EP0448332B1 - Compositions de revêtement pour papier ainsi qu'argile et carbonate de calcium apte à y être incorporés - Google Patents

Compositions de revêtement pour papier ainsi qu'argile et carbonate de calcium apte à y être incorporés Download PDF

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Publication number
EP0448332B1
EP0448332B1 EP19910302330 EP91302330A EP0448332B1 EP 0448332 B1 EP0448332 B1 EP 0448332B1 EP 19910302330 EP19910302330 EP 19910302330 EP 91302330 A EP91302330 A EP 91302330A EP 0448332 B1 EP0448332 B1 EP 0448332B1
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EP
European Patent Office
Prior art keywords
clay
deionized
calcium carbonate
slurry
solids
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 - Lifetime
Application number
EP19910302330
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German (de)
English (en)
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EP0448332A1 (fr
Inventor
Gary P. Fugitt
Dale B. Uhrig
Michael J. Whalen-Shaw
Dene H. Taylor
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.)
WestRock Packaging Systems LLC
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Mead Corp
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Publication of EP0448332A1 publication Critical patent/EP0448332A1/fr
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Publication of EP0448332B1 publication Critical patent/EP0448332B1/fr
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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
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/38—Coatings with pigments characterised by the pigments
    • D21H19/385—Oxides, hydroxides or carbonates
    • 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
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/38—Coatings with pigments characterised by the pigments
    • D21H19/40—Coatings with pigments characterised by the pigments siliceous, e.g. clays

