U.S. patent application number 13/020158 was filed with the patent office on 2012-08-09 for wet strength resins derived from renewable resources.
Invention is credited to John Collins Dyer.
Application Number | 20120199298 13/020158 |
Document ID | / |
Family ID | 46599861 |
Filed Date | 2012-08-09 |
United States Patent
Application |
20120199298 |
Kind Code |
A1 |
Dyer; John Collins |
August 9, 2012 |
WET STRENGTH RESINS DERIVED FROM RENEWABLE RESOURCES
Abstract
The present invention relates to cationic polymers, such as
polyaminoamide epichlorohydrin (PAE), that are derived from
renewable resources and can be used to produce wet strength resins
suitable for a variety of applications, such as in absorbent paper
articles.
Inventors: |
Dyer; John Collins;
(Evendale, OH) |
Family ID: |
46599861 |
Appl. No.: |
13/020158 |
Filed: |
February 3, 2011 |
Current U.S.
Class: |
162/123 ;
162/157.1; 162/157.3; 162/157.5; 162/157.6; 162/164.3; 525/430 |
Current CPC
Class: |
D21H 13/00 20130101;
D21H 13/02 20130101; D21H 17/55 20130101; D21H 21/20 20130101; C08G
73/0286 20130101; D21H 17/45 20130101; D21H 13/14 20130101; D21H
13/24 20130101 |
Class at
Publication: |
162/123 ;
525/430; 162/164.3; 162/157.1; 162/157.5; 162/157.3; 162/157.6 |
International
Class: |
D21H 17/45 20060101
D21H017/45; D21H 13/00 20060101 D21H013/00; D21H 27/30 20060101
D21H027/30; D21H 13/24 20060101 D21H013/24; D21H 13/02 20060101
D21H013/02; C08G 69/26 20060101 C08G069/26; D21H 13/14 20060101
D21H013/14 |
Claims
1. A polymer of Formula I: ##STR00034## wherein A is Cl, Br, OH,
NO.sub.3, or BF.sub.4; each W independently is (CH.sub.2).sub.1-8
or ##STR00035## each Y independently is (CH.sub.2).sub.1-8 or
##STR00036## each R.sup.1 independently is H, ##STR00037## and each
R.sup.2 is H; or R.sup.1 and R.sup.2 together with the nitrogen to
which they are attached form with ##STR00038## the proviso that
about 20 mole percent to about 40 mole percent of R.sup.1 are H;
each R.sup.3 independently is H or OH; p is 1-8; each q
independently is 0-8; wherein the molar ratio of W to Y is about
0.8:1 to about 1.4:1; and, wherein Formula I has a biobased content
of at least about 95%.
2. The polymer of claim 1, wherein the biobased content is at least
about 97%.
3. The polymer of claim 2, wherein the biobased content is at least
about 99%.
4. The polymer of claim 1, wherein each W independently is
(CH.sub.2).sub.1-8, each Y independently is (CH.sub.2).sub.1-8, and
p is 1-3.
5. The polymer of claim 4, wherein each W independently is
(CH.sub.2).sub.2-4, and each Y independently is
(CH.sub.2).sub.2-4.
6. The polymer of claim 5, wherein A is Cl, each W independently is
(CH.sub.2).sub.4, each Y independently is (CH.sub.2).sub.2, and p
is 1.
7. A method for synthesizing the polymer of claim 1, the method
comprising: (a) reacting: (i) ##STR00039## having a biobased
content of at least about 95%; and, (ii) ##STR00040## having a
biobased content of at least about 95%; to form ##STR00041## having
a biobased content of at least about 95%; and, (b) functionalizing
the product from step (a) with ##STR00042## having a biobased
content of at least about 95%, to form the polymer of claim 1;
wherein each W independently is (CH.sub.2).sub.1-8 or ##STR00043##
each Y independently is (CH.sub.2).sub.1-8 or ##STR00044## each Z
independently is H or ##STR00045## each R.sup.3 independently is H
or OH; p is 1-8; each q independently is 0-8; and, the molar ratio
of W to Y is about 0.8:1 to about 1.4:1.
8. The method of claim 7, wherein the biobased content of the
polymer of Formula I is at least about 97%.
9. The method of claim 8, wherein the biobased content of the
polymer of Formula I is at least about 99%.
10. A paper article comprising a polymer of Formula I: ##STR00046##
wherein A is Cl, Br, OH, NO.sub.3, or BE.sub.1; each W
independently is (CH.sub.2).sub.1-8 or ##STR00047## each Y
independently is (CH1).sub.1-8 or ##STR00048## each R.sup.1
independently is H, ##STR00049## and each R.sup.2 is H; or R.sup.1
and R.sup.2 together with the nitrogen to which they are attached
form ##STR00050## with the proviso that about 20 mole percent to
about 40 mole percent of R.sup.1 are H. each R.sup.3 independently
is H or OH; p is 1-8; each q independently is 0-8; wherein the
molar ratio of W to Y is about 0.8:1 to about 1.4:1; and, Formula I
has a bio-based content of at least about 95%; and, wherein the
paper has a dry strength of about 300 g/in per ply to about 2000
g/in per ply, and a wet strength of about 60 g/in per ply to about
400 g/in per ply.
11. The article of claim 10, wherein the biobased content of the
polymer of Formula I is at least about 97%.
12. The article of claim 11, wherein the biobased content of the
polymer of Formula I is at least about 99%.
13. The article of claim 10, wherein each W independently is
(CH.sub.2).sub.1-8, each Y independently is (CH.sub.2).sub.1-8, and
p is 1-3.
14. The article of claim 13, wherein each W independently is
(CH.sub.2).sub.2-4, and each Y independently is
(CH.sub.2).sub.2-4.
15. The article of claim 14, wherein A is Cl, each W independently
is (CH.sub.2).sub.4, each Y independently is (CH.sub.2).sub.2, and
p is 1.
16. The article of claim 10, wherein the article comprises a
natural fiber, a synthetic fiber, or a mixture thereof.
17. The article of claim 16, wherein the natural fiber is derived
from a source selected from the group consisting of oak, maple,
eucalyptus, pine, aspen, birch, and mixtures thereof.
18. The article of claim 16, wherein the synthetic fiber is
selected from the group consisting of a polyolefin, a polyester, a
cellulosic fiber, and mixtures thereof.
19. The article of claim 10 further comprising an additive selected
from the group consisting of an additional wet strength resin, a
dry strength resin, a debonder, a pigment, a dye, a fluorescer, and
mixtures thereof.
20. The article of claim 10, wherein the article has a dry strength
of about 500 g/in per ply to about 1500 g/in per ply, and a wet
strength of about 100 g/in per ply to about 300 g/in per ply.
21. The article of claim 10, wherein the article comprises a basis
weight of about 10 pounds per 30,000 square feet (lbs/ 30,000
ft.sup.2) to about 30 lbs/30,000 ft.sup.2.
22. The article of claim 21, wherein the basis weight is about 15
lbs/30,000 ft.sup.2 to about 28 lbs/30,000 ft.sup.2.
23. The article of claim 10, wherein the article is single ply or
multiple-ply.
24. The article of claim 10, wherein the article is selected from
the group consisting of a towel, a tissue, and a paperboard.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to cationic polymers (e.g.,
polyaminoamide epichlorohydrin resins) that are derived from
renewable resources and can be used to produce resins suitable for
a variety of applications, such as wet strength additives in
absorbent paper articles.
BACKGROUND OF THE INVENTION
[0002] The use of disposable products made from webs of paper, such
as paper towels, facial tissues, and sanitary tissues, is pervasive
in modern industrialized societies. These products must exhibit
certain physical characteristics, such as strength, softness, and
absorbency. Strength is the ability of a paper to retain its
physical integrity during use. Softness is the pleasing tactile
sensation the user perceives when contacting or crumpling the
paper. Absorbency is the characteristic of the paper that allows it
to take up and retain certain fluids, particularly water, aqueous
solutions, and aqueous suspensions. Absorbency encompasses the
absolute quantity of fluid a given amount of paper will hold, the
rate at which the paper will absorb the fluid and, when the paper
is formed into an article (e.g., towel, wipe), the ability of the
paper to cause a fluid to preferentially be taken up into the paper
and leave a wiped surface dry.
[0003] The wet strength of paper can be increased through the
incorporation of an additive that both adheres to the pulp, and
forms a network that represses swelling of cellulose fibers,
inhibiting the separation of fiber-fiber contacts when paper is
rewetted. These wet strength additives are typically water soluble,
cationic polymers that can form crosslinked networks with
themselves or with cellulose. The earliest cationic wet strength
resins were condensation products of urea and formaldehyde with
small amounts of polyamines
[0004] Polyaminoamide epichlorohydrin (PAE) resins were developed
as wet strength resins in the 1950s and 1960s, as described in U.S.
Pat. No. 2,926,154, incorporated herein by reference. PAE resins
are produced by condensing a polyamine (e.g., diethylenetriamine)
with a dibasic acid (e.g., adipic acid) or its ester to form a
polyaminoamide. Epichlorohydrin is reacted with the primary and
secondary amino groups of the polyaminoamide to form epoxides and
chlorohydrins. At neutral pH and above ambient temperatures, the
chlorohydrin groups cyclize spontaneously to form
3-hydroxyazetidinium groups. These strained rings confer both
reactivity and pH independent cationic charge to the resin
macromolecule. Some of the azetidinium groups crosslink the
macromolecules concurrently with the alkylation and cyclization
reactions during resin manufacture, as described in Espy, Tappi J.
