EP0000922B1 - A process for preparing a non-woven fibrous web from fibers and a latex, and the non-woven fibrous material so prepared - Google Patents

A process for preparing a non-woven fibrous web from fibers and a latex, and the non-woven fibrous material so prepared Download PDF

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Publication number
EP0000922B1
EP0000922B1 EP78100677A EP78100677A EP0000922B1 EP 0000922 B1 EP0000922 B1 EP 0000922B1 EP 78100677 A EP78100677 A EP 78100677A EP 78100677 A EP78100677 A EP 78100677A EP 0000922 B1 EP0000922 B1 EP 0000922B1
Authority
EP
European Patent Office
Prior art keywords
latex
fiber
woven fibrous
amount
polymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP78100677A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0000922A1 (en
Inventor
Ritchie Antone Wessling
William Albert Foster
Dale Martin Pickelman
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dow Chemical Co
Original Assignee
Dow Chemical Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dow Chemical Co filed Critical Dow Chemical Co
Publication of EP0000922A1 publication Critical patent/EP0000922A1/en
Application granted granted Critical
Publication of EP0000922B1 publication Critical patent/EP0000922B1/en
Expired legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/41—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing ionic groups
    • D21H17/44—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing ionic groups cationic

Definitions

  • This invention is concerned with the use of a cationic latex by wet-end addition in a process for making high strength non-woven fibrous material and the product formed by such a process.
  • a latex in the manufacture of non-woven materials by wet-end addition, or as a beater additive, is well known.
  • the latex has been an anionic latex but a water-soluble cationic deposition aid has been used therewith.
  • a low-charge density cationic latex should be used in order to get good deposition on the fibers without the use of a deposition aid.
  • the prior art teaches the utility of bound charge in a wet-end process but does not teach or suggest the advantage of using high levels of bound charge in a structured particle latex to get high strength in the products.
  • FR-A 2.308.660 discloses structured cationic particle latexes constituted by a non-ionic organic core encapsulated by a thin layer of an organic water-insoluble polymer, having cationic pH independent groups chemically bound at or near the particle surface, the cationic groups being present in an amount of from 0,01 to 0,5 milliequivalent per gram of structured particle and their amount being also present at a range of from 0,4 to 2,5 milliequivalent per gram of copolymer in the thin layer.
  • latex particles are described as useful as coating for hydrophobic material.
  • the cationic latex is used in an amount below that required to cause charge reversal on the fiber.
  • the use of a deposition aid is not a significant factor.
  • An advantage of the process and product of this invention is that the polymer from the latex is uniformly distributed on the fiber and is bonded thereto. Consequently stronger webs are obtained.
  • the fiber is any kind of negatively charged, water-insoluble, natural or synthetic fiber or blend of fibers which can be dispersed in aqueous slurry. Either long or short fibers, or mixtures thereof are useful. Suitable also are reclaimed waste papers and cellulose from cotton and linen rags, straws and glass fibers. Particularly useful fibers are the cellulosic and lignocellulosic fibers commonly known as wood pulp of the various kinds such as mechanical pulp, steam-heated mechanical pulp, chemi- mechanical pulp, semichemical pulp and chemical pulp. Specific examples are groundwood pulp, unbleached sulfite pulp, bleached sulfite pulp, unbleached sulfate pulp and bleached sulfate pulp. The process is valuable in being able to use crude, low quality pulp such as "screenings", i.e., coarse byproduct pulp from unbleached chemical pulps.
