EP2892718A1 - Liants d'éthylène d'acétate de vinyle fonctionnalisés pour revêtements de papier et de carton - Google Patents

Liants d'éthylène d'acétate de vinyle fonctionnalisés pour revêtements de papier et de carton

Info

Publication number
EP2892718A1
EP2892718A1 EP12884053.5A EP12884053A EP2892718A1 EP 2892718 A1 EP2892718 A1 EP 2892718A1 EP 12884053 A EP12884053 A EP 12884053A EP 2892718 A1 EP2892718 A1 EP 2892718A1
Authority
EP
European Patent Office
Prior art keywords
unsaturated
paper product
pphm
product according
monomers
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.)
Withdrawn
Application number
EP12884053.5A
Other languages
German (de)
English (en)
Other versions
EP2892718A4 (fr
Inventor
Yifang SHI
Rajeev Farwaha
Yunlong Zhang
Yi Han
Hendrikus Van BOXTEL
Gerhard Bauer
Jörg SCHULTE
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.)
Celanese Sales Germany GmbH
Original Assignee
Celanese Emulsions GmbH
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 Celanese Emulsions GmbH filed Critical Celanese Emulsions GmbH
Publication of EP2892718A1 publication Critical patent/EP2892718A1/fr
Publication of EP2892718A4 publication Critical patent/EP2892718A4/fr
Withdrawn legal-status Critical Current

Links

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
    • D21H19/10—Coatings without pigments
    • D21H19/12—Coatings without pigments applied as a solution using water as the only solvent, e.g. in the presence of acid or alkaline compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2/00—Processes of polymerisation
    • C08F2/44—Polymerisation in the presence of compounding ingredients, e.g. plasticisers, dyestuffs, fillers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2/00—Processes of polymerisation
    • C08F2/12—Polymerisation in non-solvents
    • C08F2/16—Aqueous medium
    • C08F2/22—Emulsion polymerisation
    • 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
    • D21H19/10—Coatings without pigments
    • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • 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
    • D21H19/10—Coatings without pigments
    • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/24—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H19/32—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds obtained by reactions forming a linkage containing silicon in the main chain of the macromolecule
    • 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
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • 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
    • D21H19/80—Paper comprising more than one coating
    • D21H19/82—Paper comprising more than one coating superposed
    • 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

Definitions

  • the present invention relates to aqueous, surfactant-stabilized, functionalized vinyl ester/ethylene-based emulsion interpolymers demonstrating enhanced dry pick strength when used in paper coating formulations.
  • Pigmented paper coating formulations generally comprise an aqueous synthetic polymer binder emulsion and pigment and may contain other additives typically used in the paper coating art.
  • Illustrative of the polymer binders in the emulsion field are vinyl acetate copolymers and interpolymers, including vinyl acetate/ethylene and vinyl acetate/alkyl acrylate copolymers and interpolymers, and styrene/butadiene and styrene/acrylate copolymers.
  • Such copolymers and interpolymers can also contain other co-monomers such as, for example, a copolymerized ethylenically unsaturated mono- or dicarboxylic acid or other unsaturated co-monomers which can function as cross-linking agents.
  • U.S. Patent No. 4,395,499 discloses high strength pigment binders for paper coating having increased water retention and stability.
  • the coating compositions contain an aqueous synthetic polymer latex comprising a dispersed interpolymer of a vinyl ester; a polyethylenically unsaturated co- monomer which can be triallyl cyanurate, triallyl isocyanurate, diallyl maleate, diallyl fumarate, divinyl benzene or diallyl phthalate; an ethylenically unsaturated mono- or dicarboxylic acid co-monomer or half ester thereof; and optionally an alkyl acrylate co-monomer.
  • a variety of emulsion polymerization components and techniques can influence binding strength, but, in general, vinyl acetate-based binders (e.g., polyvinyl acetate, vinyl acetate-ethylene, vinyl acetate-acrylate, and the vinyl acetate-based binders discussed above) are known to provide lower binding strength than more commonly used coating binders like styrene butadiene and styrene acrylate. To compensate for the lower IGT pick resistance provided by paper coating compositions using such vinyl ester based binders, higher binder levels are required, and this, of course, hurts the profitability of the coated paper and paperboard products made with these types of coating binders.
  • vinyl acetate-based binders e.g., polyvinyl acetate, vinyl acetate-ethylene, vinyl acetate-acrylate, and the vinyl acetate-based binders discussed above
  • VAE vinyl acetate/ethylene
  • U.S. Patent No. 3,337,482 discloses paper coating compositions containing pigments and binder emulsions comprising copolymers of ethylene, vinyl acetate and ethylenically unsaturated mono- or di-carboxylic acids such as acrylic acid or maleic acid.
  • the binder emulsions of the '482 patent are prepared by emulsion polymerization of the co-monomers using a nonionic emulsfier which contains polyoxyethylene oleyl or lauryl phenyl ethers.