Definitions

  • the present invention relates in one aspect to a paper coating composition.
  • the compositions of the present invention are characterized in that they are prepared using a deionized clay and/or deionized calcium carbonate and optionally other low ionic strength components.
  • Paper coating compositions are widely used in the paper industry to provide high grade printing surfaces.
  • compositions which have been used are compositions comprised essentially of a major proportion of a mineral or organic pigment and a minor proportion of a binder in the form of a latex of a film-forming polymer.
  • Suitable pigments have included finely divided clay, calcium sulfoaluminate also known as satin white, oxides of titanium, aluminium, silicon and zinc, calcium carbonate and microsized particles of high softening point polymers which are insoluble in the binder.
  • Suitable binder polymers have been those which are film-forming at ambient and higher temperatures. The coating is spread over the paper surface by a roll coater, trailing blade, air knife, brush or other known means, after which it is dried and calendered.
  • our coatings containing only low ionic strength pigments and coatings using low ionic strength pigments as a substantial component of the pigment portion display unique properties.
  • practical embodiments of coating in according with the present invention have substantially reduced viscosities that give them similar rheological properties at 3 to 4% higher solids.
  • our coatings when applied to paper have substantially higher sheet gloss and porosity.
  • coating compositions having improved rheology and glossability can be obtained by using a deionized clay or calcium carbonate in the coating composition.
  • deionized refers to a low ionic strength clay or calcium carbonate which has been treated to remove at least a portion of the ions it contains.
  • the clay or calcium carbonate starting material from which the ions are removed is herein referred to as "untreated”. It is important to emphasize that in this context commercially available clays are considered untreated.
  • our materials are deionized by the use of an ion exchange resin or by multiple washes with deionized or distilled water.
  • BE-A-674608 discloses methods for coating paper with compositions including clay and/or calcium carbonate and latex.
  • SU-A-1229240 discloses methods of removing univalent ions from an aluminosilicate suspension for use in the preparation of a sorbent for manufacturing capacitor and cable paper.
  • a paper coating composition comprising clay and/or calcium carbonate slurry and a latex, characterised in that said clay is deionized and has a conductivity less than about 1500 micromhos as a slurry of 70% solids, and said calcium carbonate is deionized and has a conductivity less than about 700 micromhos as a slurry of 70% solids.
  • the invention provides a slurry of deionized clay, said deionized clay being present in an amount of about 60 to 75%, and said slurry having a conductivity of less than about 1500 micromhos at 70% solids.
  • the invention provides, in a third alternative aspect thereof, a slurry of deionized calcium carbonate containing about 70 to 80% deionized calcium carbonate, and having a conductivity less than about 700 micromhos at 70% solids.
  • the invention also extends to the clay or calcium carbonate resulting from drying these slurries.
  • the low ionic strength clay is suitably a kaolin clay slurry which has been highly washed to give it substantially lower dissolved salt content than a conventional clay. Slurries of this clay range from about 60 to 75% solids with a preferred range of about 70 to 72%. Such deionized clay slurries have conductivities less than 1500 micromhos at 70% solids and more preferably conductivities less than 1300 micromhos at 70% solids. The conventional analog to this clay slurry has a conductivity of greater than 3000 micromhos at 70% solids.
  • the low ionic strength of the liquid phase gives the clay slurry unique properties. The particles have a higher degree of colloidal stability as measured by their zeta potential.
  • the low ionic strength clay slurry has improved rheology as shown by substantially reduced high shear viscosity and dilatancy.
  • the improved rheology allows a low ionic strength clay slurry to contain about 2% higher solids than its conventional counterpart but have comparable rheology.
  • Low ionic strength ground calcium carbonate may be prepared by highly washing calcium carbonate to give it substantially lower dissolved salt content than a conventional ground calcium carbonate slurry. Slurries of this material contain 70 to 80% solids with the preferred range being 75 to 80% solids. Such deionized calcium carbonate slurries have conductivities less than 700 micromhos at 70% solids and preferably less than 500 micromhos. The low ionic strength of the liquid phase gives the ground calcium carbonate slurry unique properties. The particles have a higher degree of colloidal stability as measured by zeta potential.
  • the low ionic strength ground calcium carbonate slurry has improved rheology as shown by substantially reduced high shear viscosity and dilatancy.
  • the improved rheology allows a low ionic strength ground calcium carbonate slurry to contain 1 to 2% higher solids than its conventional counterpart but have comparable rheology.
  • Our coating compositions using these materials are advantageous because for comparable clay or calcium carbonate concentrations, they provided higher gloss and they can be used at higher solids.
  • optically flat black glass plates which are used as an ideal substrate to reflect the properties of a pigment or a coating without interference from surface roughness, up to a 20 point improvement in gloss was obtained.
  • On paper not only can higher gloss be achieved, but comparable gloss levels can be obtained with less calendering.
  • the present invention provides a coating composition which, in its simplest form comprises deionized clay or deionized calcium carbonate and a latex.
  • the compositions may also generally include those additives commonly used in paper coatings such as dispersants, defoamers, pH modifiers, lubricants and other binders like starch.
  • the deionized clay or deionized calcium carbonate is used in combination with a latex having a low ionic strength.