78(4):90-99. Examples of PAE resins are shown below.
##STR00001##
[0005] An example of the crosslinking mechanism of a PAE resin is
shown below.
##STR00002##
[0006] The materials used to produce PAE resins (e.g.,
diethylenetriamine, adipic acid, epichlorohydrin) are derived from
non-renewable resources, such as petroleum, natural gas, and coal.
As used herein, "renewable resource" refers to one that is produced
by a natural process at a rate comparable to its rate of
consumption (e.g., within a 100 year time frame). The resource can
be replenished naturally, or via agricultural techniques.
Nonlimiting examples of renewable resources include plants (e.g.,
sugar cane, beets, corn, potatoes, citrus fruit, woody plants,
lignocellulosics, hemicellulosics, cellulosic waste), animals,
fish, bacteria, fungi, and forestry products. These resources can
be naturally occurring, hybrids, or genetically engineered
organisms. Natural resources such as crude oil, natural gas, coal,
and peat, which take longer than 100 years to form, are examples of
non-renewable resources. As used herein, "petroleum" refers to
crude oil and its components of paraffinic, cycloparaffinic, and
aromatic hydrocarbons. Crude oil may be obtained from tar sands,
bitumen fields, and oil shale.
[0007] Thus, the price and availability of the petroleum, natural
gas, and coal feedstock ultimately have a significant impact on the
price of PAE resins. As the worldwide price of petroleum, natural
gas, and/or coal escalates, so does the price of PAE resins and
articles made using PAE resins, such as paper towels. Furthermore,
many consumers display an aversion to purchasing products that are
derived from petrochemicals. In some instances, consumers are
hesitant to purchase products made from limited non-renewable
resources (e.g., petroleum, natural gas, and coal). Other consumers
may have adverse perceptions about products derived from
petrochemicals as being "unnatural" or not environmentally
friendly.
[0008] Accordingly, it would be desirable to provide cationic
polymers suitable for use as wet strength resins using monomers
derived from renewable resources, where the resulting polymer has
desired performance characteristics, such as appropriate wet
strength, dry strength, and wet strength to dry strength ratio with
no negative impact on properties, such as paper softness.
SUMMARY OF THE INVENTION
[0009] In one aspect, the invention relates to a polymer of Formula
I:
##STR00003## [0010] wherein A is Cl, Br, OH, NO.sub.3, or BF.sub.4;
[0011] each W independently is (CH.sub.2).sub.1-8 or
[0011] ##STR00004## [0012] each Y independently is
(CH.sub.2).sub.1-8 or
[0012] ##STR00005## [0013] each R.sup.1 independently is H,
##STR00006##
[0013] and each R.sup.2 is H; or R.sup.1 and R.sup.2 together with
the nitrogen to which they are attached form
##STR00007##
with the proviso that about 20 mole percent to about 40 mole
percent of R.sup.1 are H; [0014] each R.sup.3 independently is H or
OH; [0015] p is 1-8; [0016] each q independently is 0-8; [0017]
wherein the molar ratio of W to Y is about 0.8:1 to about 1.4:1;
and, [0018] wherein Formula I has a biobased content of at least
about 95%, preferably at least about 97%, more preferably at least
about 99%.
[0019] In another aspect, the invention relates to a method of
synthesizing the polymer of Formula I, wherein the method
comprises:
[0020] (a) reacting: [0021] (i)
##STR00008##
[0021] having a biobased content of at least about 95%; and, [0022]
(ii)
##STR00009##
[0022] having a biobased content of at least about 95%; [0023] to
form
##STR00010##
[0023] having a biobased content of at least about 95%; and,
[0024] (b) functionalizing the product from step (a)
##STR00011##
with having a biobased content of at least about 95%; [0025]
wherein each W independently is (CH.sub.2).sub.1-8 or
[0025] ##STR00012## [0026] each Y independently is
(CH.sub.2).sub.1-8 or
[0026] ##STR00013## [0027] each Z independently is H or
[0027] ##STR00014## [0028] each R.sup.3 independently is H or OH;
[0029] p is 1-8; [0030] each q independently is 0-8; and, [0031]
the molar ratio of W to Y is about 0.8:1 to about 1.4:1.
[0032] In yet another aspect, the invention relates to a paper
article comprising a polymer of Formula I, wherein the paper
article has a dry strength of about 300 g/in per ply to about 2000
g/in per ply, and a wet strength of about 60 g/in per ply to about
400 g/in per ply. In some embodiments, the paper article is
selected from the group consisting of a towel, a tissue (e.g., a
facial tissue), and paperboard having single or multiple ply
characteristics.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] A sustainable, wet strength resin has now been found that is
entirely derived from renewable resources. As used herein,
"sustainable" refers to a material having an improvement of greater
than 10% in some aspect of its Life Cycle Assessment, when compared
to similar virgin, petroleum-based material. As used herein, "Life
Cycle Assessment" (LCA) or "Life Cycle Inventory" (LCI) refers to
the investigation and evaluation of the environmental impacts of a
given product or service caused or necessitated by its existence.
The LCA or LCI can involve a "cradle-to-grave" analysis, which
refers to the full Life Cycle Assessment or Life Cycle Inventory
from manufacture ("cradle") to use phase and disposal phase
("grave"). All inputs and outputs are considered for all the phases
of the life cycle. As used herein, "End of Life" (EoL) scenario
refers to the disposal phase of the LCA. Alternatively, LCA can
involve a "cradle-to-gate" analysis, which refers to an assessment
of a partial product life cycle from manufacture ("cradle") to the
factory gate (i.e., before it is transported to the consumer) as a
pellet.
[0034] The renewable wet strength resins of the invention are
advantageous because they have the same performance characteristics
as wet strength resins made from petroleum-based resources, yet
improved sustainability, which reduces dependence on petroleum
supplies.
[0035] All percentages herein are by weight unless specified
otherwise.
Cationic Polymers Comprising Monomers Derived from Renewable
Resources
[0036] In one aspect, the invention relates to a sustainable,
cationic polymer of Formula I:
##STR00015## [0037] wherein A is Cl, Br, OH, NO.sub.3, or BF.sub.4;
[0038] each W independently is (CH.sub.2).sub.1-8 or
[0038] ##STR00016## [0039] each Y independently is
(CH.sub.2).sub.1-8 or
[0039] ##STR00017## [0040] each R.sup.1 independently is H,
##STR00018##
[0040] and each R.sup.2 is H; or R.sup.1 and R.sup.2 together with
the nitrogen to which they are attached form
##STR00019##
with the proviso that about 20 mole percent to about 40 mole
percent, preferably about 25 mole percent to about 35 mole percent,
for example, about 30 mole percent, of R.sup.1 are H; [0041] each
R.sup.3 independently is H or OH; [0042] p is 1-8; and, [0043] each
q independently is 0-8.
[0044] In some embodiments, the molar ratio of W to Y is about
0.8:1 to about 1.4:1, preferably about 0.9:1 to about 1.2:1, for
example, about 0.92:1 to about 1.14:1
[0045] The polymer of Formula I has a biobased content of at least
about 95%, preferably at least about 97%, more preferably at least
about 99%, for example, 100%. As used herein, "biobased content"
refers to the amount of biobased carbon in a material as a percent
of the weight (mass) of the total organic carbon in the product.
For example, polyethylene contains two carbon atoms in its
structural unit. If ethylene is derived from a renewable resource,
then a homopolymer of polyethylene theoretically has a biobased
content of 100% because all of the carbon atoms are derived from a
renewable resource. A copolymer of polyethylene could also
theoretically have a biobased content of 100% if both the ethylene
and the co-monomer are each derived from a renewable resource. As
another example, polyethylene terephthalate contains ten carbon
atoms in its structural unit (i.e., two carbon atoms from the
ethylene glycol monomer and eight carbon atoms from the
terephthalic acid monomer). If the ethylene glycol portion is
derived from a renewable resource, but the terephthalic acid is
derived from a petroleum-based resource, the theoretical biobased
content of the polyethylene terephthalate is 20%.
[0046] In some embodiments, each W independently is
(CH.sub.2).sub.1-8, preferably (CH.sub.2).sub.2-4, for example,
(CH.sub.2).sub.4.
[0047] In some embodiments, each Y independently is
(CH.sub.2).sub.1-8, preferably (CH.sub.2).sub.2-4, for example,
(CH.sub.2).sub.2.
[0048] In some embodiments, p is 1-4, preferably 1-3, for example,
1.
[0049] In some preferred embodiments, each A is Cl, each W
independently is (CH.sub.2).sub.4, each Y independently is
(CH.sub.2).sub.2, each R.sup.1 and R.sup.2 are as described above,
and p is 1. In some embodiments, the wet strength polymer is
polyetherimide that has been functionalized with
epichlorohydrin.
[0050] Nonlimiting examples of the wet strength polymer are shown
in the below Table 1, wherein each R.sup.1 and R.sup.2 are as
previously described.