  • EP 0 140 227 discloses high strength pigment binders for paper coating having increased water retention and stability.
  • the coating compositions comprise an aqueous synthetic polymer latex and pigment and may contain other additives used in the art of pigmented paper coating.
  • the latex comprises a vinyl ester, an organofunctional silane, carboxyl and/or amide functionality and optionally ethylene and/or other polymerizable comonomers.
  • VAE -based products can be realized if the binding strength exhibited by such VAE-type binders can be made comparable to the binding strength of non-vinyl ester-based binders such as those based on styrene butadiene and styrene acrylate.
  • U.S. Pat. Publ. 2012/0021237 discloses surfactant-stabilized latex emulsions that can be used as binders in paper coating compositions.
  • Such latex emulsions comprise an interpolymer formed by emulsion polymerizing monomers selected from vinyl esters, e.g., vineyl acetate; ethylene; certain unsaturated mono- and di-carboxylic acid materials such as acrylic acid or maleic anhydride; and certain polyethylenically unsaturated cross-linking co-monomers such as diallyl phthalate.
  • These latex emulsions are stabilized with surfactants that are substantially free of environmentally suspect alkyl phenol ethoxylates (APEs).
  • APEs environmentally suspect alkyl phenol ethoxylates
  • the paper coating compositions containing latex emulsion binders of this type exhibit especially desirable coating strength as quantified by the Dry Pick Values (as defined therein) which such compositions provide.
  • these copolymers are prepared by polymerizing appropriate co-monomers in an aqueous emulsion.
  • emulsions can be stabilized by adding conventional surfactants (anionic, nonionic, cationic) as emuslifiers.
  • emulsions may also be stabilized by including protective colloids such as those based on polyvinyl alcohols (PVOH), ionically modified starches, water-soluble starches, starch ethers, polyacrylic acid, carboxymethyl cellulose, natural gums, gelatin, synthetic polymers, or water-soluble cellulose ethers such as hydroxyethyl cellulose (HEC).
  • PVOH polyvinyl alcohols
  • HEC hydroxyethyl cellulose
  • Substantially all-surfactant-based vinyl ester/ethylene (VAE) latex emulsions are especially desirable from the standpoint of permitting effective compounding of the emulsion with the various types of filler materials which are used in paper coating compositions.
  • Substantially all-surfactant stabilized binder emulsions also provide excellent compatibility with other materials typically used by the paper industry in paper manufacture such as styrene-butadiene rubber (SB ) emulsions.
  • substantially all-surfactant-based vinyl ester/ethylene emulsions when serving as paper coating compositions, can lead to some processing problems during paper manufacture.
  • processing problems can manifest themselves when the paper coated with the all-surfactant binder emulsion exits the curing oven at 110 °C - 120 °C and then travels over a series of guide rollers and possibly through a shearing machine.
  • Substantially all-surfactant stabilized coating compositions have a tendency to transfer to the rollers and create build-up which can cause maintenance issues. In addition, at times this build-up can transfer back to the paper which can cause undesired abnormalities on the paper surface.
  • the present invention is directed to a paper product comprising a planar fibrous cellulose substrate, and a pre-coating composition disposed on a surface of said substrate comprising an interpolymer prepared by the emulsion polymerization of (i) one or more vinyl ester monomers; (ii) ethylene; (iii) an unsaturated silane co-monomer; and (iv) one or more emulsion-stabilizing ionic co-monomers comprising one or more of: (a) an unsaturated, substituted organic sulfonic acid or salt thereof, (b) an unsaturated, organic phosphonic acid or salt thereof, (c) an unsaturated, substituted organic sulfonate or sulfate, or (d) an unsaturated, organic phosphonate or phosphate, in the presence of (v) a stabilizing system which comprises one or more anionic and/or nonionic surfactants but less than about 1 pphm of any protective colloid material
  • Another embodiment of the present invention is directed to a process for forming a coated paper product, comprising (a) coating a planar fibrous cellulose substrate with a coating composition to form a wet coated substrate, wherein the coating composition comprises an interpolymer prepared by the emulsion polymerization of (i) one or more vinyl ester monomers; (ii) ethylene; (iii) an unsaturated silane co-monomer; and (iv) one or more emulsion-stabilizing ionic co-monomers comprising at least an unsaturated, substituted organic sulfonic acid or salt thereof, an unsaturated, organic phosphonic acid or salt thereof, an unsaturated, substituted organic sulfonate or sulfate, or an unsaturated, organic phosphonate or phosphate, in the presence of (vi) a stabilizing system which comprises one or more anionic and/or nonionic surfactants but less than about 1 pphm of any protective colloid material; and (vii
  • Figure 1 is a graph illustrating the relative Dry Pick Resistance between two examples of the present invention and a conventional paper coating.
  • the present invention relates to aqueous, surfactant-stabilized, interpolymer latex binder emulsions that demonstrate excellent dry pick strength when such binder emulsions are incorporated into coating compositions for paper products.