  • a latex having a low ionic strength can be manufactured to have low salt and free surfactant content, or can be prepared by treating commercially available latexes with an ion exchange resin to remove ions therefrom.
  • Clays may be provided as calcined, non-calcined, predispersed, non-predispersed or physically delaminated clays.
  • Representative clays for use in practice of the present invention include Ultragloss 90 and Ultrawhite 90 sold by Engelhard Minerals & Chemicals Corporation, Edison, N.J. 08817; Hydragloss 90, Hydratex, and Hydrafine sold by J. M. Huber Corporation, Menlo Park, N.J. 08837; and Nuclay, and Lustra Clay sold by Freeport Kaolin Company, a division of Freeport Sulphur Company, New York, N.Y. 10017. No. 1, No. 2 and fine and delaminated clays may be used.
  • pigments can also be employed along with the paper coating clay. These include titanium dioxide, talc, Satin White, hydrated alumina commonly employed as an extender for titanium dioxide, and calcium carbonate (which is preferably deionized). These pigments are used in amounts up to 30% by weight.
  • clays and calcium carbonate may be deionized by suspending a normal process clay filtercake or calcium carbonate in deionized water, filtering the suspension, followed by 0-3 repetitions of the suspension-filtration process and finally deflocculation with about 0.3% sodium polyacrylate having a molecular weight between 1000 and 5000.
  • other traditional dispersants can be used. It is anticipated that other techniques for deionization will also be useful.
  • the clays and calcium carbonate can also be deionized by preparing a slurry of the clay, water and an ion exchange resin and screening out the ion exchange resin after the clay is deionized. This is shown in Example 4.
  • washing is typically conducted at room temperatures but higher or lower temperatures are also effective. Washing is continued until the desired level of deionization is achieved.
  • the deionized clays are characterized by both the median particle size, modal particle size, and the size distribution. These measurements are made by sedimentation and expressed as a mass distribution using the Sedigraph 5100 particle sizer. Samples are diluted to test solids of 7% using their own supernatant. Further, deionized clays are defined by changes in particle size and distribution relative to the non-deionized clays. Typical results are shown in Table 1.
  • the latexes used in practice of the present invention may also be selected from among those latexes commonly used in this art. Particularly preferred are the resins which exhibit primarily elastomeric properties, often described as the rubbery polymers, such as the copolymers styrene-butadiene and styrene-isoprene, or either of them slightly carboxylated by incorporation of from 3 to 10% acrylic acid. Suitable commercial examples are the lateies sold by Dow Chemical Company No. 316, 620, and 640. More generally, the latexes may be latexes of homopolymers or copolymers of C4-C10 dienes such as butadiene, 2-methylbutadiene, pentadiene-1.3, etc.
  • the copolymers may be copolymers of vinyl monomers such as styrene, acrylic acid and its esters, methacrylic acid and its esters, nitriles and amides. If desired, rubbery polymer latices may be blended with minor proportions of latices of hard or resinous polymers having a high MFT such as polystyrene, polyacrylonitrile, polymethyl methacrylate, copolymers of the monomers of these resinous polymers such as styrene-acrylonitrile resins and resinous copolymers of these monomers with other copolymerizable monomers such as copolymers of styrene with butadiene in which styrene forms more than 70 weight % of the polymer.
  • vinyl monomers such as styrene, acrylic acid and its esters, methacrylic acid and its esters, nitriles and amides.
  • rubbery polymer latices may be blended with minor proportion
  • latices in which the copolymer is composed of about 0-60 weight % of a C4-C6 conjugated diolefin, 40 to 99% of a styrene and 0.1-5% of a polymerizable unsaturated monomer having a polar group such as a carboxyl group in its structure.
  • the solid content of the latex is generally 20 to 55% by weight.
  • latexes can be manufactured using additives which are designed to minimize ionic strength or they can be prepared by treating commercially available latexes to reduce their ionic strength.
  • a technique which may be used to deionize or reduce the ionic strength of a commercial latex involves diluting the latex to about 34% solids with deionized water and adding a mixed anionic and cationic ion exchange resin such as Dow MR3 or Rohm and Haas Amberlite 150 at a dry weight ratio between 0.1:1 and 2:1 to the latex. After about 1 to 2 hours the ion exchange resin can be strained from the latex.
  • a mixed anionic and cationic ion exchange resin such as Dow MR3 or Rohm and Haas Amberlite 150 at a dry weight ratio between 0.1:1 and 2:1
  • the pH of the latex is preferably about 6.0 to 10.0.
  • Paper coating compositions in accordance with the invention may also contain a hydrocolloid.
  • the hydrocolloid may be deionized as well.
  • Conventional paper coating hydrocolloids may be used such as starch, polyvinyl alcohol, proteins.
  • the starch optionally used may also be selected from those starches commonly used in this art. Suitable commercial examples include all commercial starches produced for the paper industry. These starches are preferably deionized by diluting to 5% with deionized water and filtering once or diluting to 10-20% and filtering 2 or 3 times. The slurry need only be mixed for 5-10 minutes before filtering or can be separated by gravity settling.
  • the starch or hydrocolloid has a preferred conductivity of less than 0.5 millimhos at 20% solids and 23°C.
  • the deionized clay may be treated with a dispersing agent to disperse the deionized clay in the latex.
  • a dispersing agent such as polyacrylates may be used for this purpose.
  • compositions may contain about 60 to 85% by weight pigment (of which 50 to 100% is deionized clay and/or calcium carbonate), about 1 to 40 and preferably 3 to 20% latex and about 0 to 5% of starch or other hydrocolloid.
  • Clay and calcium carbonate are often used together in a ratio of clay to calcium carbonate of about 7:1 to 1:3.
  • binders e.g., proteins, viscosity modifiers, e.g., sodium polyacrylates, defoamers, pH modifiers (preferred coatings have a pH of 6 to 10), lubricants, and other film-forming latices, etc. may be included.
  • Our Clay containing coating compositions i.e., the combination of clay, latex, and any pigment, starch, or other additive