TABLE-US-00001 TABLE 1 ##STR00020## a b p a b p a b p a b p a b p 1
1 1 1 6 2 1 3 4 1 8 5 1 5 7 2 1 1 2 6 2 2 3 4 2 8 5 2 5 7 3 1 1 3 6
2 3 3 4 3 8 5 3 5 7 4 1 1 4 6 2 4 3 4 4 8 5 4 5 7 5 1 1 5 6 2 5 3 4
5 8 5 5 5 7 6 1 1 6 6 2 6 3 4 6 8 5 6 5 7 7 1 1 7 6 2 7 3 4 7 8 5 7
5 7 8 1 1 8 6 2 8 3 4 8 8 5 8 5 7 1 2 1 1 7 2 1 4 4 1 1 6 1 6 7 2 2
1 2 7 2 2 4 4 2 1 6 2 6 7 3 2 1 3 7 2 3 4 4 3 1 6 3 6 7 4 2 1 4 7 2
4 4 4 4 1 6 4 6 7 5 2 1 5 7 2 5 4 4 5 1 6 5 6 7 6 2 1 6 7 2 6 4 4 6
1 6 6 6 7 7 2 1 7 7 2 7 4 4 7 1 6 7 6 7 8 2 1 8 7 2 8 4 4 8 1 6 8 6
7 1 3 1 1 8 2 1 5 4 1 2 6 1 7 7 2 3 1 2 8 2 2 5 4 2 2 6 2 7 7 3 3 1
3 8 2 3 5 4 3 2 6 3 7 7 4 3 1 4 8 2 4 5 4 4 2 6 4 7 7 5 3 1 5 8 2 5
5 4 5 2 6 5 7 7 6 3 1 6 8 2 6 5 4 6 2 6 6 7 7 7 3 1 7 8 2 7 5 4 7 2
6 7 7 7 8 3 1 8 8 2 8 5 4 8 2 6 8 7 7 1 4 1 1 1 3 1 6 4 1 3 6 1 8 7
2 4 1 2 1 3 2 6 4 2 3 6 2 8 7 3 4 1 3 1 3 3 6 4 3 3 6 3 8 7 4 4 1 4
1 3 4 6 4 4 3 6 4 8 7 5 4 1 5 1 3 5 6 4 5 3 6 5 8 7 6 4 1 6 1 3 6 6
4 6 3 6 6 8 7 7 4 1 7 1 3 7 6 4 7 3 6 7 8 7 8 4 1 8 1 3 8 6 4 8 3 6
8 8 7 1 5 1 1 2 3 1 7 4 1 4 6 1 1 8 2 5 1 2 2 3 2 7 4 2 4 6 2 1 8 3
5 1 3 2 3 3 7 4 3 4 6 3 1 8 4 5 1 4 2 3 4 7 4 4 4 6 4 1 8 5 5 1 5 2
3 5 7 4 5 4 6 5 1 8 6 5 1 6 2 3 6 7 4 6 4 6 6 1 8 7 5 1 7 2 3 7 7 4
7 4 6 7 1 8 8 5 1 8 2 3 8 7 4 8 4 6 8 1 8 1 6 1 1 3 3 1 8 4 1 5 6 1
2 8 2 6 1 2 3 3 2 8 4 2 5 6 2 2 8 3 6 1 3 3 3 3 8 4 3 5 6 3 2 8 4 6
1 4 3 3 4 8 4 4 5 6 4 2 8 5 6 1 5 3 3 5 8 4 5 5 6 5 2 8 6 6 1 6 3 3
6 8 4 6 5 6 6 2 8 7 6 1 7 3 3 7 8 4 7 5 6 7 2 8 8 6 1 8 3 3 7 8 4 7
5 6 8 2 8 1 7 1 1 4 3 1 1 5 1 6 6 1 3 8 2 7 1 2 4 3 2 1 5 2 6 6 2 3
8 3 7 1 3 4 3 3 1 5 3 6 6 3 3 8 4 7 1 4 4 3 4 1 5 4 6 6 4 3 8 5 7 1
5 4 3 5 1 5 5 6 6 5 3 8 6 7 1 6 4 3 6 1 5 6 6 6 6 3 8 7 7 1 7 4 3 7
1 5 7 6 6 7 3 8 8 7 1 8 4 3 8 1 5 8 6 6 8 3 8 1 8 1 1 5 3 1 2 5 1 7
6 1 4 8 2 8 1 2 5 3 2 2 5 2 7 6 2 4 8 3 8 1 3 5 3 3 2 5 3 7 6 3 4 8
4 8 1 4 5 3 4 2 5 4 7 6 4 4 8 5 8 1 5 5 3 5 2 5 5 7 6 5 4 8 6 8 1 6
5 3 6 2 5 6 7 6 6 4 8 7 8 1 7 5 3 7 2 5 7 7 6 7 4 8 8 8 1 8 5 3 8 2
5 8 7 6 8 4 8 1 1 2 1 6 3 1 3 5 1 8 6 1 5 8 2 1 2 2 6 3 2 3 5 2 8 6
2 5 8 3 1 2 3 6 3 3 3 5 3 8 6 3 5 8 4 1 2 4 6 3 4 3 5 4 8 6 4 5 8 5
1 2 5 6 3 5 3 5 5 8 6 5 5 8 6 1 2 6 6 3 6 3 5 6 8 6 6 5 8 7 1 2 7 6
3 7 3 5 7 8 6 7 5 8 8 1 2 8 6 3 8 3 5 8 8 6 8 5 8 1 2 2 1 7 3 1 4 5
1 1 7 1 6 8 2 2 2 2 7 3 2 4 5 2 1 7 2 6 8 3 2 2 3 7 3 3 4 5 3 1 7 3
6 8 4 2 2 4 7 3 4 4 5 4 1 7 4 6 8 5 2 2 5 7 3 5 4 5 5 1 7 5 6 8 6 2
2 6 7 3 6 4 5 6 1 7 6 6 8 7 2 2 7 7 3 7 4 5 7 1 7 7 6 8 8 2 2 8 7 3
8 4 5 8 1 7 8 6 8 1 3 2 1 8 3 1 5 5 1 2 7 1 7 8 2 3 2 2 8 3 2 5 5 2
2 7 2 7 8 3 3 2 3 8 3 3 5 5 3 2 7 3 7 8 4 3 2 4 8 3 4 5 5 4 2 7 4 7
8 5 3 2 5 8 3 5 5 5 5 2 7 5 7 8 6 3 2 6 8 3 6 5 5 6 2 7 6 7 8 7 3 2
7 8 3 7 5 5 7 2 7 7 7 8 8 3 2 8 8 3 8 5 5 8 2 7 8 7 8 1 4 2 1 1 4 1
6 5 1 3 7 1 8 8 2 4 2 2 1 4 2 6 5 2 3 7 2 8 8 3 4 2 3 1 4 3 6 5 3 3
7 3 8 8 4 4 2 4 1 4 4 6 5 4 3 7 4 8 8 5 4 2 5 1 4 5 6 5 5 3 7 5 8 8
6 4 2 6 1 4 6 6 5 6 3 7 6 8 8 7 4 2 7 1 4 7 6 5 7 3 7 7 8 8 8 4 2 8
1 4 8 6 5 8 3 7 8 8 8 1 5 2 1 2 4 1 7 5 1 4 7 2 5 2 2 2 4 2 7 5 2 4
7 3 5 2 3 2 4 3 7 5 3 4 7 4 5 2 4 2 4 4 7 5 4 4 7 5 5 2 5 2 4 5 7 5
5 4 7 6 5 2 6 2 4 6 7 5 6 4 7 7 5 2 7 2 4 7 7 5 7 4 7 8 5 2 8 2 4 8
7 5 8 4 7
[0051] Additional nonlimiting examples of the wet strength polymer
are shown in the below Table 2, wherein each R.sup.1 and R.sup.2
are as previously described.
