EP1835075A1 - Verfahren zur Herstellung einer mehrlagigen Pappe - Google Patents

Verfahren zur Herstellung einer mehrlagigen Pappe Download PDF

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Publication number
EP1835075A1
EP1835075A1 EP07251134A EP07251134A EP1835075A1 EP 1835075 A1 EP1835075 A1 EP 1835075A1 EP 07251134 A EP07251134 A EP 07251134A EP 07251134 A EP07251134 A EP 07251134A EP 1835075 A1 EP1835075 A1 EP 1835075A1
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EP
European Patent Office
Prior art keywords
fiber
paperboard
slurry
anionic
starch
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EP07251134A
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English (en)
French (fr)
Inventor
Daniel T. Bunker
Donald D. Halabisky
Shahrokh A. Naieni
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Weyerhaeuser Co
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Weyerhaeuser Co
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    • 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
    • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
    • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
    • D21H23/04—Addition to the pulp; After-treatment of added substances in the pulp
    • D21H23/06—Controlling the addition
    • D21H23/08—Controlling the addition by measuring pulp properties, e.g. zeta potential, pH
    • D21H23/10—Controlling the addition by measuring pulp properties, e.g. zeta potential, pH at least two kinds of compounds being added
    • 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
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/18—Reinforcing agents
    • 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
    • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
    • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
    • D21H23/04—Addition to the pulp; After-treatment of added substances in the pulp
    • D21H23/06—Controlling the addition
    • D21H23/08—Controlling the addition by measuring pulp properties, e.g. zeta potential, pH
    • 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
    • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/10—Mixtures of chemical and mechanical pulp
    • 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
    • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/16—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only modified by a particular after-treatment
    • D21H11/20—Chemically or biochemically modified fibres
    • 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
    • D21H17/21—Macromolecular organic compounds of natural origin; Derivatives thereof
    • D21H17/24—Polysaccharides
    • D21H17/28—Starch
    • 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
    • D21H17/21—Macromolecular organic compounds of natural origin; Derivatives thereof
    • D21H17/24—Polysaccharides
    • D21H17/28—Starch
    • D21H17/29—Starch cationic
    • 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
    • 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
    • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/54—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen
    • 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
    • D21H17/63—Inorganic compounds
    • D21H17/66—Salts, e.g. alums
    • 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
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • 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
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • D21H27/38—Multi-ply at least one of the sheets having a fibrous composition differing from that of other sheets

Definitions

  • This invention relates to methods of making plies for paperboards and to paperboards.
  • the application relates to a method for increasing the bond strength in a multi-ply paperboard that has high crosslinked cellulose fiber present in at least one of the plies.
  • This application is particularly concerned with a method improving the internal bond strength of paperboard with greater than 25 percent crosslinked fiber in at least one, ply.
  • additives are added to the slurry in various combinations and order while maintaining the ionic demand of the slurry at less than zero. Paperboard with high ZDT, Scott Bond and Taber Stiffness is obtained. -
  • the invention provides a method for forming at least one ply of a paperboard comprising the steps of forming a slurry of cellulose fibers comprising crosslinked fibers, adding mechanically refined fiber, adding an anionic starch subsequent to adding said mechanically refined fiber, adding a cationic fixative subsequent to adding said anionic starch, wherein, after each addition step, the slurry ionic demand is less than zero, depositing said slurry on a foraminous support, forming a fibrous web layer by withdrawing liquid from said slurry, drying said web to form a paperboard.
  • the invention also provides a method for forming a paperboard comprising the steps of forming a slurry of cellulose fibers comprising crosslinked fibers, adding mechanically refined fiber, adding a cationic fixative and mixing with said slurry, adding an anionic starch subsequent to adding said cationic fixative, wherein, after each addition step, the slurry ionic demand is less than zero, depositing said slurry on a foraminous support, forming a fibrous web layer by withdrawing liquid from said slurry, drying said web to form a paperboard.
  • the invention further provides a method for forming at least one ply of a paperboard comprising the steps of forming a slurry of cellulose fibers comprising crosslinked fibers, adding mechanically refined fiber, adding an anionic starch subsequent to adding said mechanically refined fiber, adding a first cationic fixative subsequent to adding said anionic starch, adding a second cationic fixative subsequent to adding said first cationic fixative, wherein, after each addition step, the slurry ionic demand is less than zero, depositing said slurry on a foraminous support, forming a fibrous web layer by withdrawing liquid from said slurry, drying said web to form a paperboard.
  • the density of the stratum will drop below 0.4 g/cc.