  • the cationic latex comprises a water-insoluble copolymer having particles with a high density of pH independent bound charges at or near the particle surface in an amount of from 0.15 milliequivalent to 0.6 milliequivalent, preferably from 0.18 milliequivalent to 0.4 milliequivalent, per gram of copolymer.
  • the composition of the latex copolymer is such as to provide a glass transition temperature (Tg) from -80°C to 100°C, preferably from -25°C to 40°C. Ordinarily, tensile strength of the product increases as the Tg increases up to the point where the polymer does not fuse properly with the times and temperatures encountered in the wet-end process.
  • the latexes are structured particle latexes having a non-ionic polymer core encapsulated by a thin polymer layer having bound charges as pH independent cationic groups at or near the particle surface.
  • One method of obtaining such latexes is by copolymerizing under emulsion polymerization conditions an ethylenically unsaturated, activated-halogen monomer onto the particle surface of a non-ionic, organic polymer which is slightly cationic through the presence of adsorbed cationic surfactant.
  • the resulting latex is reacted with a non-ionic nucleophile to form a latex suitable for use in the practice of this invention.
  • Latexes prepared by usual emulsion polymerization conditions have high enough molecular weight to be useful. Usually the degree of polymerization will be greater than 1000. The lower limit can be expressed as the start of the plateau region when properties are plotted against molecular weight.
  • the particle size of the latex also has a significant effect. Tensile strength of the product increases as the particle size of the latex decreases. Ordinarily the particle size for best results will be below 1500nm especially from 600nm to 1000nm.
  • bound as applied to groups or charges in this sepcification is meant that they are not desorbable under the conditions of processing. A convenient test is by dialysis against deionized water.
  • pH independant groups as applied to ionic groups is meant that the groups are predominantly in ionized form over a wide range in pH, e.g. 2-12.
  • Representative of such groups are sulfonium, sulfoxonium, isothiouronium, pyridinium and quaternary ammonium.
  • non-ionic as applied to the monomers in this specification is meant that the monomers are not ionic per se nor do not become ionic by a simple change in pH.
  • a monomer containing an amine group is non-ionic at high pH, the addition of a water-soluble acid reduces the pH and forms a water-soluble salt; hence, such a monomer is not included.
  • the non-ionic nucleophiles are not similarly restricted, i.e., "non-ionic" as used with nucleophiles applies to such compounds which are non-ionic under conditions of use and tertiary amines, for example, are included.
  • Optional wet-end constituents used in the process to make the products of this invention include pigments and other common wet-end additives. While conventional deposition aids may be used, there is no particular advantage obtained thereby.
  • the maximum amount of cationic latex used in the practice of this invention is not significantly greater than the amount required to reach the charge neutralization point of the fiber being used.
  • the amount of latex depends on the charge on the latex and the charge on the fiber. As the charge on the fiber is increased, the amount of a particular latex which can be used is increased with a resulting higher tensile strength in the product. For a particular fiber, as the charge on the latex is increased the amount of latex which can be used is decreased. At a particular level of latex, the tensile strength normally increases with the charge density on the latex particle up to the point where the structured particle morphology is Iost, i.e., when the particle becomes soluble or a microgel.
  • the amount of cationic latex usually ranges from 0.5 percent to 5 percent of solids based on the dry weight of the fiber.