  • the coating compositions can be used as a paper pre-coating, and subsequently overcoated with a top coating composition.
  • Such latex binder emulsions contain an interpolymer comprising a vinyl ester co- monomer which has been copolymerized with a selected amount of ethylene, an unsaturated silane co-monomer, one or more emulsion-stabilizing ionic co- monomers comprising one or more of an unsaturated, substituted sulfonic acid, an unsaturated phosphonic acid, or an ester of one of those acids, and with a stabilizing system which comprises one or more anionic and/or nonionic surfactants but less than about 1 pphm of any protective colloid material.
  • the emulsion polymerization can be carried out in conventional manner to form a binder latex containing the desired interpolymer.
  • the vinyl esters utilized in the formation of the interpolymer of the latex binder emulsions herein are the esters of alkanoic acids, the acid having from one to about 13 carbon atoms.
  • Typical examples include vinyl formate, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl isobutyrate, vinyl valerate, vinyl-2- ethyl-hexanoate, vinyl isooctanoate, vinyl nonate, vinyl decanoate, vinyl pivalate, vinyl versatate, etc.
  • vinyl acetate is the preferred monomer because of its ready availability and low cost.
  • the vinyl ester is preferably present in the interpolymer in an amount ranging from about 67 pphm to 99 pphm (parts per hundred based on total monomers in the interpolymer). More preferably, the vinyl ester content of the interpolyer used in the paper coating compositions herein will range from about 70 pphm to 90 pphm.
  • the second major component of the interpolymer formed in the binder latex is ethylene.
  • Ethylene will generally comprise from about 1.0 pphm to 30.0 pphm of the interpolymer. More preferably, ethylene will be present in the interpolymer in an amount ranging from about 2 pphm to 25 pphm.
  • the third component of the interpolymer in the binder latex comprises a minor amount of an unsaturated silane co-monomer.
  • This co-monomer can generally correspond to a substituted silane of the structural Formula I:
  • R denotes an organic radical olefinically unsaturated in the ⁇ -position
  • R 1 R2 and R 3 which may be identical or different, denote halogen, preferably chlorine, or the group -OZ, Z denoting hydrogen or primary or secondary alkyl or acyl radicals optionally substituted by alkoxy groups.
  • Suitable unsaturated silane compounds of the Formula I are preferably those in which the radical R in the formula represents an ⁇ -unsaturated alkenyl of 2 to 10 carbon atoms, particularly of 2 to 4 carbon atoms, or an ⁇ -unsaturated carboxylic acid ester formed from unsaturated carboxylic acids of up to 4 carbon atoms and alcohols carrying the Si group of up to 6 carbon atoms.
  • the radical R in the formula represents an ⁇ -unsaturated alkenyl of 2 to 10 carbon atoms, particularly of 2 to 4 carbon atoms, or an ⁇ -unsaturated carboxylic acid ester formed from unsaturated carboxylic acids of up to 4 carbon atoms and alcohols carrying the Si group of up to 6 carbon atoms.
  • radicals R , R , R are preferably the group -OZ, Z representing primary and/or secondary alkyl radicals of up to 10 carbon atoms, preferably up to 4 carbon atoms, or alkyl radicals substituted by alkoxy groups, preferably of up to 3 carbon atoms, or acyl radicals of up to 6 carbon atoms, preferably of up to 3 carbon atoms, or hydrogen.
  • Most preferred unsaturated silane co-monomers are vinyl trialkoxy silanes.
  • Examples of preferred silane compounds of the Formula I include vinyltrichlorosilane, vinylmethyldichlorosilane, y-methacryloxypropyltris(2- methoxyethoxy)silane, vinylmethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, vinyldiethoxysilanol, vinylethoxysilanediol, allyltriethoxysilane, vinyltripropoxysilane, vinyltriisopropoxysilane, vinyltributoxysilane, vinyltriacetoxysilane, trimethylglycolvinylsilane, ⁇ - methacryloxypropyltrimethylglycolsilane, ⁇ -acryloxypropyltriethoxysilane and ⁇ - methacryloxypropyltrimethoxysilane.
  • the unsaturated silane co-monomer as described above is selected and used in forming the interpolymer of the coating compositions used herein in amounts which are effective to alter interpolymer molecular weight, branching and/or flow properties in a certain manner, such as from about 0.1 pphm to about 3 pphm, or even from about 0.1 pphm to about 1.5 pphm, or from about 0.2 pphm to about 0.5 pphm.
  • the interpolymer additionally contains minor amounts, such as from about 0.1 pphm to about 5 pphm, or from about 0.1 pphm to about 1.0 pphm, or from about 0.2 pphm to about 0.5 pphm of one or more additional co-monomer types that assist in the stabilizing of the latex emulsion which is formed.
  • Such stabilizing co-monomers are those that are ionic in character by virtue of containing acid moieties or the salts or half-esters of such acid moieties.