  • the internal bond strength can drop so low as to not only be well below levels required for converting the paperboard into packaging products but also below the level where conventional methods of increasing the internal strength cannot provide enough increase to meet minimum levels needed for converting. This effect can occur either in the entire structure or some fraction within the structure.
  • the present application provides a method for increasing the internal bond of low density paperboard back into the range which is useable for converting.
  • a distinguishing characteristic of the present application is that at least one ply of the paperboard, whether a single-ply or a multiple-ply structure, contains crosslinked cellulose fibers and strength enhancing additives such as mechanically refined fiber, anionic and cationic starches and other additives to offset the board strength lost by adding the crosslinked cellulosic fibers.
  • the crosslinked cellulosic fibers increase the bulk density of the insulating paperboard characteristics of the board.
  • the paperboard also contains chemical pulp fibers.
  • chemical pulp fibers useable in the present application are derived primarily from wood pulp. Suitable wood pulp fibers for use with the application can be obtained from well-known chemical processes such as the kraft and sulfite processes, with or without subsequent bleaching.
  • Softwoods and hardwoods can be used. Details of the selection of wood pulp fibers are well known to those skilled in the art. For example, suitable cellulosic fibers produced from southern pine that are useable in the present application are available froma number of companies including Weyerhaeuser Company under the designations C-Pine, Chinook, CF416, FR416, and NB416. A bleached Kraft Douglas Fir pulp (D. Fir), and Grande Prairie Softwood, all manufactured by Weyerhaeuser are examples of northern softwoods that can be used.
  • Mercerized fibers such as HPZ and mercerized flash dried fibers such as HPZ III, both manufactured by Buckeye Technologies, Memphis TN, and Porosinier- J-HP available from Rayonier Performance Fibers Division, Jessup, GA are also suitable for use in the present application when used with crosslinked cellulose fibers.
  • Non crosslinked cellulose fibers include chemithermomechanical pulp fibers (CTMP), bleached chemithermomechanical pulp fibers (BCTMP), thermomechanical pulp fibers (TMP), refiner groundwood pulp fibers, groundwood pulp fibers, TMP (thermomechanical pulp) made by Weyerhaeuser, Federal Way, WA, and CTMP (chemi-thermomechanical pulp) obtained from NORPAC, Longview, WA, sold as a CTMP NORPAC Newsprint Grade, jet dried cellulosic fibers and treated jet dried cellulosic fibers manufactured by the Weyerhaeuser Company by the method described in U.S. Application No.10/923,447 filed August 20, 2004 . These fibers are twisted kinked and curled. Additional fibers include flash dried and treated flash dried fibers as described in U.S. 6,837,970 ,
  • Suitable crosslinking agents for making crosslinked fibers include carboxylic acid crosslinking agents such as polycarboxylic acids.
  • carboxylic acid crosslinking agents such as polycarboxylic acids.
  • Polycarboxylic acid crosslinking agents e.g., citric acid, propane tricarboxylic acid, and butane tetracarboxylic acid
  • catalysts are described in U.S. Patent Nos. 3,526,048 ; 4,820,307 ; 4,936,865 ; 4,975,209 ; and 5,221,285
  • C 2 -C 9 polycarboxylic acids that contain at least three carboxyl groups e.g., citric acid and oxydisuccinic acid
  • crosslinking agents is described in U.S. Patent Nos. 5,137,537 ; 5,183,707 ; 5,190,563 ; 5,562,740 ; and 5,873,979 .
  • Polymeric polycarboxylic acids are also suitable crosslinking agents for making crosslinked fibers. These include polymeric polycarboxylic acid crosslinking agents are described in U.S. Patent Nos. 4,391,878 ; 4,420,368 ; 4,431,481 ; 5,049,235 ; 5,160,789 ; 5,442,899 ; 5,698,074 ; 5,496,476 ; 5,496,477 ; 5,728,771 ; 5,705,475 ; and 5,981,739 . Polyacrylic acid and related copolymers as crosslinking agents are described U.S. Patent Nos. 5,549,791 and 5,998,511 . Polymaleic acid crosslinking agents are described in U.S. Patent No.
  • crosslinked cellulosic fibers are present in at least one layer at a level of 25 to 80 percent by total fiber weight of the ply.
  • the crosslinked fibers are present at a level of 40 to 75 percent by total fiber weight of the layer and in yet another embodiment they are present at a level of 50 to 70 percent by total fiber weight of the layer.