  • the process to prepare the product of this invention preferably is carried out as follows: A dilute aqueous suspension of the fiber is formed in the normal manner often in a concentration of from 0.5 percent to 6 percent. The latex is added at any convenient concentration, often in the concentration as supplied and the resulting mixture is stirred, usually for at least two minutes depending somewhat on the equipment available. The aqueous suspension usually is then diluted further, often with white water from the process. Optional wet-end additives can be added at any suitable time. A wet web is formed by flowing the resulting suspension over a porous support such as a screen, draining the wet web, wet pressing and completely drying the web by heating. Pressing and heating may be carried out simultaneously.
  • ambient temperature pressing followed by heating to complete drying rfiay be employed.
  • other compacting, shaping, tempering and curing steps may be included.
  • the temperatures used for hot pressing, curing and tempering or other heating steps often are from 100°C to 250°C, although higher or lower temperatures are operable.
  • the product is prepared from the resulting suspension, for example, on a paper machine such as a Fourdrinier machine or a cylinder machine or in a laboratory sheet forming apparatus.
  • the product is a dried, non-woven fibrous web with one dimension much smaller than the other two with the fibers uniformly distributed through the smaller dimension, preferentially oriented in the plane of the web and bonded to a uniformly distributed polymer phase formed from a structured particle latex.
  • a base latex was prepared by batch emulsion polymerization from the monomers shown in Table I using dodecylbenzyldimethylsulfonium chloride as surfactant.
  • the particles of the, base latex were encapsulated (capped) with a copolymer of vinylbenzyl chloride by adding "cap monomers" of the kind and in the proportions shown in Table I in a continuously added manner over about one hour under emulsion polymerization conditions.
  • the resulting latex was mixed with an excess of a nucleophile and was allowed to react to form a bound charge on the latex particles.
  • the reaction was stopped at the desired degree of charge by removing the excess nucleophile by distillation. Except as otherwise indicated the nucleophile was dimethylsulfide and accordingly the resulting pH independent cationic group was sulfonium. In those examples where the quaternary ammonium group is indicated, the nucleophile was 2-(dimethylamino)ethanol.
  • a handsheet (Comparative Example 1-C) was prepared in the same manner except the latex was omitted.
  • Additional handsheets were prepared in the same manner as described in Example 1 except that different latexes with differing particle sizes were used and the pH of the furnish was adjusted to 4.5 to 5 with sulfuric acid.
  • a comparative handsheet (7-C) was prepared in the same manner except that no latex was used. Data for this comparative example also are shown in Table III.
  • Handsheets were prepared in the same manner except different latexes were used and the size of each handsheet was 30.48 cm x 30.48 cm (7.5 grams).
  • the latex for Example 11 had bound quaternary ammonium groups and the other examples had sulfonium groups.
  • the handsheets showed uniform distribution of latex in the fibers.
  • Tensile values are recorded as breaking length, in meters, and are determined according to TAPPI Standard T 494-os-70 except the values are the average of 3 samples rather than 10 and the jaw gap is 5.08 cm rather than 20.32 cm.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Paper (AREA)
EP78100677A 1977-08-17 1978-08-16 A process for preparing a non-woven fibrous web from fibers and a latex, and the non-woven fibrous material so prepared Expired EP0000922B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US825319 1977-08-17
US05/825,319 US4178205A (en) 1977-08-17 1977-08-17 High strength non-woven fibrous material