TABLE-US-00002 TABLE 2 ##STR00021## b p q q' q'' R.sup.3 R.sup.3'
R.sup.3'' b p q q' q'' R.sup.3 R.sup.3' R.sup.3'' 1 1 1 1 0 H H H 1
5 1 1 0 H H H 2 1 1 1 0 H H H 2 5 1 1 0 H H H 3 1 1 1 0 H H H 3 5 1
1 0 H H H 4 1 1 1 0 H H H 4 5 1 1 0 H H H 5 1 1 1 0 H H H 5 5 1 1 0
H H H 6 1 1 1 0 H H H 6 5 1 1 0 H H H 7 1 1 1 0 H H H 7 5 1 1 0 H H
H 8 1 1 1 0 H H H 8 5 1 1 0 H H H 1 1 1 1 0 H H OH 1 5 1 1 0 H H OH
2 1 1 1 0 H H OH 2 5 1 1 0 H H OH 3 1 1 1 0 H H OH 3 5 1 1 0 H H OH
4 1 1 1 0 H H OH 4 5 1 1 0 H H OH 5 1 1 1 0 H H OH 5 5 1 1 0 H H OH
6 1 1 1 0 H H OH 6 5 1 1 0 H H OH 7 1 1 1 0 H H OH 7 5 1 1 0 H H OH
8 1 1 1 0 H H OH 8 5 1 1 0 H H OH 1 1 1 1 0 OH H H 1 5 1 1 0 OH H H
2 1 1 1 0 OH H H 2 5 1 1 0 OH H H 3 1 1 1 0 OH H H 3 5 1 1 0 OH H H
4 1 1 1 0 OH H H 4 5 1 1 0 OH H H 5 1 1 1 0 OH H H 5 5 1 1 0 OH H H
6 1 1 1 0 OH H H 6 5 1 1 0 OH H H 7 1 1 1 0 OH H H 7 5 1 1 0 OH H H
8 1 1 1 0 OH H H 8 5 1 1 0 OH H H 1 2 1 1 0 H H H 1 6 1 1 0 H H H 2
2 1 1 0 H H H 2 6 1 1 0 H H H 3 2 1 1 0 H H H 3 6 1 1 0 H H H 4 2 1
1 0 H H H 4 6 1 1 0 H H H 5 2 1 1 0 H H H 5 6 1 1 0 H H H 6 2 1 1 0
H H H 6 6 1 1 0 H H H 7 2 1 1 0 H H H 7 6 1 1 0 H H H 8 2 1 1 0 H H
H 8 6 1 1 0 H H H 1 2 1 1 0 H H OH 1 6 1 1 0 H H OH 2 2 1 1 0 H H
OH 2 6 1 1 0 H H OH 3 2 1 1 0 H H OH 3 6 1 1 0 H H OH 4 2 1 1 0 H H
OH 4 6 1 1 0 H H OH 5 2 1 1 0 H H OH 5 6 1 1 0 H H OH 6 2 1 1 0 H H
OH 6 6 1 1 0 H H OH 7 2 1 1 0 H H OH 7 6 1 1 0 H H OH 8 2 1 1 0 H H
OH 8 6 1 1 0 H H OH 1 2 1 1 0 OH H H 1 6 1 1 0 OH H H 2 2 1 1 0 OH
H H 2 6 1 1 0 OH H H 3 2 1 1 0 OH H H 3 6 1 1 0 OH H H 4 2 1 1 0 OH
H H 4 6 1 1 0 OH H H 5 2 1 1 0 OH H H 5 6 1 1 0 OH H H 6 2 1 1 0 OH
H H 6 6 1 1 0 OH H H 7 2 1 1 0 OH H H 7 6 1 1 0 OH H H 8 2 1 1 0 OH
H H 8 6 1 1 0 OH H H 1 3 1 1 0 H H H 1 7 1 1 0 H H H 2 3 1 1 0 H H
H 2 7 1 1 0 H H H 3 3 1 1 0 H H H 3 7 1 1 0 H H H 4 3 1 1 0 H H H 4
7 1 1 0 H H H 5 3 1 1 0 H H H 5 7 1 1 0 H H H 6 3 1 1 0 H H H 6 7 1
1 0 H H H 7 3 1 1 0 H H H 7 7 1 1 0 H H H 8 3 1 1 0 H H H 8 7 1 1 0
H H H 1 3 1 1 0 H H OH 1 7 1 1 0 H H OH 2 3 1 1 0 H H OH 2 7 1 1 0
H H OH 3 3 1 1 0 H H OH 3 7 1 1 0 H H OH 4 3 1 1 0 H H OH 4 7 1 1 0
H H OH 5 3 1 1 0 H H OH 5 7 1 1 0 H H OH 6 3 1 1 0 H H OH 6 7 1 1 0
H H OH 7 3 1 1 0 H H OH 7 7 1 1 0 H H OH 8 3 1 1 0 H H OH 8 7 1 1 0
H H OH 1 3 1 1 0 OH H H 1 7 1 1 0 OH H H 2 3 1 1 0 OH H H 2 7 1 1 0
OH H H 3 3 1 1 0 OH H H 3 7 1 1 0 OH H H 4 3 1 1 0 OH H H 4 7 1 1 0
OH H H 5 3 1 1 0 OH H H 5 7 1 1 0 OH H H 6 3 1 1 0 OH H H 6 7 1 1 0
OH H H 7 3 1 1 0 OH H H 7 7 1 1 0 OH H H 8 3 1 1 0 OH H H 8 7 1 1 0
OH H H 1 4 1 1 0 H H H 1 8 1 1 0 H H H 2 4 1 1 0 H H H 2 8 1 1 0 H
H H 3 4 1 1 0 H H H 3 8 1 1 0 H H H 4 4 1 1 0 H H H 4 8 1 1 0 H H H
5 4 1 1 0 H H H 5 8 1 1 0 H H H 6 4 1 1 0 H H H 6 8 1 1 0 H H H 7 4
1 1 0 H H H 7 8 1 1 0 H H H 8 4 1 1 0 H H H 8 8 1 1 0 H H H 1 4 1 1
0 H H OH 1 8 1 1 0 H H OH 2 4 1 1 0 H H OH 2 8 1 1 0 H H OH 3 4 1 1
0 H H OH 3 8 1 1 0 H H OH 4 4 1 1 0 H H OH 4 8 1 1 0 H H OH 5 4 1 1
0 H H OH 5 8 1 1 0 H H OH 6 4 1 1 0 H H OH 6 8 1 1 0 H H OH 7 4 1 1
0 H H OH 7 8 1 1 0 H H OH 8 4 1 1 0 H H OH 8 8 1 1 0 H H OH 1 4 1 1
0 OH H H 1 8 1 1 0 OH H H 2 4 1 1 0 OH H H 2 8 1 1 0 OH H H 3 4 1 1
0 OH H H 3 8 1 1 0 OH H H 4 4 1 1 0 OH H H 4 8 1 1 0 OH H H 5 4 1 1
0 OH H H 5 8 1 1 0 OH H H 6 4 1 1 0 OH H H 6 8 1 1 0 OH H H 7 4 1 1
0 OH H H 7 8 1 1 0 OH H H 8 4 1 1 0 OH H H 8 8 1 1 0 OH H H
[0052] In another aspect, the invention relates to a method for
synthesizing the polymer of Formula I, wherein the method
comprises: [0053] (a) reacting:
[0054] compound (i):
##STR00022##
and
[0055] compound (ii):
##STR00023##
[0056] to form compound (iii):
##STR00024##
and, [0057] (b) functionalizing compound (iii) with
[0057] ##STR00025## [0058] wherein each W independently is
(CH.sub.2).sub.1-8 or
[0058] ##STR00026## [0059] each Y independently is
(CH.sub.2).sub.1-8 or
[0059] ##STR00027## [0060] each Z independently is H or
[0060] ##STR00028## [0061] each R.sup.3 independently is H or OH;
[0062] p is 1-8; and, [0063] each q independently is 0-8; [0064]
wherein compounds (i), (ii), and (iii) each have a biobased content
of at least about 95%, preferably about 97%, more preferably about
99%, for example, about 100%.
[0065] In some embodiments, the molar ratio of W to Y is about
0.8:1 to about 1.4:1, preferably about 0.9:1 to about 1.2:1, for
example, about 0.92:1 to about 1.14:1.
[0066] In some embodiments, each W independently is
(CH.sub.2).sub.1-8, preferably (CH.sub.2).sub.2-4, for example,
(CH.sub.2).sub.4. In some embodiments, compound (i) is a
dicarboxylic acid or tricarboxylic acid selected from the group
consisting of malonic acid, succinic acid, glutaric acid, adipic
acid, pimelic acid, suberic acid, azelaic acid, sebacic acid,
citric acid, isocitric acid, propane-1,2,3-dicarboxylic acid, and
mixtures thereof. In some preferred embodiments, compound (i) is
selected from the group consisting of malonic acid, succinic acid,
glutaric acid, adipic acid, and mixtures thereof. For example,
compound (i) is adipic acid.
[0067] In some embodiments, each Y independently is
(CH.sub.2).sub.1-8, preferably (CH.sub.2).sub.2-4, for example,
(CH.sub.2).sub.2, and p is 1-4, preferably 1-3, for example, 1. In
some embodiments, compound (ii) is a polyalkylene polyamine having
two primary amines and at least one secondary amine. In some
embodiments, compound (ii) is selected from the group consisting of
diethylenetriamine, triethylenetetramine, tetraethylenepentamine,
dipropylenetriamine, and mixtures thereof. In some preferred
embodiments, compound (ii) is diethylenetriamine.
Derivation of Monomers from Renewable Resources
[0068] The sustainable cationic polymers of the invention are
derived from renewable resources. In some embodiments, the
sustainable cationic polymer can be formed by reacting a renewable
polyalkylene polyamine with a renewable dicarboxylic or a renewable
tricarboxylic acid to form a renewable polyamide, and then
functionalizing the renewable polyamide with renewable
epichlorohydrin to form a renewable wet strength cationic polymer.
In some embodiments, the wet strength polymer is renewable
polyetherimide that has been functionalized with renewable
epicholorohydrin.
[0069] Many of the renewable monomers of the invention are derived
from bio-ethylene, bio-propylene, or bio-alcohols derived from
renewable resources. As used herein, the prefix "bio-" is used to
designate a material that has been derived from a renewable
resource.
Bio-Alcohol Production
[0070] Monofunctional alcohols, such as methanol; ethanol; isomers
of propanol, butanol, pentanol, and hexanol; cyclopentanol;
isobornyl alcohol; and higher alcohols; and polyfunctional
alcohols, such as ethylene glycol, isomers of propanediol, and
glycerol, can be derived from renewable resources via a number of
suitable routes (see, e.g., WO 2009/155086 and U.S. Pat. No.
4,536,584, each incorporated herein by reference).
[0071] In one route, a renewable resource, such as corn starch, can
be enzymatically hydrolyzed to yield glucose and/or other sugars.