  • the technology relies on the ability to balance the ionic demand in the wet end of the paper machine such that 1) anionic polymeric materials can be retained on the fibers and fines without excess remaining in the water system, 2) the fibers and system do not pass through the zero charge point which destabilizes retention and drainage 3) since pulp fibers are anionic, some cationic material can be added, however, adding too much cationic material without balancing the excess anionic demand will either cause the fibers to flocculate reducing formation and/or cause the drainage to drop, impacting the runnability.
  • Each of the components used in the paperboard containing crosslinked fiber in this disclosure has a specific charge density typically measured by ionic demand titration.
  • a Mutek PCD-Titrator was used for the particle charge titration coupled with the PCD 02 Particle Charge Detector for measuring the ionic demand of the component or fiber furnish. The method was performed according to a procedure from A.E. Staley Manufacturing, a subsidiary of Tate and Lyle, Decatur, IL The method is as follows.
  • Ionic Demand refers to the amount of anionic or cationic charge required to neutralize the counter ion charge and is expressed in meq/g or ueq/kg.
  • an additive with an ionic demand of +2.2 meq/g has an anionic demand of 2.2 meq/g; an additive with an ionic demand of -1.8 meq/g has a cationic demand of 1.8 meq/g.
  • the difference between the total and available ionic demand represents the amount of charge that is internal to the fiber that is not accessible to polymers of molecular weight above 300,000 g/mole.
  • the available ionic demand is more representative of the results obtained in practice than the total ionic demand.
  • the fiber slurry is anionic to start with and should remain anionic through the paper making process i.e. the ionic demand of the slurry should less than zero.
  • Mechanically refined fiber can be added to the slurry to increase the strength of the paperboard.
  • the mechanically refined fiber has a Canadian Standard Freeness of less than 125 mL CSF, a curl index of 1/3 or less of the unrefined fiber and a kink angle of 1/2 or less of the unrefined fiber.
  • mechanically refined fiber is added to the slurry followed by the addition of an anionic starch and then followed by addition of a cationic fixative. After each addition step the slurry ionic demand is less than zero.
  • the slurry is deposited on a foraminous support, dewatered forming a web and dried to form a paperboard.
  • the total starch level on dry fiber is from 50 to 120 lb/t. In another embodiment the total starch level on dry fiber is from 60 to 100 lb/t. In yet another embodiment the total stach level is 80 to 90 lb/t.
  • Cationic fixatives such as cationic starch (e.g. STA-LOK® 300, STA-LOK® 330 and RediBOND ®2038) have a low anionic demand i.e. less than 1 meq/g.
  • Other cationic additives such as Kymene®557H have a high anionic demand (+2.2 meq/g).
  • the cationic fixative has an anionic demand of greater than zero but less than one meq/g.
  • the cationic fixative has an anionic demand of from 1 meq/g to 10 meq/g.
  • the paperboard of the present application may be one of several structures. In one embodiment the paperboard is a single ply structure, in another the paperboard is a two-ply structure and in yet another embodiment the paperboard is a multi-ply structure.
  • the addition order of the additive can vary.
  • mechanically refined fiber is added to the slurry followed by the addition of an anionic starch and then followed by addition of a cationic fixative. After each addition step the slurry ionic demand is less than zero.
  • the slurry is deposited on a foraminous support, dewatered forming a web and dried to form a paperboard.
  • mechanically refined fiber is added to the slurry followed by the addition of a cationic fixative and then followed by addition of an anionic starch. After each addition step the slurry ionic demand is less than zero.
  • the slurry is deposited on a foraminous support, dewatered forming a web and dried to form a paperboard.
  • mechanically refined fiber is added to the slurry followed by the addition of an anionic starch and then followed by addition of first cationic fixative, followed by adding a second cationic fixative. After each addition step the slurry ionic demand is less than zero.
  • the slurry is deposited on a foraminous support, dewatered forming a web and dried to form a paperboard.
  • the first cationic fixative may have an anionic demand of from 1 meq/g to 10 meq/g and the second fixant may have an anionic demand of greater than zero but less than 1.
  • Fiber and polymer binders were applied to low density board so that internal bond strength increases by 100% or more with 10% or less increase in density.
  • the effect of refining on freeness and ionic demand is shown in Table 11.
  • mechanically refined fiber is mechanically refined wood pulp for example, Lodgepole Pine having a Canadian Standard Freeness ⁇ 125 mL, a index 1/2 or less of unrefined starting fiber and a kink angle of 1/2 or less of the unrefined starting fiber. Curl Index and kink angle were determined using a Fiber Quality Analyzer (FQA) as published in the Journal of Pulp and Paper Science 21(11):J367 (1995 ). Mechanically refined fiber can be generated to meet these criteria by different refining methods which have different impact on conventional fiber properties. Table III shows the effect on Z-direction tensile and density of various formulations with mechanically refined fiber. ZDT was determined by TAPPI 541.
