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
  • D21H19/44—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
  • D21H19/58—Polymers or oligomers of diolefins, aromatic vinyl monomers or unsaturated acids or derivatives thereof
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
  • C09D133/04—Homopolymers or copolymers of esters
  • C09D133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
  • C09D133/062—Copolymers with monomers not covered by C09D133/06
  • C09D133/064—Copolymers with monomers not covered by C09D133/06 containing anhydride, COOH or COOM groups, with M being metal or onium-cation
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
  • C08L33/04—Homopolymers or copolymers of esters
  • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
  • C08L33/062—Copolymers with monomers not covered by C08L33/06
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24934—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including paper layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31855—Of addition polymer from unsaturated monomers
  • Y10T428/3188—Next to cellulosic
  • Y10T428/31895—Paper or wood
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31855—Of addition polymer from unsaturated monomers
  • Y10T428/3188—Next to cellulosic
  • Y10T428/31895—Paper or wood
  • Y10T428/31906—Ester, halide or nitrile of addition polymer

Definitions

• the present invention provides a binder composition including a copolymer binder and a hydrophobically modified alkali-soluble emulsion polymer.
• the binder composition is useful in paper coating compositions especially in paper coating compositions for low coating weight papers which are applied at high coating speeds.
• the binder composition of this invention provides good runnability at high coating speeds and provides paper coatings with good appearance including gloss, brightness, opacity, and good printability.
• a coating process including the steps of preparing a paper coating composition by admixing ingredients comprising 100 parts by dry weight pigment slurry; from 1.6 to 9.8 parts by dry weight copolymer binder containing as polymerized units 98.5 to 70% of at least one first monomer selected from the group including C 2 -C 8 esters of (meth)acrylic acid, 1 to 30% of at least one second monomer selected from the group including styrene, acrylonitrile, and methyl methacrylate, 0.5 to 5% of at least one third monomer selected from the group including acrylic acid, methacrylic acid, acrylamide, methacrylamide, and 2-acrylamido-2-methylpropanesulfonic acid; wherein the copolymer binder is an emulsion polymer and has a glass transition temperature in the range of ⁇ 35° C.
• the copolymer binder is an aqueous emulsion polymer which includes as polymerized units from 70 to 98.5 weight % of a first monomer, 1 to 30 weight % of a second monomer, and from 0.1 to 5 weight % of a third monomer, based on the weight of the copolymer binder.
• the first monomers are ethylenically unsaturated monomers which may include C 2 to C 8 esters of (meth)acrylic acid such as ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, butyl methacrylate, 2-hydroxyethyl acrylate, and hydroxyethyl methacrylate.
• the third monomers are selected from carboxylic acid containing monomers such as acrylic acid, itaconic acid, maleic acid, methacrylic acid, and fumaric acid; (meth)acrylamide and substituted (meth)acrylamides; 2-acrylamido-2-methylpropanesulfonic acid; and mixtures thereof.
• Preferred third monomers include acrylic acid, methacrylic acid, acrylamide, methacrylamide, and 2-acrylamido-2-methylpropanesulfonic acid.
• the copolymer binder may be prepared by various processes known in the art including solution, suspension, and emulsion polymerization.
• a preferred process is aqueous emulsion polymerization which may require the use of one or more surfactants for emulsifying the monomers and for maintaining the polymer obtained in a stable, dispersed condition.
• Suitable surfactants include anionic, nonionic surfactants, and mixtures thereof, using from 0.1 to 10 weight % of surfactant based on the weight of total monomers.
• Suitable nonionic dispersing agents include, for examples, alkyl phenoxypolyethoxy ethanols, having alkyl groups of from 7 to 18 carbon atoms and from 6 to 60 oxyethylene units such as, for example, heptyl phenoxypolyethoxyethanols; ethylene oxide derivatives of long chained carboxylic acids such as lauric acid, myristic acid, palmitic acid, oleic acid, or mixtures of acids such as those found in tall oil containing from 6 to 60 oxyethylene units; ethylene oxide condensates of long chained alcohols such as octyl, decyl, lauryl, or cetyl alcohols containing from 6 to 60 oxyethylene units; ethylene oxide condensates of long-chain or branched chain amines such as dodecyl amine, hexadecyl amine, and octadecyl amine, containing from 6 to 60 oxyethylene units; and block copo
• surfactant-containing monomers examples include surfactant esters such as C 8 -C 30 alkylphenoxy (ethyleneoxy) 6 ⁇ 100 ethyl (meth)acrylates and C 8 -C 30 alkoxy (ethyleneoxy) 6 ⁇ 50 ethyl (meth)acrylates, C 8 -C 30 alkylphenoxy ethyl (meth)acrylates, and C 8 -C 30 alkoxy ethyl (meth)acrylates.
• Other linkages such as, but not limited to ethers, amides and urethanes may be used.
• surfactant-containing monomers include vinyl esters of C 8 -C 30 carboxylic acid and C 8 -C 30 alkyl ester of (meth)acrylate.
• Chain transfer agents may be used to control the molecular weight of the HASE polymer. Suitable chain transfer agents are mercaptans, such as, for example, dodecylmercaptan, methyl mercaptopropionate, and mercaptopropionic acid. The chain transfer agent may be used at from 0.05 to 10 weight % based on the total weight of the HASE polymer.
