CN103469675A - 底漆及相关的纸板结构 - Google Patents

底漆及相关的纸板结构 Download PDF

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CN103469675A
CN103469675A CN2013103910790A CN201310391079A CN103469675A CN 103469675 A CN103469675 A CN 103469675A CN 2013103910790 A CN2013103910790 A CN 2013103910790A CN 201310391079 A CN201310391079 A CN 201310391079A CN 103469675 A CN103469675 A CN 103469675A
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priming paint
calcium carbonate
pigment blend
clay
pressboard substrate
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CN103469675B (zh
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G.P.富吉特
S.G.布什豪斯
J.R.霍根
W-H.何
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WestRock MWV LLC
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Abstract

底漆，包括粗研磨碳酸钙和具有至少约40:1的平均纵横比的超扁平状粘土的颜料共混物。

Description

底漆及相关的纸板结构
本申请是以下申请的分案申请：申请日2009年1月23日,申请号200980110406.2，发明名称“底漆及相关的纸板结构”。
优先权
本专利申请要求2008年3月21日提交的美国申请序号61/038,579和2008年12月2日提交的美国申请序号12/326,430的优先权，且这两篇申请的全部内容通过引用并入到此处。
技术领域
本专利申请涉及纸板用涂料，更尤其涉及底漆以及用所公开的底漆形成的光滑纸板结构。
背景技术
纸板用于各种包装应用。例如，无菌液体包装纸板用于包装饮料硬纸盒、箱等。因此，消费者常常优选具有大体上光滑表面和较少缺陷的纸板，以有利于高质量文本和图形的印刷，从而提高在纸板中包装的产品的视觉吸引力。
通常，纸板平滑度通过湿式双辊压光（stack calendering）方法来实现，在该方法中，纸板被再润湿，并通过具有两个或多个硬辊的压光装置。该湿式双辊压光方法通过压缩纤维网络而减少原料纸板中的纹孔（pit）和裂隙，从而使纸板光滑（参见图1）。结果获得了光滑的纸板，具有减小的板厚度和松厚度（bulk），因此，挺度减低。然而，挺度对于许多纸板应用如无菌液体包装纸板来说是重要的要求。因此，使用普通湿式双辊压光方法制备光滑而硬挺的纸板要求增加纸板的基重，从而明显地增加了原材料成本。
另外，制造厂家已经尝试了通过用包括各种颜料如粘土、碳酸钙、TiO2等的底漆涂布纸板的整个表面，然后用第二涂层和时常甚至第三涂层（一般称为面涂层）罩涂（overcoat）该底漆，从而使纸板表面变光滑。已发现，大量的施涂于纸板表面上的相对精细的颜料颗粒提供了更光滑的表面，而不需要湿式双辊压光，从而保持了松厚度。例如，如图2所示，施涂于纸板的粗糙表面上的较大量(例如，10.6磅/3000 ft2或更高)的相对精细的研磨碳酸钙如CARBITAL? 95 (乔治亚州Roswell的Imerys Pigments，Inc.)提供了最大的平滑度。的确，已经了解到，施涂于纸板表面上的颜料越多，所得到的平滑度越好。然而，较大量的颜料的使用显著增加了光滑和高度可印刷的纸板的制备成本。
