood kraft pulp / CNF cellulose fibrils / PCC load, allowed a complete fixation of the load on the small fraction of fibrous surfaces. The aggregated PCC particles are well bonded by the matrix composed of cellulose and a film-forming binder.
[00069] Still with reference to figure 7, this shows the wet resistance value of the continuous sheet obtained without and with the treatment technology of the invention. As mentioned earlier, wet resistance of the web is very critical to the operability of the paper machine producing supercharged sheets. To evaluate the effect of the binder on the wet strength of the continuous sheet of the supercharged sheets, a pilot test of the paper machine was performed using the following conditions. An aqueous composition made of fibrillated long fibers was composed of 70% bleached well-developed softwood thermomechanical pulp (CSF = 50 ml) / 30% refined bleached softwood kraft pulp (CSF: 350 ml) was mixed with 70% of PCC, then the mixture was treated with 0.5% Acronal binder (trademark) of Tg 0 ° C. The temperature of the dough mixture was 50 ° C. For the treated binder composition, the following coadditives were added: 0.12% BASF polyvinylamine (PVAm) and 1.2% cationic starch, followed by a double auxiliary retention system (0.04% cationic polyacrylamide / 0.03% anionic micropolymer). This mass was successfully used to make paper with a base weight ranging between 75 and 90 g / nr and a load content of up to 50% in the double-wire pilot paper machine at a speed of 800 m / min. For comparison purposes, the highly loaded sheets were also produced in the absence of binder and coadditive. As shown in figure 7, the presence of the binder significantly improved the wet strength of the web. This improvement was more significant in the higher load content. EXAMPLES:
[00070] The method of the present invention can be better described and understood by the following illustrative examples. In the examples, the results were obtained using both laboratory techniques and pilot scale tests of the paper machine. Example 1:
[00071] The paper samples of figures 6a and 6b produced during the pilot test of the paper machine were compared with a thin commercial paper (copy grade). The highly loaded sheets had strength and stiffness similar to that of typical thin papers made from kraft pulp having only 20% load. Table 1 shows the results of the tests. All% of chemical dosages are based on the weight of the dry materials. Table 1. Comparison of commercial paper with test papers
Example 2.
[00072] To further improve the wet strength of the continuous sheet of charged sheets, CNF cellulose fibrils are incorporated into the dough composition. In a laboratory experiment, CNF was produced in accordance with USSN 61 / 333.509, Hua et al. CNF was additionally treated to allow adsorption on the surface of chitosan (a natural linear cationic polymer extracted from sea shells). The total adsorption of chitosan was close to 10% based on the mass of CNF. The modified CNF surface treated in this way carried cationic charges and the primary amino groups and had a surface charge of 60 meq / kg. The modified CNF surface was then mixed in a thin paper mass at a dosage of 2.5%. The dough contains 40% bleached kraft pulp (soft wood: hard wood = 25:75, refined to 230 ml CSF) and 60% PCC. Sheets of paper containing 50% PCC were prepared on a dry weight basis of eight grams per square meter. For comparison, paper towels were also made with the same mass, but without CNF. In the absence of CNF, the resulting wet sheet in 50% solids showed a TEA index of only 23 mJ / g. In the presence of 2.5% CNF, the TEA was improved to 75 mJ / g, more than three times higher than the control. Example 3:
[00073] The 50/50 kraft pulp of bleached softwood / CNF was mixed with 80% of the PCC. The CNF was produced according to the description of USSN 61 / 333.509 mentioned above, Hua et al. The bleached softwood kraft pulp was also mixed with 80% PCC, in the presence and absence of CNF. The bleached softwood kraft pulp was refined in a low consistency refiner (4%) to a 350 ml CSF. The consistency of each dough was 10%. Acronal resin at Tg = 3 ° C was added at a dosage of 1% to each mixture of preheated dough to 50 ° C. Then, the coadditives were introduced treated mass: 0.5% polyvinylamine (PVAm), followed by 3% cooked cationic starch. After 10 min the mixture of the auxiliary retention system (0.02% CP AM and 0.06% anionic micropolymer) was introduced and retention was determined using a conventional dynamic drainage flask equipped with a papermaking fabric 60 / 86 mesh and the dough was scraped at 750 rpm. For comparison, retention without the introduction of a retention aid was also determined. In the absence of CNF, PCC retention was only 50%. In the presence of CNF, PCC retention was over 95%, indicating that CNF has a very positive effect on PCC retention. Example 4:
[00074] Sheets of commercial mineral paper (single layer and three layers), made by extrusion and calendering process were tested for comparison purposes with the supercharged sheets of the invention. The results are shown in Tables 2a and 2b Table 2a: Commercial mineral paper
Average light absorption coefficient of leaves above is 0.24 m2 / kg Table 2b: Commercial mineral papers