The resultant sugars can be converted into alcohols by
fermentation.
[0072] In another route, monofunctional alcohols, such as ethanol
and propanol are produced from short chain acids, fatty acids, fats
(e.g., animal fat), and oils (e.g., monoglycerides, diglycerides,
triglycerides, and mixtures thereof). These short chain acids,
fatty acids, fats, and oils can be derived from renewable
resources, such as animals or plants. "Short chain acid" refers to
a straight chain monocarboyxlic acid having a chain length of 3 to
5 carbon atoms. "Fatty acid" refers to a straight chain
monocarboxylic acid having a chain length of 6 to 30 carbon atoms.
"Monoglycerides," "diglycerides," and "triglycerides" refer to
multiple mono-, di- and tri-esters, respectively, of (i) glycerol
and (ii) the same or mixed short chain acids and/or fatty
acids.
[0073] Nonlimiting examples of short chain acids include propionic
acid, butyric acid, and valeric acid. Nonlimiting examples of
saturated fatty acids include caproic acid, enanthic acid, caprylic
acid, pelargonic acid, capric acid, undecylic acid, lauric acid,
tridecylic acid, myristic acid, pentadecylic acid, palmitic acid,
margaric acid, stearic acid, nonadecylic acid, arachidic acid,
heneicosylic acid, behenic acid, tricosylic acid, lignoceric acid,
pentacosylic acid, cerotic acid, heptacosylic acid, montanic acid,
nonacoxylic acid, melissic acid, henatriacontylic acid, lacceroic
acid, psyllic acid, geddic acid, ceroplastic acid, and
hexatriacontylic acid. Nonlimiting examples of unsaturated fatty
acids include oleic acid, myristoleic acid, palmitoleic acid,
sapienic acid, linoleic acid, linolenic acid, arachidonic acid,
eicosapentaenoic acid, and docosahexaenoic acid. Nonlimiting
examples of monoglycerides include monoglycerides of any of the
fatty acids described herein. Nonlimiting examples of diglycerides
include diglycerides of any of the fatty acids described herein.
Nonlimiting examples of the triglycerides include triglycerides of
any of the fatty acids described herein, such as, for example, tall
oil, corn oil, soybean oil, sunflower oil, safflower oil, linseed
oil, perilla oil, cotton seed oil, tung oil, peanut oil, oiticica
oil, hempseed oil, marine oil (e.g. alkali-refined fish oil),
dehydrated castor oil, and mixtures thereof. Alcohols can be
produced from fatty acids through reduction of the fatty acids by
any method known in the art. Alcohols can be produced from fats and
oils by first hydrolyzing the fats and oils to produce glycerol and
fatty acids, and then subsequently reducing the fatty acids.
[0074] In another route, genetically engineered cells and
microorganisms are provided that produce products from the fatty
acid biosynthetic pathway (i.e., fatty acid derivatives), such as
fatty alcohols, as described in International Patent Application
Publication No. WO 2008/119082, incorporated herein by reference.
For example, a gene encoding a fatty alcohol biosynthetic
polypeptide that can be used to produce fatty alcohols, or a fatty
aldehyde biosynthetic polypeptide that can be used to produce fatty
aldehydes, which subsequently can be converted to fatty alcohols,
is expressed in a host cell. The resulting fatty alcohol or fatty
aldehyde then is isolated from the host cell. Such methods are
described in U.S. Patent Application Publication Nos. 2010/0105963
and 2010/0105955, and International Patent Application Publication
Nos. WO 2010/062480 and WO 2010/042664, each incorporated herein by
reference.
[0075] In another route, fatty acyl chains are produced from
renewable biocrude or hydrocarbon feedstocks using recombinant
microorganisms, wherein at least one hydrocarbon is produced by the
recombinant microorganism. The fatty acyl chains subsequently can
be converted to fatty alcohols using methods known in the art. The
microorganisms can be engineered to produce specific degrees of
branching, saturation, and length, as described in U.S. Patent
Application Publication No. 2010/017826, incorporated herein by
reference.
Bio-Ethylene Production
[0076] Bio-ethylene can be formed from the dehydration of
bio-ethanol Bio-ethanol can be derived from, for example, (i) the
fermentation of sugar from sugar cane, sugar beet, or sorghum; (ii)
the saccharification of starch from maize, wheat, or manioc; and
(iii) the hydrolysis of cellulosic materials. U.S. Patent
Application Publication No. 2005/0272134, incorporated herein by
reference, describes the fermentation of sugars to form alcohols
and acids.
[0077] As previously described, suitable sugars used to form
ethanol include monosaccharides, disaccharides, trisaccharides, and
oligosaccharides. Sugars, such as sucrose, glucose, fructose, and
maltose, are readily produced from renewable resources, such as
sugar cane and sugar beets. Sugars also can be derived (e.g., via
enzymatic cleavage) from other agricultural products (i.e.,
renewable resources resulting from the cultivation of land or the
husbandry of animals). For example, glucose can be prepared on a
commercial scale by enzymatic hydrolysis of corn starch. Other
common agricultural crops that can be used as the base starch for
conversion into glucose include wheat, buckwheat, arracaha, potato,
barley, kudzu, cassava, sorghum, sweet potato, yam, arrowroot,
sago, and other like starchy fruit, seeds, or tubers. The sugars
produced by these renewable resources (e.g., corn starch from corn)
can be used to produce ethanol, as well as other alcohols, such as
propanol, and methanol. For example, corn starch can be
enzymatically hydrolyzed to yield glucose and/or other sugars. The
resultant sugars can be converted into ethanol by fermentation.
[0078] In one embodiment, bio-ethylene is produced from sugar cane.
The life cycle stages of ethylene production from sugar cane
include (i) sugar cane farming, (ii) fermentation of sugar cane to
form bio-ethanol, and (iii) dehydration of bio-ethanol to form
ethylene. Specifically, sugar cane is washed and transported to
mills where sugar cane juice is extracted, leaving filter cake,
which is used as fertilizer, and bagasse (residual woody fiber of
the cane obtained after crushing). The bagasse is burned to
generate steam and the electricity used to power the sugar cane
mills, thereby reducing the use of petroleum-derived fuels. The
sugar cane juice is fermented using yeast to form a solution of
ethanol and water. The ethanol is distilled from the water to yield
about 95% pure bio-ethanol. The bio-ethanol is subjected to
catalytic dehydration (e.g., with an alumina catalyst) to produce
bio-ethylene.
[0079] Advantageously, a Life Cycle Assessment and Inventory of
ethylene produced from sugar cane shows favorable benefits in some
aspects over ethylene produced from petroleum feedstock for global
warming potential, abiotic depletion, and fossil fuel consumption.
For example, some studies have shown that about one ton of
polyethylene made from virgin petroleum-based sources results in
the emission of up to about 2.5 tons of carbon dioxide to the
environment, as previously described. Thus, use of up to about one
ton of polyethylene from a renewable resource, such as sugar cane,
results in a decrease of about 5 tons of environmental carbon
dioxide versus using one ton of polyethylene derived from
petroleum-based resources.
Bio-Propylene
[0080] Bio-propylene can be formed from the dehydration of
bio-propanol. Renewable resources used to derive bio-propanol are
as previously described. Bio-propanol also can be derived from
bio-ethylene. In this pathway, bio-ethylene is converted into
bio-propionaldehyde by hydroformylation using carbon monoxide and
hydrogen in the presence of a catalyst, such as cobalt octacarbonyl
or a rhodium complex. Hydrogenation of the bio-propionaldehyde in
the presence of a catalyst, such as sodium borohydride and lithium
aluminum hydride, yields bio-propan-1-ol, which can be dehydrated
in an acid catalyzed reaction to yield bio-propylene, as described
in U.S. Patent Application Publication No. 2007/0219521,
incorporated herein by reference.
A. Dicarboxylic Acid
[0081] The dicarboxylic acid derived from renewable resources can
be represented by compound (i):
##STR00029## [0082] wherein each W independently is
(CH.sub.2).sub.1-8 or
[0082] ##STR00030## [0083] each R.sup.3 independently is H or OH;
and, [0084] each q independently is 0-8.
Bio-Malonic Acid
[0085] In some embodiments, compound (i) is bio-malonic acid. In
one route, bio-malonic acid can be produced by first oxidizing
bio-ethylene in the presence of a silver catalyst to form
bio-ethylene oxide, which undergoes hydroformylation to produce
bio-3-hydroxypropionaldehyde. The bio-3-hydroxypropionaldehyde is
hydrogenated to from bio-1,3-propanediol, which is oxidized using
methods known to one skilled in the art to form bio-malonic
acid.
[0086] In another route, the bio-1,3-propanediol can be produced
through the fermentation of glycerol using Clostridium bacteria
(e.g., Clostridium diolis). As previously described, glycerol can
be obtained from fatty acids, fats, and oils.
[0087] In yet another route, the bio-1,3-propanediol can be
produced through the conversion of corn syrup effected by a
genetically modified strain of E. coli.
Bio-Succinic Acid
[0088] In some embodiments, compound (i) is bio-succinic acid.
Bio-succinic acid is a by-product of sugar fermentation. It also
can be produced by oxidizing bio-1,4-butanediol, according to
methods known to one skilled in the art.
