Reinforced porous fibre product

• US 8,354,003 B2
• Filed: 02/20/2009
• Issued: 01/15/2013
• Est. Priority Date: 03/14/2008
• Status: Expired due to Fees

• Current Assignee: Nordkalk OY AB (Sigmaroc Plc)
• Original Assignee: Nordkalk OY AB (Sigmaroc Plc)
• Inventors: Virtanen, Pentti
• Primary Examiner(s): Halpern, Mark
• Application Number:
  US12/922,466
• Publication Number:
  US 20110061827A1
• Time in Patent Office: 1,425 Days
• Field of Search: 162/158, 162/181.1, 162/181.6, 106/286.5, 106/287.34, 106/287.17, 106/287.24, 106/287.23, 428/402, 428/402.21, 428/402.22, 428/24, 428/332, 428/338
• US Class Current: 162/158
• CPC Class Codes: D21H 17/66 Salts, e.g. alums
• CPC Class Codes: D21H 17/68 siliceous, e.g. clays
• CPC Class Codes: D21H 21/52 Additives of definite length or shape
• CPC Class Codes: D21H 27/10 Packing paper packaging materials of special type or form B65D65/38

Abstract

The present invention relates to a porous fiber product, which contains chemical pulp or wood fibers, between which structural filler particles are attached, as well as to a method of manufacturing this product, wherein filler drops are produced in a spray dryer from the aqueous solution of the filler, the drops forming filler particles when the water evaporates, the particles being attached to the chemical pulp or wood fibers.

Claims

1. A kraft paper product formed into sack paper comprising:

a plurality of fibres, the fibres comprising at least one of chemical pulp or wood;

a plurality of agglomerated filler particles attached between the fibres as structural filler particles in the form of at least partially calcined kaolin agglomerates, the structural filler particles having an essentially spherical shape and a size of 10-40 microns, and

a binder both between the fibres and between the fibres and the particles, the binder comprising silicon dioxide, alum, aldehyde or a mixture thereof.

2. The product according to claim 1, wherein the filler particles consist of the agglomerates, granules or sinters of metakaolin.

3. The product according to claim 1, wherein the amount of silicon dioxide in the binder is 0.5-50% by weight.

4. The product according to claim 3, wherein the amount of silicon dioxide in the binder is 0.5-3% by weight.

5. The product according to claim 1, wherein the amount of alum in the binder is 0.5-50% by weight.

6. The product according to claim 5, wherein the amount of alum in the binder is 0.5-3% by weight.

7. The product according to claim 1, wherein the amount of aldehyde in the binder is 0.5-50% by weight.

8. The product according to claim 7, wherein the amount of aldehyde in the binder is 0.5-5% by weight.

9. The product according to claim 1, wherein the silicon dioxide is silicon dioxide micro gel or silicon dioxide sol.

10. The product according to claim 1, wherein the aldehyde is glyoxal.

11. The product according to claim 1, wherein the product contains not more than 25% by weight of filler particles.

12. The product according to claim 1, wherein the filler particles have a size of −

20-40 microns.

13. The product according to claim 1, wherein the product is a sack paper product.

14. The product according to claim 1, wherein the product is a paper bag.

15. A method for manufacturing a kraft paper product comprising:

forming an aqueous dispersion comprising a filler in the form of at least partially calcined kaolin agglomerates;

mixing the aqueous dispersion with a binder comprising at least one of silicon dioxide, alum or aldehyde;

producing filler drops from the aqueous dispersion in a spray dryer;

forming filler particles having a size of 10-40 microns are formed by evaporation of excess water from the filler drops;

attaching the formed filler particles to a plurality of fibres dispersed in water, the fibres comprising at least one of chemical pulp or wood; and

forming sack paper from the dispersion.

16. The method according to claim 15, further comprising the step of adding an acidic chemical to the aqueous dispersion after adding the binder.

17. The method according to claim 16, wherein the acidic chemical is one of an acid, an aluminium sulphate and a chemical having a sulphate group.