[00075] The sheets of paper (150 g / m2) of the present invention were prepared, without and with the introduction of CNF, using a dynamic sheet forming machine from aqueous compositions containing up to 80% PCC. For the compositions, 1% Acronal binder was added. The CNF produced according to the invention of the aforementioned USSN 61 / 333.509, Hua et al, has been modified with a poly vinyl amine (PVAm), to make it positively charged. The temperature of the aqueous composition was 50 ° C. For the treated binder mass the cationic starch coadditive, at a dosage rate of 3% was added and mixing continued for 10 minutes, then the retention aid was introduced. The double retention auxiliary (RA) system, composed of cationic polyacrylamide and anionic micropolymer was used, then the leaves were produced. For all experiments, the dosages of cationic polyacrylamide and anionic micropolymer were 0.02% and 0.06%. The formed continuous sheets were pressed in a laboratory roller press, then dried in a photographic dryer at 105 ° C. Before the test, the dried leaves were conditioned in a room at 50% RH and 23 ° C for 24 hours.
[00076] For the experiments to produce highly loaded sheets of 150 g / m2, the bleached pulp fiber used was BSKP refined bleached softwood kraft pulp (CSF = 350 ml), the load suspension was provided with a scalenehedral HO PCC structure provided by Specialty Minerals Inc. The PCC suspension used in these examples has a consistency of 20% and an average particle size of 1.4 pm.
[00077] The results of highly loaded sheets with load (single layer or three layers) are shown in Table 2c and 2d. Table 2c: Overloaded sheets with load (single layer) of the present invention
Average light absorption coefficient of leaves above is 0.17 m2 / kg
[00078] The order of addition of the ingredients to make the final doughs and to produce the highly loaded sheets is described below: A: (75% PCC / 25% rBSKP) + 1% Acronal binder + 0.5% PVAm + 3 % CS + RA; B: (75% PCC / 10% CNF / 15% rBSKP) + 1% Acronal ligand + 0.5% PVAm + 3% CS + RA; C: (75% PCC / 15% CNF / 15% rBSKP) + 1% Acronal binder + 0.5% PVAm + 3% CS + RA. Table 2d: Overloaded sheets (three layers: Top / Middle / Bottom) of the present invention
Average light absorption coefficient of leaves above is 0.17 m2 / kg
[00079] The order of addition of the ingredients to make the final doughs and to produce the highly loaded sheets is described below: E: upper and lower layers: (70% PCC / 30% rBSKP) + 1% Acronal binder + 0, 5% PVAm + 3% CS; Middle layer: (75% PCC / 25% rBSKP) + 1% Acronal ligand + 3% CS; F: upper and lower layers: (70% PCC / 10% CNF / 20% rBSKP) * 1% Acronal binder + 0.5% PVAm + 3% CS; Middle layer: (75% PCC / 10% CNF / 15% rBSKP) + 1% Acronal ligand + 3% CS; G: upper and lower layers (85% PCC / 15% CNF) + 1% Acronal binder + 0.5% PVAm + 3% CS; Middle layer: (75% PCC / 10% CNF / 15% rBSKP) + 1% Acronal ligand + 3% CS.
[00080] All percentages here are by weight unless otherwise indicated.

