Paper, cardboard or paperboard-like material and a process for its production

• US 5,294,299 A
• Filed: 02/03/1993
• Issued: 03/15/1994
• Est. Priority Date: 11/07/1988
• Status: Expired due to Fees

• Current Assignee: Manfred Zeuner, Peter Doblanzki
• Original Assignee: Manfred Zeuner, Peter Doblanzki
• Inventors: Zeuner, Manfred, Doblanzki, Peter
• Primary Examiner(s): Chin, Peter
• Application Number:
  US08/013,131
• Time in Patent Office: 405 Days
• Field of Search: 162/145, 162/152, 162/156, 162/164.6, 162/168.2, 162/157.1, 162/181.1, 162/181.2, 162/181.3, 162/181.5, 162/181.6, 162/181.8, 162/175
• US Class Current: 162/145
• CPC Class Codes: D21H 13/36 Inorganic fibres or flakes
• CPC Class Codes: D21H 21/52 Additives of definite length or shape

Abstract

Paper, cardboard or paperboard-like material containing inorganic fibres, inorganic particle-like additives and organic binders and flocculating agents characterized in that

(1) the particle-like inorganic additives constitute 40-80% by weight of the dry matter of the material;

(2) the inorganic particle-like additives are composed of

(2.1) a base filler of which at least 20% by weight has a particle size of <2 μm and not more than 20% by weight has a particle size of >20 μm on the one hand and <0.5 μm on the other hand, and

(2.2) an anionic flocculating active pigment of which at least 50% by weight has a primary particle size of <2 μm,

(3.1) the organic flocculating agent is a cationic polymeric carbohydrate with an average molecular weight of 100,000 to 2,000,000 and a degree of substitution of 0.01 to 0.3 and is present in a quantity of 0.5 to 6% by weight, based on the dry matter of the material, and

(3.2) 1000 g of base filler is unable to bind more than 0.1 mMol and 1000 g of anionic flocculating active pigment is able to bind at least 0.1 mMol cationic carbohydrate under flocculation.

Claims

1. A paper, cardboard or paperboard material containing inorganic fibers, inorganic particulate additives and organic binder or flocculating agents, wherein

(A) the particulate inorganic additives constitute 40 to 80% by weight of the dry matter of the material, the inorganic particulate additives are composed of

(i) 35-75% by weight of the dry matter of the material of a base filler selected from the group consisting of SiO₂, kaolin, aluminum oxide, fuller'"'"'s earth, calcium carbonate and gypsum, of which 35 to 99% by weight have a particle size of <

2 μ

m and not more than 10% by weight have a particle size of >

20 μ

m, and

(ii) 1 to 15% by weight of the dry matter of the material of an anionic flocculating active pigment of which at least 50% by weight have a primary particle size of <

2 μ

m, selected from the group consisting of aluminum hydroxide, bentonite and colloidal amorphous SiO₂, and

(B) the organic flocculating agent is a cationic polymeric carbohydrate with an average molecular weight of 100,000 to 2,000,000 and a degree of substitution of 0.01 to 0.3 and is present in a quantity of 0.5 to 6% by weight, based on the dry matter of the material,

1000 g of base filler being unable to bind more than 0.1 mMol and 1000 g of anionic flocculating active pigment being able to bind at least 0.1 mMol cationic carbohydrate under flocculation prior to the attachment to the inorganic fiber.

2. A material according to claim 1, wherein the quantity of particulate inorganic additives (A) amounts to approximately 50 to 75% by weight, based on the dry matter of the material.

3. A material according to claim 2, wherein the quantity of particulate inorganic additives (A) amounts to approximately 60 to 70% by weight, based on the dry matter of the material.

4. A material according to claim 2, wherein the inorganic fibers are selected from the group consisting of glass fibers, mineral fibers, silicic acid fibers, basalt fibers and aluminum oxide fibers.

5. A material according to claim 2, wherein at least 80% of the inorganic fibers have a length in the range of 1 to 6 mm.

6. A material according to claim 1, wherein the content of inorganic base fillers (i) amounts to 55 to 70% by weight, based on the dry matter of the material.

7. A material according to claim 1, wherein the base filler aluminum hydroxide obtained in statu nascendi from an alkali aluminate and an acid.

8. A material according to claim 7, wherein the aluminum hydroxide has been obtained in statu nascendi from sodium aluminate and sulphuric acid.

9. A material according to claim 1, wherein the base filler aluminum hydroxide obtained from an base filler aluminum salt and alkali.