[0089] In one route, bio-ethylene is first converted to
bio-acetylene. The bio-acetylene is reacted with two equivalents of
bio-formaldehyde to form bio-1,4-butynediol, which is hydrogenated
to produce bio-1,4-butanediol. Bio-formaldehyde can be produced
through the catalytic oxidation of bio-methanol using silver metal
or a mixture of iron and molybdenum or vanadium oxides.
[0090] In another route, bio-propylene oxide or bio-propanol is
converted to bio-allyl alcohol by isomerization or dehydration,
respectively. The bio-allyl alcohol is hydroformylated to form
bio-4-hydroxybutyraldehyde, which is reduced to bio-1,4-butanediol.
The bio-propylene oxide can be synthesized by the oxidation of
bio-propylene using H.sub.2O.sub.2, or by converting bio-propylene
to bio-1-chloro-2-propanol and bio-2-chloro-1-propanol using
chlorine and water, and then reacting the bio-chloropropanols with
hydroxide to form bio-propylene oxide.
[0091] In yet another route, the bio-1,4-butanediol can be produced
through the metabolization of sugar by a genetically modified
strain of E. coli.
Bio-Glutaric Acid
[0092] In some embodiments, compound (i) is bio-glutaric acid.
Bio-glutaric acid can be produced by the ring opening of
bio-butyrolactone using potassium bio-cyanide to result in
potassium bio-carboxylate-nitrile, which is hydrolyzed to
bio-glutaric acid. Potassium bio-cyanide can be produced from the
reaction of KOH with bio-hydrogen cyanide. Bio-hydrogen cyanide can
be produced by reacting bio-methane with ammonia. Bio-butyrolactone
can be produced by removing water from bio-.gamma.-hydroxybutryic
acid, which can be produced from bio-1,4-butanediol.
[0093] In another route, bio-glutaric acid is produced by reacting
bio-1,3-dibromopropane with bio-sodium or bio-potassium cyanide to
form the bio-dinitrile, which can undergo hydrolysis to form
bio-glutaric acid. The bio-1,3-dibromopropane can be formed by free
radical addition between bio-allyl bromide with HBr.
Bio-Adipic Acid
[0094] In some embodiments, compound (i) is bio-adipic acid.
Bio-adipic acid can be produced from the oxidation of fats, using
methods known to one skilled in the art. Bio-adipic acid can also
be produced through the carbonylation of bio-butadiene using two
equivalents of carbon dioxide and two equivalents of water.
Bio-butadiene can be produced from bio-ethanol either using a metal
oxide catalyst in a one-step process at 400-450.degree. C., or
oxidizing the bio-ethanol to bio-acetaldehyde, which reacts with
additional bio-ethanol over a tantalum-promoted porous silica
catalyst at 325 .degree. C. to 350.degree. C.
Bio-Pimelic Acid, Bio-Suberic Acid, and Bio-Azelaic Acid
[0095] In some embodiments, compound (i) is bio-pimelic acid,
bio-suberic acid, or bio-azelaic acid, all of which can be produced
from the oxidation of fats produced from ricinoleic acid, which can
be obtained from castor oil. In some embodiments, the double bond
of ricinoleic acid is split into bio-suberic acid and bio-azelaic
acid. Bio-azelaic acid also can be produced from the oxidation of
oleic acid with potassium permanganate, or the oxidative cleavage
of oleic acid with chromic acid or using ozonolysis.
Bio-Sebacic Acid
[0096] In some embodiments, compound (i) is bio-sebacic acid.
Bio-sebacic acid can be isolated from beef tallow. Bio-sebacic acid
can also be produced by the treatment of ricinoleic acid with
sodium hydroxide, as described in U.S. Patent Application
Publication No. 2010/0151241, incorporated herein by reference.
Bio-Citric Acid and Bio-Isocitric Acid
[0097] In some embodiments, compound (i) is bio-citric acid or
bio-isocitric acid, both of which are naturally occurring
tricarboxylic acids.
Bio-Propane-1,2,3-Tricarboxylic Acid
[0098] In some embodiments, compound (i) is
bio-propane-1,2,3-tricarboxylic acid.
Bio-propane-1,2,3-tricarboxylic acid is naturally occurring. It can
also be produced from bio-fumaric acid in two steps. Bio-fumaric
acid can be produced from bio-succinic acid.
B. Polyalkylene Polyamine
[0099] The polyalkylene polyamine derived from renewable resources
can be represented by compound (ii):
##STR00031## [0100] wherein each Y independently is
(CH.sub.2).sub.1-8 or
[0100] ##STR00032## [0101] each Z independently is H or
##STR00033##
[0101] and [0102] p is 1-8.
Bio-Diethylenetriamine, Bio-Triethylenetetramine,
Bio-Tetraethylenepentamine
[0103] In some embodiments, compound (ii) is
bio-diethylenetriamine, bio-triethylenetetramine,
bio-tetraethylenepentamine, or a mixture thereof. In one route,
bio-diethylenetriamine, biotriethylenetetramine, and
bio-tetraethylenepentamine can be produced by reacting
bio-dichloroethane with ammonia. Bio-dichloroethane can be produced
by chlorinating bio-ethylene.
[0104] In another route, bio-diethylenetriamine,
bio-triethylenetetramine, and bio-tetraethylenepentamine can be
produced by reacting bio-monoethanolamine with ammonia.
Bio-monoethanolamine can be produced by reacting bio-ethylene oxide
with ammonia. Bio-ethylene oxide can be synthesized as previously
described.
[0105] In yet another route, bio-diethylenetriamine,
bio-triethylenetetramine, and bio-tetraethylenepentamine can be
produced by reacting bio-diaminoethane with bio-monoethanolamine.
Bio-diaminoethane can be synthesized through the reaction of
bio-ethylene glycol, or bio-dichloroethane, or bio-monoethanolamine
with ammonia.
Bio-Dipropylenetriamine
[0106] In some embodiments, compound (ii) is
bio-dipropylenetriamine. Bio-dipropylenetriamine can be produce by
reacting bio-1,3-dichloropropane with ammonia.
Bio-1,3-dichloropropane can be synthesized by chlorinating
bio-propylene to form bio-1,3-dichloropropene, and then reducing
the bio-1,3-dichloropropene.
[0107] In another route, bio-dipropylenetriamine can be prepared by
reacting bio-3-aminopropanol with ammonia. Bio-3-aminopropanol can
be synthesized by reacting bio-acrylonitrile with water.
Bio-acrylonitrile can be prepared by reacting bio-propylene with
ammonia and molecular oxygen.
[0108] In yet another route, bio-dipropylenetriamine can be
prepared by reacting bio-acrylonitrile with ammonia to form
bio-1,3-propanediamine, and then reacting the
bio-1,3-propanediamine with bio-monopropanolamine.
C. Bio-Epichlorohydrin
[0109] Bio-epichlorhydrin can be produced from bio-allyl chloride.
Bio-allyl chloride can be produced by reacting bio-propylene with
chlorine at high temperature (e.g., 500.degree. C.) with the
release of hydrochloric acid. In one route, bio-allyl chloride is
hydrochlorinated using hypochlorus acid to form a mixture of
2,3-dichloro-1-propanol and 1,3-dichloro-2-propanol. Sodium
hydroxide is added to this mixture to produce bio-epichlorohydrin,
sodium chloride, and water. In another route, bio-allyl chloride is
hypochlorinated in a dilute, aqueous chlorine solution to form the
bio-dichlorohydrins, which are then dehydrochlorinated using either
calcium hydroxide or sodium hydroxide to form bio-ephichlorohydrin.
In yet another route, bio-allyl chloride is epoxidated using
aqueous hydrogen peroxide and a heteropolyphosphatotungstate
catalyst to yield bio-epichlorohydrin.
[0110] Bio-epichlorohydrin also can be produced from bio-allyl
alcohol by reacting the bio-allyl alcohol with chlorine and calcium
hydroxide, as previously described. Bio-allyl alcohol can be
produced by the hydrolysis of bio-allyl chloride, or by the
isomerization of bio-propylene oxide using a potassium alum
catalyst at high temperatures. Bio-allyl alcohol also can be
produced through the acetoxylation of bio-propene to form bio-allyl
acetate, which can be hydrolyzed to yield bio-allyl alcohol.
Bio-allyl alcohol also can be produced by oxidizing bio-propylene
to bio-acrolein, and then hydrogenating the bio-acrolein to form
bio-allyl alcohol.
Assessment of the Biobased Content of Materials
[0111] A suitable method to assess materials derived from renewable
resources is through ASTM D6866, which allows the determination of
the biobased content of materials using radiocarbon analysis by
accelerator mass spectrometry, liquid scintillation counting, and
isotope mass spectrometry. When nitrogen in the atmosphere is
struck by an ultraviolet light produced neutron, it loses a proton
and forms carbon that has a molecular weight of 14, which is
radioactive. This .sup.14C is immediately oxidized into carbon
dioxide, which represents a small, but measurable fraction of
atmospheric carbon. Atmospheric carbon dioxide is cycled by green
plants to make organic molecules during the process known as
photosynthesis. The cycle is completed when the green plants or
other forms of life metabolize the organic molecules producing
carbon dioxide, which causes the release of carbon dioxide back to
the atmosphere. Virtually all forms of life on Earth depend on this
green plant production of organic molecules to produce the chemical
energy that facilitates growth and reproduction. Therefore, the
.sup.14C that exists in the atmosphere becomes part of all life
forms and their biological products. These renewably based organic
molecules that biodegrade to carbon dioxide do not contribute to
global warming because no net increase of carbon is emitted to the
atmosphere. In contrast, fossil fuel-based carbon does not have the
signature radiocarbon ratio of atmospheric carbon dioxide. See WO
2009/155086, incorporated herein by reference.