  • our Clay containing coating compositions preferably have a conductivity less than 1.3 millimhos at 23°C and 60% total solids.
  • Our calcium carbonate containing coating compositions preferably have a conductivity less than 0.8 millimhos at 23°C and 60% solids.
  • Desirable properties are achieved when the latex and hydrocolloid as well as the clay and calcium carbonate are deionized.
  • deionization of the latex and hydrocolloid adds expense to the composition this may not always be desirable commercially.
  • the clay and calcium carbonate will be deionized, however, further improvements in rheology and gloss may be achieved if commercially desirable by deionizing the latex and hydrocolloid.
  • compositions can be applied to conventional base stocks using known paper coating techniques and optionally calendered.
  • the compositions can be applied in conventional coat weights.
  • Sample A was a regular #1 clay which was centrifuged then the sediment was resuspended in deionized water. The centrifugation-resuspension process was repeated twice. A polyacrylate dispersant was added to the resulting clay until minimum low shear viscosity was reached.
  • Sample B was prepared by triple washing a regular #1 clay with deionized water. A polyacrylate dispersant was added to the resulting clay until minimum low shear viscosity was reached.
  • Sample C was prepared by mixing a high brightness #1 clay with a mixed ion exchange resin at a 1:0.1 dry-on-dry ratio. The mixture was blended for 2 hours then screened through a 65 mesh screen to remove the beads. A polyacrylate dispersant was added to the resulting clay until minimum low shear viscosity was reached. The conductivity, Hercules and Brookfield viscosity of each clay is shown in Tables 2 and 3. Table 2 Solids Conductivity (millimhos) Clay Sample A Hercules Visc. (1100 RPM) Brookfield Visc.
  • Hydrafine clay a No. 1 kaolin clay from J.M. Huber Corporation, was deionized by washing twice with deionized water.
  • Dow RAP316 latex (a styrene butadiene latex available from Dow Chemical Company) was diluted to 34% solids and blended with an ion exchange resin (Dow MR3, a mixed cationic and anionic resin available from Dow Chemical Company) in a dry weight ratio of 1:1. The mixture was mixed for 4 hours and filtered through a 65 mesh screen to remove the ion exchange resin. The resulting latex contained 30% solids and the pH was adjusted to 8.5 with ammonia.
  • an ion exchange resin Dow MR3, a mixed cationic and anionic resin available from Dow Chemical Company
  • Coating compositions were prepared by preparing a clay suspension containing 74% solids and blending this with the starch before the latex addition to provide the coating compositions shown in Table 4: Table 4 Sample No. (wt.%) 1 Control 2 Invention Clay (Hydrofine) 87 - Deionized Clay (Hydrofine) - 87 Latex (Dow RAP 316) 10 5 Deionized Latex (Dow RAP 316) - 5 Starch (PG 250) 3 3 Solids 61.4 61.4
  • each coating was measured using a YSI Model 32 conductance meter having a range of 0.01 to 20,000 microohms. All testing was done at room temperature. The coatings were drawn down on an optically smooth black glass to measure the optical properties. Gloss was measured using a Hunter 75 degree gloss meter.
  • Example 3 The coatings described in Example 3 were applied to paper using a rigid blade coater.
  • the rawstock was a wood-free sheet, and the coater speed was 609.6m (2000 feet) per minute.
  • a precoat made up of a 50:50 blend of #2 clay and coarse calcium carbonate was used.
  • the resulting calendered and uncalendered glosses are recorded in Table 6.
  • the first batch was diluted to 40% solids while under a mixer and 200 g of a mixed cationic and anionic ion exchange resin was added.
  • the clay and resin were mixed for 2 hours. After this time, the mixture was poured through a 100 mesh screen to remove the resin.
  • a polyacrylate dispersant was added to the resulting slurry at a level of 0.3% based on dry clay. About half of the resulting dispersed deionized clay slurry was dried and added back to the remaining slurry to create a 73% solids deionized clay slurry. This slurry was used for comparison to the second batch of 70% #1 clay slurry.
  • Two ground calcium carbonate slurries (90% less than 2 ⁇ m) were made at 76% solids using the method described above.
  • One of the slurries was diluted to 50% and the same ion exchange resin was added on a 1:10 basis dry resin:dry carbonate. After 2 hours of mixing, the slurry was screened to remove the resin.
  • a polyacrylate dispersant was added at 0.015% based on dry carbonate.
  • Deionized clay and calcium carbonate slurries were produced by the method described in Example 1.
  • Deionized latex was produced by diluting a styrene-butadiene latex to 40% solids and adding an ion exchange resin to latex at a 1:10 ratio. This mixture was stirred for one hour and filtered through cheesecloth to remove the ion exchange resin.
  • a deionized polystyrene 3 plastic pigment was produced by the same process.
  • a deionized starch was produced by diluting an uncooked commercial ethylated starch to 5% solids with distilled water and then removing the water by filtration. The resulting deionized starch was cooked by conventional methods.
  • a conventional clay based paper coating and its deionized analog were prepared using the formulations shown in Table 11. These two coatings were applied to a wood-free base sheet with a rigid blade at 457.2m (1500 feet) per minute on a high speed pilot coater. Sheets of the coated paper were supercalendered on a handsheet supercalender. The test results in Table 11 show that the deionized coating at 64% solids has higher shear viscosity equivalent to its convention analog at 60. 5% solids. In addition, the supercalendered paper with the deionized coating has higher gloss with improved smoothness and porosity.
  • a conventional calcium carbonate based paper coating and its deionized analog were prepared using the formulations shown in Table 12. These two coatings were applied to a wood-free base sheet with a bent blade at 457.2m(1500 feet)per minute on a high speed pilot coater. Sheets of the coated paper were supercalendered on a handsheet supercalender. The test results in Table 12 show that the deionized coating at 69% solids has lower low shear viscosity and equivalent high shear vicosity to its conventional analog at 67% solids. In addition, the supercalendered coated sheet with the deionized coating has higher gloss.