10. A material according to claim 9, wherein the aluminum hydroxide has been obtained in statu nascendi from aluminum sulphate and sodium hydroxide.

11. A material according to claim 1, wherein the ratio between the inorganic particulate additives (A) and the cationic polymeric carbohydrate (B) is such that there is no excess charge.

12. A material according to claim 1, wherein the cationic polymeric carbohydrate (B) is selected from the group consisting of cationic starch, cationic amylopectin, a cationic galactomannan and cationic carboxymethylcellulose.

13. A material according to claim 1, wherein the content of cationic polymeric carbohydrate (B) amounts to 1 to 5% by weight, based on the dry matter of the material.

14. A material according to claim 1, wherein the content of cationic polymeric carbohydrate (B) amounts to 1 to 3% by weight, based on the dry matter of the material.

15. A material according to claim 1, wherein the cationic polymeric carbohydrate (B) has been obtained by reacting the initial carbohydrate with a quaternary ammonium compound.

16. A material according to claim 1, wherein the cationic polymeric carbohydrate (B) has an average molecular weight of 200,000 to 1,000,000, and a degree of substitution of 0.15 to 0.02.

17. A material according to claim 16, whrein the cationic polymeric carbohydrate (B) has an average molecular weight of 300,000 to 800,000.

18. A material according to claim 1, containing in addition, a cationic, anionic or nonionic retention aid.

19. A material according to claim 18, wherein the retention aid is present in a quantity of approximately 0.02 to 0.2% by weight, based on the dry matter of the material.

20. A material according to claim 18, wherein the retention aid is a cationic polyacrylamide with a molecular weight of approximately 1 to 10 million or a cationic polyethylene imine with a molecular weight of approximately 80,000 to 300,000.

21. A material according to claim 1, containing, in addition, a wet strength agent.

22. A material according to claim 1, in the form of a three-dimensional moulded body.

28. A process according to claim 1, wherein said mixture is processed on a conventional paper, cardboard or paperboard machine.

29. A process according to claim 1, wherein said mixture is cast, bound and moulded to form a three-dimensional moulded body.

30. A process according to claim 1, wherien the mixture is cast to form a fibrous web, and said fibrous web is deformed while still damp.

23. A process for the manufacture of a paper, cardboard or paperboard material containing inorganic fibers, inorganic particulate additives and organic binder or flocculating agents, wherein

(A) the particulate inorganic additives constitute 40 to 80% by weight of the dry matter of the material, the inorganic particulate additives are composed of

(i) 35-75% by weight of the dry matter of the material of a base filler selected from the group consisting of SiO₂, kaolin, aluminum oxide, fuller'"'"'s earth, calcium carbonate and gypsum, of which 35 to 99% by weight have a particle size of <

2 μ

m and not more than 10% by weight have a particle size of >

20 μ

m, and

(ii) 1 to 15% by weight of the dry matter of the material of an anionic flocculating active pigment of which at least 50% by weight have a primary particle size of <

2 μ

m, selected from the group consisting of aluminum hydroxide, bentonite and colloidal amorphous SiO₂, and

(B) the organic flocculating agent is a cationic polymeric carbohydrate with an average molecular weight of 100,000 to 2,000,000 and a degree of substitution of 0.01 to 0.3 and is present in a quantity of 0.5 to 6% by weight, based on the dry matter of the material,

1000 g of base filler being unable to bind more than 0.1 mMol and 1000 g of anionic flocculating active pigment being able to bind at least 0.1 mMol cationic carbohydrate under flocculation prior to the attachment to the inorganic fiber, and

comprising mixing an aqueous dispersion of said inorganic fibers and said particulate inorganic base fillers (i) with an aqueous suspension of said active pigment (ii), thereafter adding said cationic polymeric carbohydrate (B) to said mixture shortly before shaping, and shaping said mixture.

24. A process according to claim 23, wherein said shaping is carried out after flocs have formed in the aqueous mixture following the addition of said cationic polymeric carbohydrate (B).

25. A process according to claim 23, wherein said shaping is carried out at the end of at least 10 seconds following the addition of said cationic polymeric carbohydrate (B).

26. A process according to claim 23, wherein a retention aid is added following the addition of said cationic polymeric carbohydrate (B).

27. A process according to claim 23, wherein said inorganic fibers, said inorganic base fillers (i) and said active pigments (ii) are subjected separately to wet dispersing prior to production of said dispersion.