[0112] The application of ASTM D6866 to derive a "biobased content"
is built on the same concepts as radiocarbon dating, but without
use of the age equations. The analysis is performed by deriving a
ratio of the amount of radiocarbon (.sup.14C) in an unknown sample
to that of a modern reference standard. The ratio is reported as a
percentage with the units "pMC" (percent modern carbon). If the
material being analyzed is a mixture of present day radiocarbon and
fossil carbon (containing no radiocarbon), then the pMC value
obtained correlates directly to the amount of biomass material
present in the sample.
[0113] The modern reference standard used in radiocarbon dating is
a NIST (National Institute of Standards and Technology) standard
with a known radiocarbon content equivalent approximately to the
year AD 1950. The year AD 1950 was chosen because it represented a
time prior to thermo-nuclear weapons testing, which introduced
large amounts of excess radiocarbon into the atmosphere with each
explosion (termed "bomb carbon"). The AD 1950 reference represents
100 pMC.
[0114] "Bomb carbon" in the atmosphere reached almost twice normal
levels in 1963 at the peak of testing and prior to the treaty
halting the testing. Its distribution within the atmosphere has
been approximated since its appearance, showing values that are
greater than 100 pMC for plants and animals living since AD 1950.
The distribution of bomb carbon has gradually decreased over time,
with today's value being near 107.5 pMC. As a result, a fresh
biomass material, such as corn, could result in a radiocarbon
signature near 107.5 pMC.
[0115] Petroleum-based carbon does not have the signature
radiocarbon ratio of atmospheric carbon dioxide. Research has noted
that fossil fuels and petrochemicals have less than about 1 pMC,
and typically less than about 0.1 pMC, for example, less than about
0.03 pMC. However, compounds derived entirely from renewable
resources have at least about 95 percent modern carbon (pMC),
preferably at least about 99 pMC, for example, about 100 pMC.
[0116] Combining fossil carbon with present day carbon into a
material will result in a dilution of the present day pMC content.
By presuming that 107.5 pMC represents present day biomass
materials and 0 pMC represents petroleum derivatives, the measured
pMC value for that material will reflect the proportions of the two
component types. A material derived 100% from present day soybeans
would give a radiocarbon signature near 107.5 pMC. If that material
was diluted with 50% petroleum derivatives, it would give a
radiocarbon signature near 54 pMC.
[0117] A biobased content result is derived by assigning 100% equal
to 107.5 pMC and 0% equal to 0 pMC. In this regard, a sample
measuring 99 pMC will give an equivalent biobased content result of
93%.
[0118] Assessment of the materials described herein were done in
accordance with ASTM D6866, particularly with Method B. The mean
values quoted in this report encompasses an absolute range of 6%
(plus and minus 3% on either side of the biobased content value) to
account for variations in end-component radiocarbon signatures. It
is presumed that all materials are present day or fossil in origin
and that the desired result is the amount of biobased component
"present" in the material, not the amount of biobased material
"used" in the manufacturing process.
[0119] Other techniques for assessing the biobased content of
materials are described in U.S. Pat. Nos. 3,885,155, 4,427,884,
4,973,841, 5,438,194, and 5,661,299, and WO 2009/155086, each
incorporated herein by reference.
Method of Making Wet Strength Resin
[0120] The polymers of Formula I can be prepared by condensing a
polyalkylene amine with a dicarboxylic acid, or any active
derivative thereof, to form a polyamide, and then reacting the
polyamide with epichlorohydrin, as described in, e.g., U.S. Pat.
No. 2,926,154.
Condensation of the Polyalkylene Amide with the Dicarboxylic
Acid
[0121] The condensation of the polyalkylene amine with the
dicarboxylic acid to form the polyamide of the invention can occur
by any method known to one skilled in the art, and the reaction
parameters used for this condensation reaction depend on the exact
reaction conditions, as understood to one skilled in the art. For
example, the reaction temperature can be about 110.degree. C. to
about 250.degree. C. or higher at atmospheric pressure, preferably
about 160.degree. C. to about 210.degree. C. Under reduced pressure
conditions, the temperature of the condensation also can be reduced
accordingly. The reaction time depends on the exact reaction
conditions and occurs until a substantial amount of starting
materials have been converted to polyamide, e.g., about 30 minutes
to about 2 hours.
[0122] The amount of dicarboxylic acid used should be sufficient to
react with substantially all of the primary amine groups of the
polyalkylene polyamine, but insufficient to react with the
secondary amine groups of the polyalkylene polyamine. For example,
the ratio of dicarboxylic acid to polyalkylene amine can be about
0.8:1 to about 1.4:1, preferably about 0.9:1 to about 1.2:1, more
preferably about 0.92:1 to about 1.14:1. Ratios below about 0.8:1
result in a gelled product, while ratios above about 1.4:1 result
in low molecular weight polyamides. The composition of the
polyamide polymer and the ratio of dicarboxylic acid to
polyalkylene amine in the polymer can be determined using nuclear
magnetic resonance and_gas chromatography, and by other
characterization methods known to one skilled in the art.
[0123] The molecular weight of the polyalkylene amide can be about
5,000 to about 30,000, for example, about 10,000. "Molecular
weight" as used herein means "weight average molecular weight."
"Weight average molecular weight" means the weight average
molecular weight as determined using gel permeation chromatography
according to the protocol found in Colloids and Surfaces A. Physico
Chemical & Engineering Aspects, Vol. 162, 2000, pg.
107-121.
Functionalization of Polyamide with Epichlorohydrin
[0124] The polyamide can be functionalized with epichlorohydrin by
any method known to one skilled in the art, and the reaction
parameters used for this functionalization depend on the exact
reaction conditions, as understood to one skilled in the art. In
some embodiments, the reaction can occur in an aqueous solution.
Optionally, base can be added to the reaction solution to
neutralize some of the acid that forms during the previous
polymerization reaction.
[0125] For example, the epichlorohydrin can be reacted with the
polyamide at a temperature of about 45.degree. C. to about
100.degree. C., preferably about 45.degree. C. to about 70.degree.
C., until the viscosity of a 20% solids solution at 25.degree. C.
has reached about C or higher on the Gardner-Holdt scale. After the
reaction solution reaches the desired viscosity, sufficient water
is added to adjust the solids content of the solution to about 15%
or less. The product is cooled to about 25.degree. C., and then
stabilized by adding sufficient acid (e.g., hydrochloric acid,
sulfuric acid, nitric acid, formic acid, phosphoric acid, acetic
acid) to reduce the pH to at least about 6, preferably to at least
about 5.
[0126] In the polyamide-epichlorohydrin reaction, sufficient
epichlorohydrin should be used to convert all secondary amide
groups to tertiary amine groups and/or quaternary ammonium groups,
including cyclic structures. However, more or less epichlorohydrin
can be added to the polyamide to moderate or increase reaction
rates. For example, about 0.5 mol to about 1.8 mol, preferably
about 0.9 mol to about 1.5 mol, of epichlorohydrin per mole of
polyamide secondary amine is contemplated.
[0127] The composition of the polyaminoamide epichlorohydrin resin
and the amount of epichlorohydrin functionalization on the
polyamide can be determined using nuclear magnetic resonance, gas
chromatography, and by other characterization methods known to one
skilled in the art.
[0128] The molecular weight of the polyaminoamide epichlorohydrin
resin can be can be about 5,000 to about 30,000, for example, about
10,000. "Molecular weight" as used herein means "weight average
molecular weight." "Weight average molecular weight" means the
weight average molecular weight as determined using gel permeation
chromatography according to the protocol found in Colloids and
Surfaces A. Physico Chemical & Engineering Aspects, Vol. 162,
2000, pg. 107-121.
Paper Article Comprised of Wet Strength Resins Derived from
Renewable Resources
[0129] The invention also relates to a paper article comprising the
polymer of Formula I, as previously described herein. The paper
article can be any paper that used for absorbent purposes (e.g., a
towel, a facial tissue, a sanitary tissue, and paperboard.