  • the interpolymer should contain one or more unsaturated, substituted organic sulfonic acid or salt thereof, unsaturated, organic phosphonic acid or salt thereof, unsaturated, substituted organic sulfonate or sulfate, or unsaturated, organic phosphonate or phosphate.
  • unsaturated, substituted organic sulfonic acid or salt thereof unsaturated, organic phosphonic acid or salt thereof, unsaturated, substituted organic sulfonate or sulfate, or unsaturated, organic phosphonate or phosphate.
  • sulfate or sulfonate function such as 2-sulfoethyl methacrylate, 2-acrylamido- 2-methylpropanesulfonic acid, styrenesulfonic acid, vinylphosphonic acid, phosphate monomers such as PAM-100 and PAM-200 phosphate ester monomers available from Rhodia and corresponding salts of these monomers, 2- sulfooxyethyl methacrylate, vinylbenzene sulfonic acid, allylsulfonic acid, 2- acrylamido-2-methylpropanesulfonic acid, sulfoethyl acrylate or methacrylate, or sulfopropyl acrylate or methacrylate, and water-soluble salts thereof, acrylamido methyl propane sulfonic acid, styrene sulfonate, sodium
  • optional ionic monomers include those selected from ⁇ , ⁇ - ethylenically unsaturated C3-C8 monocarboxylic acids, ⁇ , ⁇ -ethylenically unsaturated C 4 -C 8 dicarboxylic acids and the anhydrides thereof, the C 4 -C 8 alkyl half-esters of the ⁇ , ⁇ -ethylenically unsaturated C 4 -C 8 dicarboxylic acids, and acrylic acid and methacrylic acid, and the C 4 -C 8 alkyl half esters of maleic acid, maleic anhydride, fumaric acid, and itaconic acid.
  • Acrylic acid is a particularly perferred optional ionic monomer.
  • the foregoing types of optionally present ionic co-monomers are added in very low amounts, for example, in an amount from 0.1 pphm to 5.0 pphm. More preferably, if used, the optional ionic co-monomers will comprise from about 0.2 pphm to about 2.0 pphm, or from about 0.2 to about 1.0 pphm of the monomer mixture.
  • interpolymers for use in the paper coating compositions herein which also utilize non-silicon-containing co- monomers in the interpolymers.
  • non-silicon-containing co-monomers could be, for example, any unsaturated, multi-functional, cross-linking co-monomers which, when incorporated into the interpolymer in appropriate amounts, provide interpolymers with improved coating strength properties.
  • Suitable non-silicon-containing unsaturated multi-functional co- monomers can include, for example, unsaturated compounds that contain one or more carbonyl moieties.
  • Preferred co-monomers of this type include those having two or more carbonyl moieties. Examples of such suitable co-monomers include diacetone acrylamide (DiAAA), polymerizable 1,3-dicarbonyl compounds and polymerizable 1,3-diketoamides.
  • Suitable polymerizable 1,3-dicarbonyl compounds include acetoacetoxyethyl acrylate, acetoacetoxyethyl methacrylate (AEEM), acetoacetoxypropyl methacrylate, acetoacetoxybutyl methacrylate, 2,3- di(acetoacetoxy)propyl methacrylate and allyl acetoacetate.
  • AEEM acetoacetoxyethyl methacrylate
  • acetoacetoxypropyl methacrylate acetoacetoxybutyl methacrylate
  • 2,3- di(acetoacetoxy)propyl methacrylate 2,3- di(acetoacetoxy)propyl methacrylate and allyl acetoacetate.
  • Suitable polymerizable 1,3-diketoamides include those compounds described in U.S. Patent No. 5,889,098, which patent is incorporated herein by reference.
  • Examples of compounds of this type include amido acetoacetonates such as 3-isopropenyl-a,a-dimethylbenzyl amidoacetoacetate, 4-isopropenyl-a,a- dimethylbenzyl amidoacetoacetate, 4-ethylenyl-phenyl amidoacetoacetate and the like.
  • Preferred unsaturated, multi-functional, carbonyl-containing co- monomers of the foregoing types include diacetone acrylamide (DiAAA), acetoacetoxyethyl methacrylate (AEEM), acetoacetoxypropyl methacrylate, acetoacetoxybutyl methacrylate, 2,3-di(acetoacetoxy)propyl methacrylate and allyl acetoacetate.
  • Diacetone acrylamide and acetoacetoxyethyl methacrylate are the most preferred.
  • unsaturated, carbonyl-functional co-monomers of these types can be present in the polymerization mixture in amounts ranging from about 0.1 to 4.0 pphm. More preferably such co-monomers will be present in amounts from about 0.5 to 3.5 pphm.
  • water-soluble, external cross-linking agents in the emulsion polymerization reaction mixture.
  • Water-soluble external cross-linking agents which can be employed in this manner are those which will react with the carbonyl functionalities of the non- silicon-containing, unsaturated, multifunctional co-monomers which have been polymerized into the interpolymer backbone.