Publications (2)

Publication Number Publication Date
EP0000922A1 EP0000922A1 (en) 1979-03-07
EP0000922B1 true EP0000922B1 (en) 1982-06-23

Family

ID=25243700

Family Applications (1)

Application Number Title Priority Date Filing Date
EP78100677A Expired EP0000922B1 (en) 1977-08-17 1978-08-16 A process for preparing a non-woven fibrous web from fibers and a latex, and the non-woven fibrous material so prepared

Country Status (5)

Country Link
US (1) US4178205A (enrdf_load_stackoverflow)
EP (1) EP0000922B1 (enrdf_load_stackoverflow)
JP (1) JPS5434405A (enrdf_load_stackoverflow)
CA (1) CA1107919A (enrdf_load_stackoverflow)
DE (1) DE2861910D1 (enrdf_load_stackoverflow)

Families Citing this family (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4445970A (en) * 1980-10-22 1984-05-01 Penntech Papers, Inc. High mineral composite fine paper
US4510019A (en) * 1981-05-12 1985-04-09 Papeteries De Jeand'heurs Latex containing papers
JPS58171446A (ja) * 1982-04-01 1983-10-08 Dainippon Ink & Chem Inc 熱硬化性樹脂組成物
KR890701841A (ko) * 1982-12-23 1989-12-21 리차드 지. 워터맨 섬유, 라텍스 및 유합제로부터 제조된 강직성이 향상된 시트
US4707221A (en) * 1982-12-23 1987-11-17 The Dow Chemical Company Sheets having improved stiffness from fiber, latex and coalescing agent
DE3438388A1 (de) * 1984-10-19 1986-04-24 Basf Ag, 6700 Ludwigshafen Leichtbauplatten auf basis von mineralischen fasern und thermoplastischen bindemitteln
GB8531558D0 (en) * 1985-12-21 1986-02-05 Wiggins Teape Group Ltd Loaded paper
US4895620A (en) * 1986-02-18 1990-01-23 Armstrong World Industries, Inc. Electrically conductive carbon-coated fibers
US4806207A (en) * 1987-02-15 1989-02-21 The Dow Chemical Company Structured latex particles having reinforcing and opacity characteristics
DE68916860T2 (de) * 1988-05-23 1995-03-16 Procter & Gamble Aufsaugende Strukturen aus gemischten Zellstoffen.
EP0406354B2 (en) * 1988-11-25 2003-08-20 Armstrong World Industries, Inc. Process of manufacture of composite fiberboard
DE3929226A1 (de) * 1989-09-02 1991-03-07 Hoechst Ag Neutralleimungsmittel fuer rohpapiermassen unter verwendung von kationischen kunststoffdispersionen
US5274055A (en) * 1990-06-11 1993-12-28 American Cyanamid Company Charged organic polymer microbeads in paper-making process
US5167766A (en) * 1990-06-18 1992-12-01 American Cyanamid Company Charged organic polymer microbeads in paper making process
EP0996788A1 (en) 1997-06-30 2000-05-03 Kimberly-Clark Worldwide, Inc. Medical packaging paper
FI20125569A7 (fi) 2012-05-28 2013-11-29 Nordkalk Oy Ab Saostettua karbonaattia sisältävän komposiittirakenteen valmistus ja käyttö

Family Cites Families (13)

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NL66907C (enrdf_load_stackoverflow) * 1945-07-13
US2654671A (en) * 1948-07-17 1953-10-06 Hercules Powder Co Ltd Paper product and process for its preparation
US3016325A (en) * 1955-11-01 1962-01-09 Electro Chem Fiber Seal Corp Process of combining water-insoluble additament with organic fibrous material
US3130117A (en) * 1961-03-13 1964-04-21 Dow Chemical Co Increasing the strength of paper with vinyl sulfonium polymers
DE1214985B (de) * 1961-11-29 1966-04-21 Basf Ag Verwendung von Dispersionen kationischer Copolymerisate zum Leimen von Papier
US3694393A (en) * 1969-04-04 1972-09-26 Rohm & Haas Method of producing paper,and paper obtained
US3926890A (en) * 1970-05-20 1975-12-16 Mitsubhishi Gas Chemical Compa Process for producing cationic synthetic latex involving emulsion polymerization of haloalkyl esters of acrylic and methacrylic acid followed by quarternization with tertiary amine
US3772143A (en) * 1970-10-02 1973-11-13 Dow Chemical Co Method of sizing paper with a sulphonium resin copolymer
DE2230985C3 (de) * 1972-06-24 1975-01-09 Roehm Gmbh, 6100 Darmstadt Verfahren zur Herstellung kunststoffgefüllter Papiere
JPS4938924A (enrdf_load_stackoverflow) * 1972-08-17 1974-04-11
US4017440A (en) * 1973-10-10 1977-04-12 Rohm And Haas Company Polymers stabilized with polymerizable vinylbenzyltrialkyl ammonium salt surfactant
US4056501A (en) * 1975-04-21 1977-11-01 The Dow Chemical Company Cationic structured-particle latexes
AU497808B2 (en) * 1975-04-21 1979-01-11 Dow Chemical Company, The Latexes

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
Ullmann, Encyklopädie der Techn. Chem. (4th Edn.) Vol. 17, pages 583-585 *

Also Published As

Publication number Publication date
EP0000922A1 (en) 1979-03-07
US4178205A (en) 1979-12-11
DE2861910D1 (en) 1982-08-12
JPS638240B2 (enrdf_load_stackoverflow) 1988-02-22
CA1107919A (en) 1981-09-01
JPS5434405A (en) 1979-03-13

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