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Claims (16)

  1. Une composition pour enduire le papier comprenant de l'argile et/ou un coulis de carbonate de calcium et un latex, caractérisée en ce que ladite argile est déionisée et possède une conductivité inférieure à environ 1500 microhms pour un coulis à 70% de solides, ledit carbonate de calcium est déionisé et possède une conductivité inférieure à environ 700 microhms pour un coulis à 70% de solides.
  2. Une composition pour enduire le papier selon la revendication 1, caractérisée en ce qu'elle contient environ 1 à 35% de dionide de titamium en solides.
  3. Une composition pour enduire le papier selon la revendication 1, caractérisée en ce que le latex est déionisé.
  4. Une composition pour enduire le papier selon la revendication 1, caractérisée en ce qu'elle contient un hydrocolloïde.
  5. Une composition pour enduire le papier selon la revendication 4, caractérisée en ce que ladite composition contient de 1 à 10% d'amidon en poids de solides.
  6. Une composition pour enduire le papier selon la revendication 4, caractérisée en ce que l'hydrocolloïde possède une conductivité inférieure à environ 0,5 milliohms pour un total de 2% de solides et à 23°C.
  7. Une composition pour enduire le papier selon la revendication 6, caractérisée en ce que ladite composition contient environ 30 à 100% d'argile déionisée ou de carbonate de calcium par rapport au poids total des pigments présents.
  8. Une composition pour enduire la papier selon la revendication 1, contenant de l'argile déionisée et caractérisée en ce que l'argile possède une conductivité inférieure à 1,3 millohms lorsqu'elle représente un total de 60% en poids à 23°C.
  9. Une composition pour enduire le papier selon la revendication 1, comprenant du carbonate de calcium déionisé, et caractérisée en ce que ledit carbonate de calcium possède une conductivité inférieure à environ 0,8 milliohms pour 60% de solides et à 23°C.
  10. Une composition pour enduire le papier selon la revendication 1, caractérisée en ce que le latex est sélectionné à partir de réseaux styrène-butadiène, acryliques et d'acétate de polyvinyle.
  11. Une composition pour enduire le papier selon la revendication 10, caractérisée en ce qu'elle contient environ 10 à 40% de latex en poids de solides.
  12. Une composition pour enduire le papier selon la revendication 1, comprenant de l'argile déionisée et caractérisée en ce que ladite argile est un kaolin.
  13. Un coulis d'argile déionisée, ladite argile déionisée étant présente dans des proportions d'environ 60 à 75%, et ledit coulis possédant une conductivité inférieure à environ 1500 microhms pour 70% de solides, et ne comportant pas de polyacrylamide.
  14. Une argile déionisée pouvant être obtenue en séchant le coulis de la revendication 13.
  15. Un coulis de carbonate de calcium déionisé contenant environ 70 à 80% de carbonate de calcium déionisé et possédant une conductivité inférieure à environ 700 microhms pour 70% de solides, ledit coulis ne comprenant pas de polyacrylamide.
  16. Un carbonate de calcium déionisé pouvant être obtenu en séchant le coulis de la revendication 15.
EP19910302330 1990-03-19 1991-03-18 Compositions de revêtement pour papier ainsi qu'argile et carbonate de calcium apte à y être incorporés Expired - Lifetime EP0448332B1 (fr)

