Surface sizing of cellulose based products

• US 6,087,457 A
• Filed: 03/29/1996
• Issued: 07/11/2000
• Est. Priority Date: 03/29/1996
• Status: Expired due to Fees

• Current Assignee: EKA Chemicals AB (Nouryon BV)
• Original Assignee: EKA Chemicals AB (Nouryon BV)
• Inventors: Tsai, Yi-Guan
• Primary Examiner(s): Mullis, Jeffrey C.
• Application Number:
  US08/625,616
• Time in Patent Office: 1,565 Days
• Field of Search: 526/72, 526/78, 526/79, 526/80, 526/87, 162/135, 162/168.1, 162/168.7
• US Class Current: 526/72
• CPC Class Codes: D21H 17/34 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: D21H 21/16 Sizing or water-repelling agents

Abstract

The invention relates to a method of surface sizing cellulose based products such as paper, board and paper board. The method comprises applying to the surface of said products an aqueous dispersion of a copolymer obtainable by free-radical emulsion polymerization of a monomers mixture comprising at least one monomer selected from the group consisting of styrene and derivatives thereof; at least one monomer selected from the group consisting of esters of ethylenically unsaturated carboxylic acids and alkanols; and at least one monomer selected from the group consisting of ethylenically unsaturated carboxylic and sulfonic acids and salt thereof; optionally in combination with other ethylenically unsaturated copolymerizable monomers.

Claims

1. A method of surface sizing cellulose based products in order to increase resistance to penetration by aqueous liquids which comprises applying to the surface of said products a sizing composition which comprises an aqueous dispersion of a copolymer obtained by free-radical emulsion polymerization of a monomer mixture comprising

(a) from 70 to 99% by weight of

(a1) at least one monomer selected from the group consisting of styrene and derivatives thereof;

and

(a2) at least one monomer selected from the group consisting of esters of ethylenically unsaturated carboxylic acids and alkanols;

wherein the monomer of (a1) comprises at least 50% by weight of (a); and

(b) from 0.5 to 15% by weight of at least one monomer selected from the group consisting of ethylenically unsaturated carboxylic acids and salts thereof, and ethylenically unsaturated sulfonic acids and salts thereof; and

(c) from 0.5 to 15% by weight of other ethylenically unsaturated copolymerizable monomers comprising at least one monomer containing a hydroxyl group, wherein the sum of the percentages of (a)+(b)+(c) is 100, wherein said polymerization is conducted in the absence of a protective colloid effective amount of starch.

2. The method according to claim 1, wherein the polymerization of said monomer mixture is carried out by the steps of

(i) initial polymerization of at least one monomer of group (a);

and

(ii) subsequent polymerization of monomers of groups (a), (b) and (c).

3. The method according to claim 1, wherein the monomer of group (a1) is styrene.

4. The method according to claim 1, wherein the monomer of group (a2) is selected from C₁ -C₄ alkyl acrylates, C₁ -C₄ alkyl methacrylates, and mixtures thereof.

5. The method according to claim 4, wherein the monomer of group (a2) is butyl acrylate.

6. The method according to claim 1, wherein the monomers of group (a) are used in a weight ratio (a1) to (a2) of from 5:

1 to 1;

1.

7. The method according to claim 1, wherein the monomer of group (b) is a monoethylenically unsaturated mono- or dicarboxylic acid.

8. The method according to claim 7, wherein the mono- or dicarboxylic acid is selected from the group consisting of acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, aconitic acid and mixtures thereof.

9. The method according to claim 1, wherein the monomer mixture comprises from about 90 to about 99% by weight of monomers of group (a), from about 1 to about 5% by weight of monomer of group (b) and from about 1 to about 5% by weight of monomer of group (c).

10. The method of claim 1, wherein the cellulose based products are selected from the group consisting of paper and paper board.

11. A method of surface sizing cellulose-based products which comprises applying to the surface of said products by means of a size press a sizing composition comprising an aqueous dispersion of a copolymer obtained by free-radical emulsion polymerization of a monomer mixture containing

(a) from 80 to 99% by weight of

(a1) at least one monomer selected from the group consisting of styrene and derivatives thereof, and

(a2) at least one monomer selected from the group consisting of esters of ethylenically unsaturated carboxylic acids and alkanols, where the monomer of group (a1) constitutes at least 50% by weight of the monomers of group (a);

the weight ratio of (a1) to (a2) being from about 4;

1 to 2;

1;

(b) from 0.5 to 10% by weight of at least one monomer selected from the group consisting of ethylenically unsaturated carboxylic acids and salts thereof, and ethenically unsaturated sulfonic acids and salts thereof; and

(c) from 0.5 to 10% by weight of other ethylenically unsaturated copolymerizable monomers comprising at least one monomer containing a hydroxyl group;

the sum of percentages of (a)+(b)+(c) being 100.

12. The method of claim 11, wherein the monomer mixture contains from about 90 to 99% by weight of monomers of group (a) comprising (a1) styrene and (a2) a C₁ -C₄ alkyl acrylate, C₁ -C₄ alkyl methacrylate or mixtures thereof;

from about 1 to about 5% by weight of a monomer of group (b) comprising acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, aconitic acid or mixtures thereof; and

from 0.5 to about 5% by weight a of monomer of group (c).

13. The method of claim 12, wherein the monomer mixture contains from about 0.5 to 5% by weight of a monomer of group (c) comprising at least one monomer containing a hydroxyl group.

14. The method of claim 11, wherein polymerization of said monomer mixture is carried out by steps of

(i) initial polymerization of at least one monomer of group (a);

and

(ii) subsequent polymerization of monomers of groups (a), (b) and (c).

15. A method of surface sizing cellulose-based products which comprises applying to the surface of said products a sizing composition comprising an aqueous dispersion of a copolymer obtained by free-radical emulsion polymerization of a monomer mixture containing

(a) from 80 to 99% by weight of

(a1) at least one monomer selected from the group consisting of styrene and derivatives thereof, and

(a2) at least one monomer selected from the group consisting of esters of ethylenically unsaturated carboxylic acids and alkanols;

(b) from 0.5 to 10% by weight of at least one monomer selected from the group consisting of ethylenically unsaturated carboxylic acids and salts thereof; and

ethylenically unsaturated sulfonic acids and salts thereof, and

(c) from 0.5 to 10% by weight of other ethylenically unsaturated copolymerizable monomers comprising at least one monomer selected from the group consisting of hydroxyalkyl acrylates and hydroxalkyl methacrylates;

the sum of percentages of (a)+(b)+(c) being 100.

16. The method of claim 15, wherein polymerization of said monomer mixture is carried out by the steps of

(i) initial polymerization of at least one monomer of group (a);

and

(ii) subsequent polymerization of monomers of groups (a), (b) and (c).

17. The method of claim 15, wherein the monomer mixture contains (a1) styrene;

(a2) butyl acrylate; and

(b) a monomer selected from the group consisting of acrylic acid and methacrylic acid.

18. The method of claim 15, wherein the monomer mixture contains from about 1 to 5% by weight of a monomer of group (b).

19. The method of claim 15, wherein the monomer mixture contains from about 0.5 to 5% by weight of a monomer of group (c) compsiring at least one monomer containing a hydroxyl group.

20. The method of claim 18, wherein the monomer mixture contains from about 0.5 to 5% by weight of a monomer of group (c) comprising at least one monomer containing a hydroxyl group.