  • Fir 0.256 0.4 80.15 99.3 ⁇ indicates "change in" Internal bond strength can be increased by replacing some of the cationic starch with a higher ionic strength molecule such as Kymene® as shown in the following example. 50% CHB405. 50% Lodgepole Pine refined to 400 mL CSF. 10 #/t Kymene® 557H from Hercules. - 10 #/t Stalok 400 cationic starch from Staley. Mechanically refined Lodgepole pine fiber refined at 50 ml CSF using an Escher Wyss laboratory refiner.
  • a third technology is use of a starch excess.
  • the general approach was to overcome the normal limits of effective wet-end starch, balancing the charge in the wet-end by adding excess anionic starch and fixing it to the fibers by adding cationic starch or other high charge density cationic polymers thus balancing the system to near neutral charge density.
  • the neutralization was important to prevent excessive flocculation and large impacts on drainage.
  • total starch content added to the wet can be increased to 2% to 5% based on dry fiber.
  • Anionic starch such as RediBOND® 3050 supplied by National Starch & Chemical or Aniofax® AP25 supplied by Carolina Starches can be used.
  • Cationic fixatives include common cationic starches like STA-LOK® 300 supplied by Staley Corp., Poly Aluminum Chloride (PAC) like Nalco ULTRION® 8187. or high charge density cationic polymers like M5133 and M5134, GALACTAOL® SP813D (anionic guar) and Kymene® 557H supplied by Hercules Corp. and Nalco NALKAT® 62060 (branched EPEDMA) Nalco NALKAT® 2020 (poly DADMAC).
  • a high ionic demand is represented by a polymer that has an ionic demand of 1 meq/g to 17 meq/g, either as an anionic demand or as a cationic demand.
  • Kymene®557H has an anionic demand of 2.2 meq/g
  • Hercobond®2000 has a cationic demand of 1.8 meq/g.
  • the level of anionic starch needed to obtain high strength development depends on the charge density and more importantly on the retention. Typically, 2% to 5% addition level based on dry fiber is adequate.
  • the amount of cationic fixative depends entirely on the size of the polymer and the cationic charge density. As defined herein, a fixative is a charged polymer that ionically bonds to a molecule of the opposite charge. In general the higher the charge density the smaller the amount required and for equal charge density the larger the polymer the smaller the amount required.
  • control handsheet as described above was adjusted as follows to the non-fiber portion. 40 lbs/t Aniofax AP25 was mixed with the fibers, followed by 20 lbs/t STA-LOK® 300 cationic starch. Kymene® 557H at 5#/t was added and the same combination of Stalok 300 and Aquape1625 as in Example 1, i.e. 20 lb/t and 4 lb/t, respectively. Handsheets were evaluated for density, ZDT and Scott Bond; the results are in Table V 1 combined with the results from Example 1.
  • the handsheet formulation described in Example 2 was altered to contain mechanically refined fiber fibers so that the fiber portion of the furnish is:
  • Single-ply handsheets designed to simulate the mid-ply of low density multi-ply paperboard were made. A 0.015 percent to 0.035 percent consistency slurry was used in these studies.
  • Handsheet making equipment was standard 8" x 8" sheet mold modified with an extended headbox so that twice the normal volume of stock was used. This modification was necessary to improve handsheet formation when using materials designed to generate high bulk (e.g. crosslink fiber such as CHB405 and CHB505). Fiber weights are expressed as a weight percent of the total fiber dry weight; additives are based on weight of dry fiber.
  • a series of handsheets were made using different levels of wet-end additives, different addition order and some changes in fiber furnish to demonstrate the level of internal bond strength that could be generated by starch loading the web.
  • the additives were added to the slurry in the order across each sample row and the slurry stirred after each addition.
  • Table XI shows the conditions and formulations used when making the series of handsheets Table XI-A. Handsheet Formulation And Addition Order. Code Target Basis wt. CHB405 D. Fir PVOH Celanese Celvol 165SF Mechanically Refined Fiber* Anionic Starch Avebe Aniofax AP25 Cationic Starch STA LOK® 300 Anionic Starch Avebe Aniofax AP25 Kymene® 557H Cationic Starch STALOK® 300 Aquapel 650 g/m 2 % % % % #/t #/t #/t #/t #/t #/t 1 250 60% 30% 5% 5% 0 0 0 5 25 4 2 250 60% 35% 0% 5% 0 0 0 5 25 4 2 250 60% 35% 0% 5% 0 0 0 5 25 4 3 250 60% 40% 0% 0% 40 20 0 5 20 4 4 250 60% 35% 0% 5% 40 20 0 5 20 4 5 250 60% 35% 0% 5% 0 20
  • Each handsheet was then coated with Polyvinyl Alcohol (PVA) coating, Celvol V24203 supplied by Celanese Ltd.