  • One preferred type of water-soluble cross-linking agent that optionally may be used in the paper coating compositions herein comprises a compound which contains at least two hydrazine moieties.
  • Particularly suitable are dihydrazine compounds of aliphatic dicarboxylic acids of 2 to 10, in particular 4 to 6, carbon atoms, e.g., oxalic acid dihydrazide, malonic acid dihydrazide, succinic acid dihydrazide, glutaric acid dihydrazide, adipic acid dihydrazide, sebacic acid dihydrazide, maleic acid dihydrazide, fumaric acid dihydrazide and/or itaconic acid dihydrazide.
  • Water-soluble aliphatic dihydrazines of 2 to 4 carbon atoms e.g., ethylene- 1,2-dihydrazine, propylene- 1,3 -dihydrazine or butylene-l,4-dihydrazine, are also suitable.
  • Adipic acid dihydrazide (ADH) is the most preferred water-soluble cross-linking agent for use in the compositions herein.
  • the water-soluble cross-linking agent will generally be present in the emulsion polymerization reaction mixture in an amount such that the molar ratio of cross-linking agent hydrazine groups to co-monomer carbonyl groups in the blend is between about 0.1 and about 2.0. More preferably the molar ratio of cross-linking agent hydrazine groups to copolymer carbonyl groups in the blend will be between about 0.5 and 1.5. In order to provide such ratios, the dihydrazine water-soluble cross-linking agent can be present in the polymerization mixture in amounts ranging from about 0.1 to 3.0 pphm, more preferably from about 0.2 to 2.0 pphm.
  • the foregoing unsaturated carboxylic acid-based co-monomers are also generally present in the interpolymers of the binder latex emulsions herein in certain selected amounts which serve to impart the desirable binder strength to paper coating composition containing such emulsions.
  • this type of unsaturated carboxylic acid based co-monomer will generally be present in the interpolymer in amounts of from about 0.1 pphm to 1.0 pphm. More preferably, such carboxylic acid-based co-monomers will be used in amounts of 0.2 pphm to 0.5 pphm.
  • Preferred co-monomers of this type included diallyl maleate, diallyl fumarate and diallyl phthalate.
  • This type of polyethylenically unsaturated co-monomer will be generally present in the interpolymer in amounts of from about 0.05 pphm to 0.5 pphm. More preferably, such polyethylenically unsaturated co-monomer(s)/cross-linker(s) will be used in amounts of from about 0.1 pphm to 0.3 pphm.
  • the interpolymers used to form the binder latex emulsions of the paper coating compositions herein are made by copolymerizing a vinyl ester with ethylene, an unsaturated silane co-monomer, one or more emulsion- stabilizing ionic co-monomers comprising one or more of an unsaturated, substituted sulfonic acid, an unsaturated phosphonic acid , and/or an ester of one of those acids, and with a stabilizing system which comprises one or more anionic and/or nonionic surfactants but less than about 1 pphm of any protective colloid material.
  • these several types of co-monomers are present in the interpolymer in amounts relative to each other which serve to impart to the paper coating compositions an IGT Dry Pick Value (as defined hereinafter) of at least about 5% greater than papers coated with conventional coating compositions formulated with styrene-butadiene binders, or even those formulated with VAE latex binders not having the combination of unsaturated silane co-monomer and one or more emulsion-stabilizing ionic co-monomers, described above.
  • IGT Dry Pick Value as defined hereinafter
  • the relative amounts of the co-monomers in the interpolymer are selected such that a paper coating composition containing the interpolymer-based latex emulsion exhibit a Dry Pick Value at least about 10% greater, or even about 15 % greater than those more conventional formulations.
  • the interpolymer comprising the essential co-monomers hereinbefore described can be prepared using conventional emulsion polymerization procedures which result in the preparation of binder latex emulsions for paper coating compositions. Such procedures are described in general, for example, in U.S. Patent No. 5,849,389, the disclosure of which is incorporated herein by reference in its entirety.
  • the vinyl ester, ethylene, and other co-monomers can be polymerized in an aqueous medium under pressures not exceeding 100 atmospheres in the presence of a catalyst and at least one emulsifying agent.
  • the aqueous system can be maintained by a suitable buffering agent at a pH of 2 to 6, with the catalyst being added incrementally or continuously.
  • vinyl acetate and 50% to 75% of the other co- monomers can be suspended in water and thoroughly agitated in the presence of ethylene under the working pressure to effect solution of the ethylene in the mixture up to the substantial limit of its solubility under the conditions existing in the reaction zone.
  • the vinyl acetate and other-co-monomers can then be gradually heated to polymerization temperature.
  • the homogenization period is generally followed by a polymerization period during which the catalyst, which preferably comprises a main catalyst or initiator, and may include an activator, is added incrementally or continuously together with the remaining co-monomers.