因此，对于保持纸板松厚度且提供了用于高质量印刷的所需平滑度，同时减低制造成本的底漆和相关纸板结构存在着需求。
发明内容
在一个方面，所公开的底漆可以包括粗研磨碳酸钙和具有至少约40:1的平均纵横比的超扁平状粘土的颜料共混物。
在另一个方面，纸板基材可涂有所公开的底漆，以形成涂布纸板结构。
所公开的底漆和相关纸板结构的其它方面可以从以下说明、附图和所附权利要求书中了解到。
附图说明
图1是示例性纸板基材的无涂层表面(即原料)的照片；
图2是涂有各种量（磅/ 3000 ft2）的根据现有技术的精细研磨碳酸钙的纸板基材的表面的照片对比；
图3是涂有各种量（磅/ 3000 ft2）的所公开的底漆的纸板基材的表面的照片对比；
图4是用超粗研磨碳酸钙配制的各种颜料共混物的沉降空隙体积百分率与粘土组分百分率的关系的图解说明；
图5是用粗研磨碳酸钙配制的各种颜料共混物的沉降空隙体积百分率与粘土组分百分率的关系的图解说明；
图6是用精细研磨碳酸钙配制的各种颜料共混物的沉降空隙体积百分率与粘土组分百分率的关系的图解说明；
图7是派克印刷面（Parker Print Surface ）平滑度与涂布重量的关系的第一图解对比；
图8是派克印刷面平滑度与涂布重量的关系的第二图解对比；
图9是按照所公开的方法涂有所公开的底漆的纸板基材的侧向截面图；和
图10是在第二个更大放大倍数下显示的图9的纸板基材的侧向截面图。
具体实施方式
在一个方面，该公开底漆可以包括高纵横比粘土和碳酸钙的颜料共混物。该颜料共混物可分散在载体如水中，从而有利于将底漆施涂于适当的基材如纸板基材上。其他组分如粘结剂、稳定剂、分散剂和其他颜料可以与该颜料共混物相结合，从而形成不偏离本公开范围的最终底漆。
在这里使用的“纸板基材”广义地是指能够涂布所公开的底漆的任何纸板材料。本领域技术人员将体会到，该纸板基材可以是漂白或未漂白的，且通常比纸厚和更硬挺。通常，纸板基材具有约85磅/3000 ft2或更高的无涂层基重。适当的纸板基材的实例包括瓦楞纸芯层（corrugating medium）、挂面纸板（linerboard）和固体漂白硫酸盐(SBS)。
所公开的底漆的颜料共混物的粘土组分可以是具有较高纵横比或形状系数的任何扁平状粘土（即超扁平状粘土）。在这里使用的术语“纵横比”和“形状系数”是指个体粘土颗粒的几何形状，具体地说该粘土颗粒的第一尺寸(例如，该粘土颗粒的直径或长度)与该粘土颗粒的第二尺寸(例如，该粘土颗粒的厚度或宽度)之比。术语“超扁平状”、“高纵横比”和“较高纵横比”是指通常超过40:1，例如50:1或更高，尤其70:1或更高，并且优选90:1或更高的纵横比。
在一个方面，该颜料共混物的粘土组分可以包括扁平状粘土，其中按平均计该粘土颗粒具有约40:1或更高的纵横比。在另一个方面，该粘土组分可以包括扁平状粘土，其中按平均计该粘土颗粒具有约50:1或更高的纵横比。这种粘土的例子是可从乔治亚州Roswell的Imerys Pigments, Inc.获得的CONTOUR? 1180。在另一个方面，该粘土组分可以包括扁平状粘土，其中按平均计该粘土颗粒具有约90:1或更高的纵横比。这种粘土的例子是也可从Imerys Pigments, Inc.获得的XP-6100。适当的扁平状粘土的其他例子公开在Jones等人的美国专利No. 7,208,039中，该专利的全部内容在这里通过引用而并入。
在另一个方面，颜料共混物的粘土组分可以包括具有较高平均粒度的扁平状粘土。在一个特定方面，该粘土组分可以具有约4微米或更高的平均粒度。在第二个特定方面，该粘土组分可以具有约10微米或更高的平均粒度。在第三个特定方面，该粘土组分可以具有约13微米或更高的平均粒度。