  • PVA Polyvinyl Alcohol
  • Celvol V24203 supplied by Celanese Ltd.
  • the total coat weight was about 50 g/m 2 and was divided equally between each side of the sheet.
  • the coating was added to the surface to facilitate testing Z-direction tensile (ZDT) and internal Scott Bond because low density structures without the coating tend to separate at the tape instead of the within the sheet.
  • Samples 1, 2 and 9 can be considered the controls for this experiment.
  • Sample number 9 is a fiber formulation designed to deliver low density paper and uses typical wet end chemistry (i.e. cationic starch and Kymene®557H). The result is a very low Scott Bond, but typical Taber Stiffness.
  • Sample 2 incorporates mechanically refined fiber in an effort to increase the internal bond and, by itself, results in an increase in ZDT and Scott Bond, but not enough to reach the targets needed for converting multi-ply paperboard. It is estimated the minimum necessary ZDT needed for converting is about 175-190 kPa.
  • Sample 1 incorporates mechanically refined fiber with a particle PVOH - known as a good binder but is hindered by issues with retention, cost and process reliability impacts.
  • the increase in ZDT and Scott Bond for sample 1 begins to approach the amount needed for converting paperboard.
  • Samples 3 and 4 show that by adding 4% total starch to the furnish the ZDT and Scott Bond essentially double. Adding mechanically refined fiber, Sample 4, gives an increase of about the same magnitude as it did to the original structure, Sample 2 v. Sample 4 and Sample 3 v. Sample 9.
  • Sample 5 shows reversing the order (i.e. adding cationic starch first then anionic starch) in which the cationic and anionic starch are added makes no difference to the strength development
  • Samples 6 and 7 are a case where the amount of anionic starch is doubled while the cationic starch remains constant.
  • Kymeme® 557H a higher charge density cationic polymer, is used to balance the additional anionic charge.
  • the result is further increase in internal bond, increasing ZDT by 500%, (Sample 6) over the control and Scott Bond is unaffected by the additional starch and Kymene® 557H.
  • Sample 7 shows that by adding mechanically refined fiber the effect on ZDT is negative in this case, yet the Scott Bond increases.
  • Sample 8 adjusts the source of cationic charge further, increasing the amount of Kymene ®557H and decreasing the amount of cationic starch.
  • Table XI-B the ionic demand of the system crosses from negative to positive at the last point of cationic starch addition and from Table XII the corresponding ZDT and Scott bond are further reduced indicating that when the ionic demand exceeds zero the effectiveness of the ionic binding system is reduced.
  • Table XIII shows the formulations used in the experiments. Table XIII. Handsheet Formulation and Addition Order Code CHB 405 D.Fir @ 500 ml CSF MRF Anionic Avebe Aniofax® AP25 Cationic STA LOK® 300 Nalco 8187 #/t Nalco 62060 #/t Nalco 2020 #/t Kymene® 557H #/t Cationic STALOK® 300 #/t Wt.
  • PVA Polyvinyl Alcohol
  • Celvol V24203 supplied by Celanese Ltd.
  • the total coat weight was about 50 g/m 2 and was divided equally between each side of the sheet.
  • the coating was added to the surface to facilitate testing Z-direction tensile (ZDT) and internal Scott Bond, because low density structures without the coating tend to separate at the tape instead of the within the sheet.
  • Sample code 9 from Tables XI and XII above is the base case.
  • the fiber furnish used in all of the following examples was the same, only the chemical additives and the order of addition were changed.
  • the fiber components were:
  • the pilot paper machine was a standard Fourdrinier type single ply former.
  • the design is such that there are several chemical addition points so that wet end additive effects can be studied.
  • Figure 1 shows the basic unit operations with the chemical addition points. indicated as lower case letters as in Table XV.
  • the addition points have been labeled and should be used as a reference for the formulations shown in Table XV.
  • Target basis weight was 200 g/m 2 .
  • ZDT can be increased by approximately 25% to 85% relative to the same furnish with conventional levels of cationic starch (Codes 2-8, 11-14).
  • Starch loading resulted in an increase in density of ⁇ 10% in all cases and had no significant impact on stiffness.

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