  • the catalyst which preferably comprises a main catalyst or initiator, and may include an activator, is added incrementally or continuously together with the remaining co-monomers.
  • the monomers employed may be added either as pure monomers or as a premixed emulsion.
  • Suitable polymerization catalysts include the water-soluble free- radical-formers generally used in emulsion polymerization, such as hydrogen peroxide, sodium persulfate, potassium persulfate and ammonium persulfate, as well as tert-butyl hydroperoxide, in amounts of between 0.01% and 3% by weight, preferably 0.01% and 1% by weight based on the total amount of the emulsion.
  • water-soluble free- radical-formers generally used in emulsion polymerization, such as hydrogen peroxide, sodium persulfate, potassium persulfate and ammonium persulfate, as well as tert-butyl hydroperoxide, in amounts of between 0.01% and 3% by weight, preferably 0.01% and 1% by weight based on the total amount of the emulsion.
  • reducing agents such as sodium formaldehyde- sulfoxylate, ferrous salts, sodium dithionite, sodium hydrogen sulfite, sodium sulfite, sodium thiosulfate, as redox catalysts in amounts of 0.01% to 3% by weight, preferably 0.01% to 1% by weight, based on the total amount of the emulsion.
  • the free-radical-formers can be charged in the aqueous emulsifier solution or can be added during the polymerization in doses.
  • the manner of combining the polymerization ingredients can be by various known monomer feed methods, such as, continuous monomer addition, incremental monomer addition, or addition in a single charge of the entire amounts of monomers.
  • the entire amount of the aqueous medium with polymerization additives can be present in the polymerization vessel before introduction of the monomers, or alternatively, the aqueous medium, or a portion of it, can be added continuously or incrementally during the course of the polymerization.
  • the emulsion polymerization used to prepare the interpolymer in aqueous latex form is carried out in the presence of a stabilization system which comprises one or more of certain types of anionic and/or nonionic surfactants as emulsifiers.
  • a stabilization system which comprises one or more of certain types of anionic and/or nonionic surfactants as emulsifiers.
  • Such emulsifiers are conventional and well known.
  • Suitable nonionic surfactants which can be used as emulsifiers in the emulsion stabilizing system of the coating compositions herein include polyoxyethylene condensates.
  • a wide variety of nonionic surfactants of this type are disclosed in the hereinbefore-referenced U.S. Patent No. 5,849,389.
  • Suitable anionic surfactants which can be used as emulsifiers in the emulsion stabilizing system of the coating compositions herein include alkyl aryl sulfonates, alkali metal alkyl sulfates, sulfonated alkyl esters and fatty acid soaps.
  • alkyl aryl sulfonates alkali metal alkyl sulfates, sulfonated alkyl esters and fatty acid soaps.
  • anionic surfactants of this type are also disclosed in the hereinbefore-referenced U.S. Patent No. 5,849,389.
  • the binder emulsions herein should contain no more than about 1.0 pphm and preferably no more than about 0.5 pphm of protective colloid materials.
  • emulsion polymerization can be conducted in the absence of such protective colloid materials.
  • Binder emulsions using surfactant-based stabilizing systems and containing no more than these amounts of protective colloid-forming materials are considered for purposes of this invention to be "substantially free" of protective colloid materials.
  • the latex emulsions which utilize such stabilizing systems are also those characterized herein as being “substantially all-surfactant-based" emulsions.
  • the solids content of the resulting aqueous polymer emulsion binder can be adjusted to the level desired by the addition of water or by the removal of water by distillation.
  • the desired level of polymeric solids content is from about 40 weight percent to about 70 weight percent based on the total weight of the emulsion, more preferably from about 50 weight percent to about 60 weight percent.
  • additives may be incorporated into the paper coating compositions used herein in order to modify the properties thereof.
  • these additives may be included fillers, thickeners, catalysts, dispersants, colorants, biocides, anti-foaming agents, etc.
  • co-binder materials such as polyvinyl alcohol, can be post-added in amount of at least about 1 wt% of the paper coating composition.
  • Preferred coating compositions in accordance with the present invention are loaded with filler to yield a composition comprising from about 5 to about 50 weight percent interpolymer, preferably from about 5 to about 20 weight percent, and from about 50 to about 90 weight percent filler, based on total weight of the composition.
  • the paper coating compositions herein Prior to drying, can generally have a total solids content ranging from about 50 wt% to 95 wt%. More preferably, prior to drying, the coating compositions herein will have a total solids content ranging from about 80 wt% to 90 wt%.
  • the particle size of the latex can be regulated by the quantity of non- ionic or anionic emulsifying agent or agents employed. To obtain smaller particles sizes, greater amounts of emulsifying agents are used. As a general rule, the greater the amount of the emulsifying agent employed, the smaller the average particle size.