• a method for preparing a paper coating composition including the binder composition.
• the paper coating composition which is based on 100 parts by dry weight of pigment, includes from 1.6 to 9.8 parts by dry weight of the copolymer binder and from 0.04 to 2.0 parts by dry weight of the HASE polymer.
• the paper coating composition may be admixed by blending the pigment slurry and the binder composition of this invention.
• the copolymer binder and the HASE polymer may be first combined to form the binder composition of this invention, or may be admixed individually or simultaneously with the pigment slurry.
• the binder composition of this invention is admixed with the pigment.
• an alkaline material may be added to increase the pH of the paper coating composition and activate thickening by the HASE polymer.
• the HASE polymer undergoes neutralization resulting in swelling and/or solubilization of the HASE polymer particle with concomitant thickening of the aqueous medium.
• a preferred pH range for the paper coating composition is from 6.5 to 10; a more preferred pH range is 7 to 9.
• the alkaline material may be any base which is water soluble and is compatible with the other components of the paper coating composition. Suitable alkaline materials include ammonium hydroxide, sodium hydroxide, potassium hydroxide, and triethanol amine.
• the paper coating composition may be prepared by first adding alkaline material to the pigment slurry and then adding and admixing the binder composition of this invention.
• the paper coating composition may be applied to various 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.
• 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 is used to coat paper intended for rotogravure printing.
• 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.
• Preferred coating methods for high speed application include blade coater and metered size press.
• Binder composition 1 contained 91 weight % copolymer binder 1 with a particle diameter of 0.25 ⁇ m and a glass transition temperature of ⁇ 21° C., and 9 weight % of HASE polymer.
• the binder composition had a pH of 4.3 and a Brookfield viscosity of 0.20 Pascal-sec. The binder composition was stable as evidenced by the absence of gel formation or precipitation upon storage.
• the paper coating compositions were prepared with several different ratios of the HASE polymer and the copolymer binder 2 but with the total level of HASE thickener+copolymer binder 2 at a level of 5.0 dry parts by weight based on 100 dry parts pigment by weight.
• Copolymer binder 2 was prepared by the process of Example 1 and had a composition of 77 butyl acrylate/21 styrene/1 methacrylic acid/1 2-acrylamido-2-methylpropanesulfonic acid.
• Compare paper coating compositions with the HASE thickener replaced with an alkali swellable emulsion thickener which did not contain hydrophobe groups (ASE).
• a paper coating composition containing the binder composition of this invention indicated as HASE thickener type required a lower level of thickener than the paper coating containing the copolymer binder and the comparative ASE thickener. Further, the paper coating composition had a lower high shear viscosity than the comparative paper coating composition containing the copolymer binder and ASE thickener. The lower high shear viscosity indicated that the paper coating composition containing the binder composition of this invention has better high speed runnability on a paper coater.
• Copolymer binder 3 was prepared by the process of Example 1 from 88 parts butyl acrylate, 9 parts styrene, 2 parts acrylamide, and 1 part acrylic acid. Copolymer binder 3 had a glass transition temperature of ⁇ 27° C. and a particle diameter of 0.30 ⁇ m.
• a paper coating composition containing copolymer binder 3 was prepared according to Table 3.1.
• a comparative paper coating composition was prepared by replacing the copolymer binder and thickener with a commercial self-thickening paper binder, Acronal S223V (Acronal is a registered trademark of BASF). Ammonium hydroxide was added to the paper coating compositions to adjust the pH to about 8.5.
• the paper coating compositions were coated onto 36.7 g/m 2 basis weight rotogravure grade paper at a coating speed of 762 meters per minute (2500 feet per minute) using a Cylindrical Laboratory Coater (Weyerhaeuser). The coated paper was conditioned and then tested at 25° C. and 50% relative humidity.

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• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Life Sciences & Earth Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Wood Science & Technology (AREA)
• Organic Chemistry (AREA)
• Paper (AREA)
• Paints Or Removers (AREA)
• Adhesives Or Adhesive Processes (AREA)
• Polyurethanes Or Polyureas (AREA)

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Citations (5)

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• 2001
  • 2001-02-15 US US09/783,738 patent/US20040151886A1/en not_active Abandoned
  • 2001-02-20 ZA ZA200101398A patent/ZA200101398B/xx unknown
  • 2001-02-23 EP EP01301665A patent/EP1134263B1/de not_active Expired - Lifetime
  • 2001-02-23 AT AT01301665T patent/ATE296861T1/de not_active IP Right Cessation
  • 2001-02-23 DE DE60111102T patent/DE60111102T2/de not_active Expired - Lifetime
  • 2001-03-05 BR BR0100847-1A patent/BR0100847A/pt not_active IP Right Cessation
• 2005
  • 2005-05-25 US US11/136,848 patent/US7217443B2/en not_active Expired - Lifetime

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