权利要求:
Claims (15)
[0001]
1. Papermaking paste, characterized by the fact that it comprises long fibrillated fibers, cellulose fibrils, mineral fillers, and an anionic binder, in an aqueous vehicle, said mineral fillers being in an amount of 40 to 90% in weight, based on total solids, said anionic binder being in an amount of 0.5 to 100 kg / ton (1 ton = 1.02 t) in weight, based on total solids; and said particles of mineral charge being totally and irreversibly fixed on said fibers by said anionic binder so that said aqueous vehicle is free of particles of unsecured mineral charge and particles of binder.
[0002]
2. Papermaking paste according to claim 1, characterized by the fact that said cellulose fibrils comprise at least one cellulose nanofilament (CNF), microfibrillated cellulose (MFC) and nanofibril cellulose (NFC).
[0003]
3. Papermaking paste according to claim 2, characterized by the fact that said cellulose fibrils comprise cellulosic nanofilaments with a length of 200 pm to 2 mm and a width of 30 nm to 500 nm.
[0004]
4. Papermaking paste according to any one of claims 1 to 3, characterized by the fact that said mineral filler particles are in an amount of 60% to 80% by weight based on total solids and, that said dough has a total consistency of up to 10% by weight of solids.
[0005]
5. Papermaking paste according to any one of claims 1 to 4, characterized by the fact that said fibrillated long fibers comprise 50-400 ml CSF softwood chemical fibers or 30-60 softwood thermomechanical fibers ml of CSF.
[0006]
6. Papermaking paste according to any one of claims 1 to 5, characterized by the fact that said particles of mineral filler and anionic binder are fixed on surfaces of said long fibrillated fibers and cellulose fibrils at a higher temperature than the Tg of the anionic ligand.
[0007]
7. Papermaking mass being pulp mass according to any one of claims 1 to 6, characterized by the fact that said particles of mineral charge are attached to the surfaces of cellulose fibers and fibrils by said anionic binder, and optionally further comprising coadditives.
[0008]
8. Papermaking process, characterized by the fact that it comprises: a) formation of an aqueous papermaking mass as defined in claim 1 comprising long fibrillated fibers, cellulose fibrils, mineral fillers and a particulate anionic binder , in an aqueous vehicle, and optionally includes the addition of coadditives and an auxiliary retention system, said mineral filler particles being in an amount of up to 90% by weight, based on total solids, and said particulate anionic binder being in an amount of 0.5 to 100 kg / ton (1 ton = 1.02 t) by weight, based on the total solids; b) mix the dough and submit the dough to a higher temperature than the Tg of the anionic binder to fully and irreversibly fix the charge particles with the anionic binder on the surfaces of the fibers, c) drain the dough through a screen to forming a sheet, and d) drying the sheet and optionally treating the surface of the dry sheet using conventional methods.
[0009]
Process according to claim 8, characterized in that said cellulose fibrils comprise at least one of cellulose nanofilaments (CNF), microfibrilated cellulose (MFC) and nanofibril cellulose (NFC), preferably CNF which is of a length 200 pm to 2 mm and a width of 30 nm to 500 nm.
[0010]
Process according to claim 8 or 9, characterized in that said mineral filler particles in a) are in an amount of 50% to 90% by weight based on total solids; said particulate anionic binder in a) is in an amount of 10 to 20 kg / ton (1 ton = 1.02 t) in weight, based on the total solids, said mass in a) has a total consistency of up to 10% in weight, of solids and said long fibrillated fibers comprise chemical fibers of soft wood of 50-400 ml of CSF or thermomechanical fibers of soft wood of 30-60 ml of CSF.
[0011]
Process according to any one of claims 8 to 10, characterized in that said anionic binder is incorporated into said mass in a), as an aqueous dispersion, said mass having a higher temperature than the Tg of the anionic binder ; and said mass in a) is mixed under shear with simultaneous coating and aggregation of the mineral filler particles and deposit on the fibers and fibrils.
[0012]
12. Paper made by the papermaking dough as defined in claim 1, characterized by the fact that it comprises a matrix of fibrillated long fibers, cellulose fibrils, mineral filler particles and a particulate anionic binder, said mineral filler particles being in an amount of 40% to 90% by weight of the paper, said particulate anionic binder being in an amount of 0.5 to 100 kg / ton (1 ton = 1.02 t) by weight, of the paper; and said charge particles being totally and irreversibly fixed on surfaces of said fibers and cellulose fibrils by said anionic ligand.
[0013]
13. Paper according to claim 12, characterized by the fact that said mineral filler particles are in an amount of 60% to 80% by weight, of the paper.
[0014]
Paper according to claim 12 or 13, characterized by the fact that said particles of mineral filler are bonded with the binder to the surfaces of said fibers and cellulose fibrils.
[0015]
15. Paper according to any one of claims 12 to 14, characterized in that said cellulose fibrils comprise at least one cellulose nanofilament (CNF), microfibrillated cellulose (MFC) and nanofibril cellulose (NFC), preferably CNF having a length of 200 pm to 2 mm and a width of 30 nm to 500 nm; said mineral filler particles are in an amount of 50% to 70%, or 60% to 80% by weight; said fibrillated long fibers comprise chemical softwood fibers of 50-400 ml of CSF or thermomechanical softwood fibers of 30-60 ml of CSF; and said paper has a basis weight of 80 to 400 g / m2, preferably from 100 to 300 g / m2 and, more preferably, from 150 to 200 g / m2.

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公开号 | 公开日

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US8608906B2|2013-12-17|

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JP2013542335A|2013-11-21|

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EP2622133A1|2013-08-07|

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EP2622133B1|2016-11-23|

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US20120080156A1|2012-04-05|

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CN103180511B|2016-04-06|

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AU2011308039A1|2013-03-28|

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CN103180511A|2013-06-26|

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CA2810424A1|2012-04-05|

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CA2810424C|2018-04-03|

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WO2012040830A1|2012-04-05|

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KR20130124318A|2013-11-13|

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BR112013007704A2|2016-08-09|

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JP6169970B2|2017-07-26|

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KR101861529B1|2018-06-29|

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EP2622133A4|2014-10-08|

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法律状态:
2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-06-04| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|

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2020-04-07| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2020-08-25| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-09-29| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 29/09/2011, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US38893910P| true| 2010-10-01|2010-10-01|

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US61/388939|2010-10-01|

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PCT/CA2011/001097|WO2012040830A1|2010-10-01|2011-09-29|Cellulose-reinforced high mineral content products and methods of making the same|

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