  • the actual paper coating compositions herein comprise the interpolymer latex together with a pigment, such as clay and/or calcium carbonate, and the usual paper coating additives which may include other co-binders, such as polyvinyl alcohol, protein, e.g. casein or soy protein, or starch, as is well known to those skilled in the art.
  • the coating compositions herein will also contain sufficient alkali to maintain the pH of the coating composition between 6 and 10, more preferably between 7 and 9.
  • the pigment used in the paper coating compositions herein may be any of those conventionally employed. Frequently, some or all of the pigment comprises clay and for this portion any of the clays customarily used for paper coating, including the hydrous aluminium silicates of kaolin group clays, hydrated silica clays, and the specific types of clays recommended in Chapters 10-16 of "Kaolin Clays and their Industrial Uses," by J. M. Huber Corp. (1949), New York, N.Y.
  • the other paper pigments such as, for example, calcium carbonate, titanium dioxide, blanc fixe, lithopone, zinc sulfide, or other coating pigments including plastics, for example polystyrene.
  • the other pigments can be present in various ratios, e.g. up to 50%, preferably up to 35%, by weight of the clay.
  • the pigment can comprise more than 50% of calcium carbonate relative to clay, even more than 75% calcium carbonate relative to clay, or even 100% calcium carbonate in the absence of clay.
  • the composition may also contain other additives such as zinc oxide and/or a small amount, of a dispersing or stabilizing agent such as tetrasodium pyrophosphate.
  • the paper coating compositions herein can comprise 100 parts pigment, e.g., pigments which comprise 65-100 parts calcium carbonate and 0-35 parts secondary pigment; 0.01-0.5 parts dispersing or stabilizing agent; 3-30 parts interpolymer latex (solids basis); 0-25 parts cobinder; optionally 0.02 parts defoamer; and sufficient water to provide the desired level of solids.
  • Coating compositions containing from about 40 wt% to 70 wt% solids are typical. The modification and formulation of the coating color using these materials will be within the knowledge of those skilled in the art.
  • the paper coating compositions herein may be applied to various planar, fibrous cellulose substrates including paper such as freesheet and groundwood grades; paper board; labels; paper products used for newspapers, advertisements, poster, books or magazines; and building substrates such as wall paper, wall board, or ceiling tile.
  • the paper coating composition can be used to coat paper intended for rotogravure printing.
  • the amount of the paper coating composition applied to the planar fibrous cellulose substrate is generally in the range of about 1 g/m to about 30 g/m 2 , and preferably in the range of about 3 g/m 2 to about 25 g/m 2 , or from about
  • the paper coating composition may be applied in a single step or by using two or more steps to build the final coat weight. Further, the paper coating composition may also be applied to the second side of the substrate either simultaneously or as a separate coating step.
  • the paper coating composition may be applied to the substrate by techniques well known to those in the art.
  • the paper coating composition may be applied with a roll applicator such as a metered size press; a blade coater such as a short dwell time applicator; air knife coater; slot die coater such as a jet applicator; or brush.
  • a roll applicator such as a metered size press
  • a blade coater such as a short dwell time applicator
  • air knife coater such as a jet applicator
  • Preferred coating methods for high speed application include the use of a blade coater or a metered size press.
  • the invention is also directed to a process for forming a coated paper product, comprising (a) coating a planar fibrous cellulose substrate with the coating composition described above to form a wet coated substrate; (b) drying the wet coated substrate to form a dried coated substrate; and (c) calendering the dried coated substrate to form the coated paper product.
  • the paper coating compositions of the present invention which contain the particular vinyl ester-based binder latex emulsions described herein, provide improved binding strength when applied as coating to paper substrates of the type described above.
  • This improved binding peformance can be quantifed by means of a parameter called dry pick strength, and in particular by means of a parameter called Dry Pick Value as specifically defined hereinafter.
  • Picking is defined as the lifting of a coating, film or fibers from the surface of the base paper during printing.
  • a print wheel makes contact with a paper sample to deposit the ink, then subsequent negative forces are exerted on the paper as the inked print wheel is removed from the paper surface.
  • the dry pick strength of the coated paper is measured with a method that consists of printing a strip of the coated paper in a print tester at an accelerating rate. The accelerated speed of the print wheel and the tack rating of the ink are adjusted to determine the strength of the coated paper sample at specific printing conditions.
  • Evaluation of the picking effect exhibited by selected paper substrates coated with any given type of paper coating composition can be used to quantify the binding strength and coating performance of that composition.
  • Picking evalution is carried out by means of IGT pick testing according to standard methods of measurement by the Technical Association of the Pulp and Paper Industry (TAPPI) as well known in the art.
  • TAPPI Technical Association of the Pulp and Paper Industry
  • a measure of dry and wet binding strength is provided by IGT Pick testing pursuant to TAPPI Useful Method UM 591, Surface Strength of Paper.
  • the IGT dry pick strength measures the speed, in cm/sec, required to lift the paper coating off of the surface of a paper substrate strip when printed using an ink roller and standard conditions as described in UM 591. Higher IGT dry pick numbers indicate better resistance of the coated substrate to picking and hence higher strength coating performance.