所公开的底漆的颜料共混物的碳酸钙组分可以包括研磨碳酸钙。在一个方面，该碳酸钙组分可以包括精细研磨碳酸钙。这种精细研磨碳酸钙的实例是可从乔治亚州Roswell的Imerys Pigments, Inc.获得的CARBITAL? 95，其中约95%的碳酸钙颗粒具有小于约2微米的直径。在另一个方面，该碳酸钙组分可以包括粗研磨碳酸钙。这种粗研磨碳酸钙的实例是也可从Imerys Pigments, Inc.获得的CARBITAL? 60，其中约60%的碳酸钙颗粒具有小于约2微米的直径。在另外方面，该碳酸钙组分可以包括超粗研磨碳酸钙。这种超粗研磨碳酸钙的实例是也可从Imerys Pigments, Inc.获得的CARBITAL? 35，其中仅仅约35%的碳酸钙颗粒具有小于约2微米的直径。
在另一个方面，该颜料共混物的碳酸钙组分可以具有约1微米或更高，例如约1.5微米，更尤其3微米或更高的平均粒度。
不局限于任何特定理论，据信，配制成提供较高沉降空隙体积百分率（即较膨松的颗粒堆积）的颜料共混物在较低的涂布重量下提供了高平滑度，从而减低了原材料成本。此外，据信，使用具有较高的纵横比和/或较高的平均粒度的粘土组分和具有较高的平均粒度的碳酸钙组分提供了较高和因此理想的沉降空隙体积百分率。例如，超过45%的沉降空隙体积可能是理想的，而超过47.5%的沉降空隙体积可能是更理想的，超过50%的沉降空隙体积可能是还更理想的。
一种适用于测定沉降空隙体积百分率的技术包括制备具有所需重量百分率的粘土组分与碳酸钙组分的颜料共混物样品。该颜料共混物样品然后用水稀释至50 wt%固体，以提供淤浆。将70克淤浆样品投入到离心管中，并在大约8000g下旋转约90分钟。然后从离心机中取出样品，分离出透明的上清液并称重。该沉降物通常被足够致密地填充，使得上清液容易被倒出。基于所除去的水的重量，可以计算出仍然在沉降物的空隙中含有的水的重量。然后，使用颗粒密度，可以将空隙中的水的重量转化为沉降空隙体积百分率。
参见图4-6，提供了各种颜料共混物的沉降空隙体积百分率与粘土组分在颜料共混物中的重量百分率的关系。具体而言，图4-6比较了CARBITAL? 35 (超粗)、CARBITAL? 60 (粗)和CARBITAL? 95 (精细)作为碳酸钙组分的使用以及XP-6100 (纵横比在90:1以上)、CONTOUR? 1180 (纵横比大约50:1)、CONTOUR? Xtrm (纵横比大约45:1)和KCS (纵横比大约10:1 (不是高纵横比粘土))作为粘土组分的使用。
图4-6表明，粗研磨碳酸钙(图4和5)，特别是超粗研磨碳酸钙(图4)以及高纵横比粘土，特别是纵横比在70:1以上，更有其在90:1以上的粘土（XP-6100粘土）提供了最高的沉降空隙体积百分率。
此外，图4-6中的曲线，尤其是与XP-6100粘土有关的曲线中的凹形指出，当粘土组分与碳酸钙组分共混时，获得了最大的沉降空隙体积百分率。例如，参见图4，当使用超粗研磨碳酸钙和XP-6100时，最大沉降空隙体积百分率出现在约60wt%和约90wt%的粘土组分之间。
还有，该曲线的凹形指示，粘土组分和碳酸钙组分的某些共混物提供了与使用100%高纵横比粘土相比即使不是更高也类似的沉降空隙体积百分率。因此，该曲线指示，就沉降空隙体积百分率而言，将价格比较低廉的碳酸钙与更昂贵的高纵横比粘土共混可以获得即使不优越也同等的涂料材料。的确，例如比较图4到图6，该曲线指示，碳酸钙颗粒越粗，获得较高沉降空隙体积百分率所需使用的高纵横比粘土越少。例如，参见图4，当将超粗研磨碳酸钙与XP-6100粘土共混时，粘土组分与碳酸钙组分的45:55共混物提供了与100%高纵横比粘土相同的沉降空隙体积百分率。
参见图7和8，用中试涂布器涂有各种底漆的纸板的派克印刷面（PPS）平滑度值相对于按磅/令(3000 ft2)计的底漆涂布重量来提供。本领域技术人员将体会到，取自用中试涂布器（pilot coater）制备的样品的PPS平滑度值一般高于由实际尺寸磨机所制备的样品获得的PPS平滑度值。尽管如此，使用中试涂布器取得的PPS平滑度值指示了由所公开的底漆相比于现有技术涂料所提供的改进。作为参考，当使用中试涂布器时，约7.0微米或更小的PPS平滑度值一般是理想的，约6.5微米或更小的PPS平滑度值是优选的，约6.0微米或更小的PPS平滑度值是更优选的。