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US49554790A 1990-03-19 1990-03-19
US495547 1990-03-19

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EP0448332A1 EP0448332A1 (fr) 1991-09-25
EP0448332B1 true EP0448332B1 (fr) 1995-11-15

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DE (1) DE69114557T2 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0790135A3 (fr) * 1996-01-16 1998-12-09 Haindl Papier Gmbh Méthode pour la fabrication d'un support pour l'impression utilisé pour l'impression par jet d'encre sans contact, papier fabriqué par ce procédé et son utilisation
US8142887B2 (en) * 2008-03-21 2012-03-27 Meadwestvaco Corporation Basecoat and associated paperboard structure
US7749583B2 (en) * 2008-05-28 2010-07-06 Meadwestvaco Corporation Low density paperboard
US8658272B2 (en) 2009-04-21 2014-02-25 Meadwestvaco Corporation Basecoat and associated paperboard structure including a pigment blend of hyper-platy clay and calcined clay
DE102009028520A1 (de) 2009-08-13 2011-02-17 Amberger Kaolinwerke Eduard Kick Gmbh & Co. Kg Verfahren zur Entfernung von farbgebenden Bestandteilen aus Kaolin
JP2022532203A (ja) 2019-05-10 2022-07-13 ウエストロック・エム・ダブリュー・ヴイ・エルエルシー 平滑な、および低密度の板紙構造物、ならびに、それを製造するための方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3468698A (en) * 1965-01-05 1969-09-23 Mead Corp Process of producing pigment coated paper

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EP0448332A1 (fr) 1991-09-25
DE69114557T2 (de) 1996-06-20
DE69114557D1 (de) 1995-12-21
CA2038511C (fr) 2001-06-05
CA2038511A1 (fr) 1991-09-20

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