  • the binder level in the formulations of the present invention were selected to emulate commercial coating recipes. Wire wound rods were used to coat a bleached substrate at a target coating weight value of 12 lbs./3000 ft (19.5 g/m ). This coating weight was selected to mimic the bleached board market.
  • the freshly coated boards were oven dried at about 260°F (127°C) for 30 seconds and subsequently calendered at 600 psi (4.14 MPa) and 170°F (77°C) using 1 nip.
  • the finished boards were allowed to sit for 24 hours under constant temperature and humidity conditions (72°F (22°C), 50% RH) before being tested for IGT pick resistance.
  • the Dry Pick Values as used herein are the values obtained from the dry pick testing of the coated boards as described above using an IGT Testing Systems AIC2-5 Printability Tester under conditions which include use of medium viscosity oil, 2 cm/sec, and 50 KgF.
  • the paper coating compositions of the present invention when using the binder emulsions of the present invention, exhibit Dry Pick Values in accordance with the above- described testing of at least about 75, more preferably at least about 90, and even more preferably of at least about 100.
  • the paper coating compositions of the present invention exhibit Dry Pick Values of from about 90 to 110.
  • the ink wettability or receptivity of a test coating is an important characteristic of a printing grade paper.
  • a common industry test of ink receptivity is K&N Ink Brightness, described in TAPPI Test Method RC19.
  • the K&N ink test consists of an oil-soluble dye in a varnish-base ink applied in excess to a 1-2 square inch area of test paper.
  • the ink receptivity is measured by the percentage surface brightness drop when K&N ink is applied for a short time and removed. The smaller the number for ink receptivity, the more nonporous the coating is and therefore a lesser degree of ink penetration into the coating. Low numbers indicate greater ink receptivity.
  • a number of binder emulsions based on vinyl acetate/ethylene (VAE) interpolymers were prepared using the general polymerization techniques described in Comparative Example 1 and in Examples 1-4 of U.S. Patent No. 5,576,384, incorporated herein by reference.
  • the interpolymers in the emulsions made contain relatively small amounts of additional co-monomers including some of the ionic emulsion stabilizing co-monomers and the unsaturated silane co- monomers used in the present invention.
  • All of the binder emulsions made were emulsified with various amounts of anionic and/or nonionic emulsifiers.
  • Some of the binder emulsions made also contain varying amounts of protective colloids based on polyvinyl alcohol (PVOH), hydroxyethyl cellulose, styrene acrylic acid or styrene maleic acid colloids.
  • VA vinyl acetate
  • E ethylene
  • VAE represents a vinyl acetate/ethylene binder emulsion.
  • VTMOsilane is vinyl trimethoxy silane.
  • SVS sodium vinyl sulfonate and AA is acrylic acid.
  • PVOH is polyvinyl alcohol and HEC is hydroxyethyl cellulose.
  • SBR is styrene-butadiene rubber.
  • the binder latex emulsion of Example 6 was formulated into a pre- coating composition as described in Table 2 below, and was compared to a conventional pre-coating composition containing commercially obtained SBR as the binder polymer.
  • the pre-coating compositions of Table 2 were coated onto a paper substrate at levels of 22 g/m , calendered, dried in an oven, and overcoated with a conventional top coating composition containing SBR, formulated as in Table 3 below, at a level of 22 g/m .
  • the latex binder of Example 6 provided an unusually and unexpectedly high IGT Dry Coating Strength, even as compared to that of Example 5.
  • the IGT Dry Coating Strength of boards coated with the coating composition containing the Example 6 latex binder is more than 15% greater, in fact nearly 20% greater than that containing the Example 5 latex binder.

Abstract

L'invention concerne un produit papier comprenant un substrat cellulosique fibreux plan et une composition de revêtement disposée sur une surface dudit substrat comprenant un interpolymère préparé par la polymérisation en émulsion de (i) un ou plusieurs monomères d'ester de vinyle ; (ii) éthylène ; (iii) un silane insaturé co-monomère ; et (iv) un ou plusieurs co-monomères ioniques de stabilisation d'émulsion comprenant un ou plusieurs acides sulfoniques substitués insaturés, un ou plusieurs acides acides phosphoniques insaturés ou un ester de l'un de ces acides, en présence de (v) un système de stabilisation qui comprend un ou plusieurs tensioactifs anioniques et/ou non ioniques, mais moins d'environ 1 pphm de tout matériau colloïde protecteur ; et (v) de l'eau.
EP12884053.5A 2012-09-10 2012-09-10 Liants d'éthylène d'acétate de vinyle fonctionnalisés pour revêtements de papier et de carton Withdrawn EP2892718A4 (fr)

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US20160115649A1 (en) 2016-04-28
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EP2892718A4 (fr) 2016-06-08
CN104411488B (zh) 2018-08-17

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