特别有意义的是，如图7所示，包括粗或超粗碳酸钙和高纵横比粘土尤其XP-6100粘土的底漆提供了较高的沉降空隙体积百分率，并且在约9磅/令或更低的涂布重量下在纸板基材上提供了通常在约7微米以下的PPS平滑度值。实际上，如图7中的曲线的正斜率所示，所得纸板的改进平滑度（即较低的PPS平滑度值）直接与较低的涂布重量相关联。该数据与本领域技术人员的预期相反，本领域技术人员将预期在高涂布重量下有较高的平滑度值。
实际上，当使用实际尺寸的磨机时，包括CARBITAL? 35 (研磨碳酸钙)和XP-6100(高纵横比和高平均粒度粘土) 的50:50颜料共混物的底漆在6磅/令的较低涂布重量下获得了大约2微米的PPS平滑度值。
因此，用包括研磨碳酸钙，特别是粗或超粗研磨碳酸钙以及高纵横比粘土，特别是纵横比在约70:1以上的粘土，更尤其是具有较高平均粒度的高纵横比粘土的底漆涂布基材例如纸板，获得了光滑的纸板结构而没有牺牲膨松度，并且通过将较昂贵的扁平状的粘土与价格比较低廉的研磨碳酸钙组合，同时需要令人惊讶的低涂布重量来获得所需平滑度，从而减低了制造成本。
此外，本领域技术人员将体会到，所选择的高纵横比粘土的类型和所选择的研磨碳酸钙的类型以及粘土组分与碳酸钙组分的比率可以基于所需平滑度通过成本考虑来决定。
所公开的底漆可以足够填充基材中的纹孔和裂隙的量施涂于基材如纸板（例如无菌液体包装纸板）的表面上，而无需涂布基材的整个表面。因此，所公开的底漆与所公开的用于施涂该底漆的方法一起，可以用来以较少量的底漆获得高表面平滑度。实际上，如上所述，高表面平滑度可以用出乎意料的少量的所公开的底漆来实现。
在一个方面，使用刮刀涂布机，将底漆施涂于基材上，使得刮刀涂布机推动底漆进入基材的纹孔和裂隙内，同时从基材的表面上除去底漆。具体地说，如图9和10所示，底漆可以更类似于抹墙粉（spackling）的方式施涂，其中基本上所有的底漆存在于基材表面的纹孔和裂隙中而非基材的表面上。
在这一点上，本领域技术人员将体会到，当所公开的底漆在刮刀涂布机中使用时，在移动基材与涂布机的刮刀之间的间距可以减到最小，从而促进填充表面的纹孔和裂隙，而不明显地将底漆沉积在基材的表面上（即，在基材的表面上形成不连续膜）。换句话说，涂布机的刮刀可以定位成充分靠近移动基材的表面，使得涂布机的刮刀推动底漆进入基材表面的纹孔和裂隙中，同时从基材的表面上除去过量的底漆。
实施例1
根据本公开的一个方面所制备的第一颜料共混物包括50 wt% CARBITAL? 35 (粗研磨碳酸钙)和50wt% XP-6100 (超扁平状粘土)。在固定式混合机中，通过将该50:50颜料共混物与水、胶乳粘合剂和增稠剂合并来制备涂料配制剂。以足够形成淤浆的量添加水。按上述方式，使用刮刀涂布机，将涂料配制剂以下列涂布重量施涂于具有约126磅/3000ft2的基重的纸板原料上：6.7、7.9、8.9和11.3磅/3000 ft2。照片结果在图3中示出，而PPS平滑度值在图7中提供（数据点用圆圈标记）。
因此，如图3所示，所公开的底漆和相关的方法在较低的涂布重量下提供了最佳的平滑度（比较图2与图3）。具体地说，在6.7磅/3000 ft2的涂布重量下获得了最大平滑度，而在7.9磅/3000 ft2的涂布重量下获得了良好的平滑度，在8.9磅/3000 ft2的涂布重量下获得了较低的平滑度，在11.3磅/3000 ft2的涂布重量下获得了甚至更低的平滑度。
实施例2
根据本公开的一个方面所制备的第二颜料共混物包括50 wt% Omya Hydrocarb? 60 (购自瑞士Oftringen的Omya AG的粗研磨碳酸钙)和50wt% XP-6170 (购自Imerys Pigments, Inc.的超扁平状粘土)。在固定式混合机中，通过将该50:50颜料共混物与水、胶乳和淀粉粘合剂以及增稠剂合并来制备涂料配制剂。以足够形成淤浆的量添加水。按上述方式，使用刮刀涂布机，将涂料配制剂以5.8磅/3000ft2和6.8磅/3000ft2的涂布重量施涂于具有约106磅/3000ft2的基重的纸板原料上，从而提供了在较低涂布重量下具有改进平滑度的纸板结构。
因此，在这一点上，本领域技术人员将体会到，根据本公开配制以包括粗研磨碳酸钙，尤其超粗研磨碳酸钙和超扁平状粘土，尤其具有超过70:1的纵横比的超扁平状粘土，更尤其是具有较高平均粒度（例如约10微米或更大）的高纵横比粘土的底漆，在较低的涂布重量下提供了增高的表面平滑度，特别是当使用所公开的方法施涂于基材上时。
虽然上述颜料共混物包括扁平状粘土和研磨碳酸钙，尤其粗研磨碳酸钙，但本领域技术人员将领会到，可以使用替代的颜料共混物，而不偏离本发明的范围。例如，所公开的底漆的颜料共混物可以包括扁平状粘土和一种或多种除研磨碳酸钙以外的其他无机颜料，例如沉淀碳酸钙、滑石或高岭土。
虽然已经显示和描述了所公开的底漆和相关纸板结构的各个方面，但在阅读了本说明书之后本领域技术人员可以想到一些变化。本专利申请包括这种变化，并且仅仅根据权利要求的范围来限定。

Claims (19)

1.底漆，包含颜料共混物，其中颜料共混物具有超过45%的沉降空隙体积率，该沉降空隙体积率通过以下方法进行测量：使该颜料共混物用水稀释至50 wt%固体，在8000g下将70克产生的淤浆的样品离心90分钟；并在将透明的上清液倒出并称重后，基于所除去的水的重量，计算出仍然在沉降物的空隙中的水的重量；然后，使用颗粒密度，将空隙中的水的重量转化为沉降空隙体积百分率。
2.根据权利要求1所述的底漆，其中沉降空隙体积率超过47.5%。
3.根据权利要求1所述的底漆，其中沉降空隙体积率超过50%。
4.根据权利要求1所述的底漆，其中颜料共混物包括研磨碳酸钙组分和超扁平状粘土组分。
5.根据权利要求4所述的底漆，其中所述超扁平状粘土组分的平均纵横比是至少40:1。
6.根据权利要求4所述的底漆，其中所述超扁平状粘土组分的平均纵横比是至少70:1。
7.根据权利要求4所述的底漆，其中所述超扁平状粘土组分的平均纵横比是至少90:1。
8.根据权利要求4所述的底漆，其中至多60%的所述研磨碳酸钙组分具有小于2微米的粒度。
9.根据权利要求4所述的底漆，其中至多35%的所述研磨碳酸钙组分具有小于2微米的粒度。
10.根据权利要求4所述的底漆，其中所述研磨碳酸钙组分是所述颜料共混物的至少10 wt%且所述颜料共混物的至多60 wt%。
11.根据权利要求4所述的底漆，其中所述颜料共混物由所述超扁平状粘土组分和所述研磨碳酸钙组分组成。
12.根据权利要求1所述的底漆，其进一步包括载体，其中所述颜料共混物分散在所述载体中，从而形成淤浆。
13.纸板结构，包括涂有根据权利要求1所述的底漆的纸板基材。
14.根据权利要求13所述的纸板结构，其中所述纸板结构具有至少85磅/3000平方英尺的基重的纸板基材。
15.根据权利要求13所述的纸板结构，其中所述底漆在所述纸板基材的表面上形成了不连续膜。
16.根据权利要求13所述的纸板结构，其中所述纸板基材作为在其表面上界定了多个纹孔的纤维网幅形成的，且所述底漆基本上在所述多个纹孔内接受，没有基本上完全覆盖所述表面。
17.根据权利要求13所述的纸板结构，其中所述底漆以每面至多9磅/3000平方英尺的所述纸板基材的涂布重量施涂于所述纸板基材上。
18.根据权利要求13所述的纸板结构，其中所述底漆以每面至多8磅/3000平方英尺的所述纸板基材的涂布重量施涂于所述纸板基材上。
19.根据权利要求13所述的纸板结构，其中所述底漆以每面至多7磅/3000平方英尺的所述纸板基材的涂布重量施涂于所述纸板基材上。
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