Nonlimiting examples of paper articles include bath towels, facial
tissue, industrial wipers, Kleenex, kraft paper, napkins, paper
coveralls, plates, tablecloth covers, toilet seat covers, towels,
white butcher paper, C-fold towers, household towels, multi-fold
towels, roll towels, single fold towels. Additional examples of
paper articles include airmail papers, artboards, artists papers,
baking paper, blotting papers, book binding materials, book cover
material, book end papers, book papers, bookjacket papers, bulky
book papers, business papers, carbonless papers, carbonless reels,
carbonless sheets, cardstock, cartonboards, cast coated papers,
check papers, cigarette papers, colored papers, copier papers,
copier/laser paper, corrugating medium, cover papers, cupstock,
diazo paper, digital papers, directory papers, display boards,
document/presentation papers, drawing office papers, duplicator
papers, electrical application papers, embossed papers &
boards, envelope papers, manila envelope papers, facsimile paper,
filter papers, fluorescent papers & boards, folding boxboard,
forest stewardship council (FSC) Papers, glassine papers, graphical
boards, greaseproof papers, grey board, gummed papers, handmade
papers & boards, inkjet papers, ivory boards, ivory papers,
Kraft boards, Kraft lined chip, Kraft papers, Kraftliner, label
papers, label papers (coated), label papers (uncoated), laid
papers, laminates, laser printing papers (not copier), letter file,
liquid packaging board, listing papers, long life papers &
boards, lightweight coated paper (LWC), manila boards, manila
envelopes, medical papers, metallized papers & boards,
machine-finished (MF) papers, machine glazed (MG) bleached papers,
MG papers, mini web reels, multi-layer boards, medium weight coated
(MWC) papers, near woodfree papers & boards, newsprint,
recycled newsprint, OCR papers, offset papers, on-machine coated
papers & boards, one-time carbon, packaging boards, packaging
papers, part mechanical papers & boards, pen plotter & map
papers, poster papers, preprint papers, pressboards, pulpboard, rag
bank & bond papers, real art papers & boards, recycled
boards, recycled coated paper & board, recycled
graph.board(100% PCW), recycled graph.board(<100% PCW), recycled
graph.paper(<100% PCW), recycled graphical paper (100% PCW),
recycled papers, release papers, sack and Kraft Paper, SC gravure,
SC offset, security papers, self-adhesive base papers,
self-adhesive papers, silicone papers, solid bleached board,
special coated paper, special surface papers & boards, stamp
papers, stationery, synthetic papers, tag papers & boards,
testliner, textured papers & boards, thermal paper, thermal
transfer papers, thin opaques/bible papers, ticket boards, tissue,
translucent paper, tube papers & boards, ULWC, uncoated
mechanical papers, vegetable parchment, wallpaper base, watermarked
papers, web Offset reels, wet strength papers, WF bulky coated
papers & boards, WF envelope/cartridge, WF gloss coated papers
& boards, WF gloss coated for dig.print, WF matt coated papers
& boards, WF matt coated for dig.print, WF one side coated
papers & boards, WF satin coated papers & boards, WF silk
coated papers & boards, WF uncoated papers & boards, white
lined chipboard, and wove papers.
[0130] The paper article of the invention includes a natural fiber,
a synthetic fiber, or a mixture thereof having a length of about
0.8 mm to about 5 mm. If the fiber is less than about 0.8 mm, the
fiber can break apart during manufacturing. If the fiber is greater
than about 5 mm, the fiber can aggregate during manufacturing to
cause clumps in the resulting paper article.
[0131] In some embodiments, the natural fiber is from a hardwood
source, such as, for example, oak, maple, and eucalyptus. In some
embodiments when the fiber is from a hardwood source, the fiber is
about 0.8 mm to about 2 mm long. In some embodiments, the natural
fiber is from a softwood source, such as, for example, pine, aspen,
and birch. In some embodiments when the fiber is from a softwood
source, the fiber is about 2 mm to about 5 mm long. In some
embodiments, the fiber is synthetic, such as, for example, a
polyolefin, a polyester, or a cellulosic fiber (e.g., cellulose
acetate and/or rayon).
[0132] The paper article of the invention can further include one
or more additives commonly used in papermaking. Nonlimiting
examples of useful additives include additional wet strength agents
(e.g., urea-formaldehyde resins, melamine formaldehyde resins,
polyethyleneimine resins, polyacrylamide resins, polyvinylamine
resins, dialdehyde starches, and derivatives thereof), dry strength
additives (e.g., polysalt coacervates rendered water soluble by the
inclusion of ionization suppressors, carboxylmethyl cellulose),
debonders, which increase the softness of the paper webs (e.g.,
quaternary ammonium chlorides such as ditallowdimethyl ammonium
chloride and bis(alkoxy-(2-hydroxy)propylene) quaternary ammonium
compounds), pigments, dyes, fluorescers, and the like. In some
embodiments when the paper article of the invention includes
carboxymethyl cellulose (CMC), the CMC acts synergistically with
the wet strength resin of the invention and is present in an amount
of about 0.1 wt. % to about 0.2 wt. % for every 1 wt. % of wet
strength resin.
[0133] The paper article of the invention can be single ply or
multiple-ply (e.g., 2-ply, 3-ply, 4-ply, 5-ply, or 6-ply). It has a
dry strength of about 300 g/in per ply to about 2000 g/in per ply,
preferably about 500 g/in per ply to about 1500 g/in per ply, more
preferably about 700 g/in per ply to about 1200 g/in per ply, and a
wet strength of about 60 g/in per ply to about 300 g/in per ply,
preferably about 100 g/in per ply to about 300 g/in per ply, more
preferably about 140 g/in per ply to about 240 g/in per ply. The
paper article of the invention has a wet/dry tensile ratio of about
10% to about 30%, preferably about 15% to about 25%, for example,
about 20%. The basis weight of the paper article of the invention
is about 10 pounds per 30,000 square feet (lbs/30,000 ft.sup.2) to
about 30 lbs/30,000 ft.sup.2, for example, about 15 lbs/30,000
ft.sup.2 to about 28 lbs/30,000 ft.sup.2. The wet strength of the
paper article of the invention can be determined by methods known
to one skilled in the art, such as a suitable ASTM method. The dry
strength of the paper article of the invention can be determined by
methods known to one skilled in the art, such as a suitable ASTM
method. The wet/dry tensile ratio of the paper article of the
invention can be determined by methods known to one skilled in the
art, such as a suitable ASTM method. The basis weight of the paper
article of the invention can be determined by methods known to one
skilled in the art, such as a suitable ASTM method.
[0134] The paper article of the invention can be formed by any
method known to one skilled in the art. For example, a five step
process for the formation of the paper of invention is described
below (see, e.g., U.S. Pat. No. 4,637,859, incorporated herein by
reference).
[0135] In the first step, an aqueous dispersion of papermaking
fibers and the polymer of Formula I is provided. Papermaking fibers
useful in the present invention include bleached or unbleached
cellulosic fibers commonly known as wood pulp fibers. Fibers
derived from soft woods (gymnosperms or coniferous trees) and hard
woods (angiosperms or deciduous trees) are contemplated for use in
this invention. The wood pulp fibers can be produced from native
wood by any pulping process known to one skilled in the art.
Chemical processes (e.g., sulfite, sulphate, soda processes),
mechanical processes (e.g., thermochemical), semi-chemical, and
semi-mechanical processes are suitable. Preferably, when the paper
web of this invention is intended for use in absorbent products
such as paper towels, bleached northern softwood Kraft pulp fibers
are preferred. In addition to the various wood pulp fibers, other
cellulosic fibers such as cotton linters, rayon, and bagasse can be
used in this invention. Synthetic fibers such as polyester and
polyolefin fibers can also be used and, in fact, are preferred in
certain applications.
[0136] The second step includes forming an embryonic web of
papermaking fibers from the aqueous dispersion provided in the
first step. Any equipment commonly used in the art for dispersing
fibers is appropriate. The fibers are normally dispersed at a
consistency of about 0.1% to about 0.3% at the time an embryonic
web is formed. Percent consistency is defined as 100 times the
quotient obtained when the weight of dry fiber in the system under
discussion is divided by the total weight of the system. An
alternative method of expressing moisture content of a system
sometimes used in the papermaking art is pounds of water per pound
of fiber or, alternatively and equivalently, kilograms of water per
kilogram of fiber. The correlation between the two methods of
expressing moisture content can be readily developed. For example,
a web having a consistency of 25%, 50%, or 70%, comprises 3, 1, and
0.33 kilograms of water per kilogram of fiber, respectively. Fiber
weight is always expressed on the basis of dry fibers.
[0137] The aqueous dispersion of papermaking fibers and embryonic
web formed from the web can further include various additives
commonly used in papermaking Nonlimiting examples of useful
additives include additional wet strength agents (e.g.,
urea-formaldehyde resins, melamine formaldehyde resins,
polyethyleneimine resins, polyacrylamide resins, and dialdehyde
starches), dry strength additives (e.g., polysalt coacervates
rendered water soluble by the inclusion of ionization suppressors),
debonders, which increase the softness of the paper webs (e.g.,
quaternary ammonium chlorides such as ditallowdimethyl ammonium
chloride and bis(alkoxy-(2-hydroxy)propylene) quaternary ammonium
compounds), pigments, dyes, fluorescers, and the like.
[0138] Complete descriptions of useful wet strength agents can be
found in Tappi Monograph Series No. 29, Wet Strength in Paper and
Paperboard, Technical Association of Pulp and Paper Industry (New
York, 1965), incorporated herein by reference, and in other common
references. Dry strength additives are described more fully in U.S.
Pat. No. 3,660,338, incorporated herein by reference, and in other
common references. The levels at which these materials are useful
in paper webs is also described in the noted references. Specific
debonders that can be used in the present invention are described
in U.S. Pat. Nos. 3,554,863, 4,144,122, and 4,351,699, each
incorporated herein by reference.
[0139] The resulting embryonic web is deposited onto a foraminous
surface (i.e., the first foraminous member), and a portion of the
aqueous dispersing medium is removed. As used herein, an "embryonic
web" is a web of fibers that is subjected to rearrangement on a
deflection member. The fibers in the embryonic web normally
comprise a relatively large quantity of water with typical
consistencies in the range of about 5% to about 25%, and is
normally too weak to be capable of existing without the support of
an extraneous element, such as a Fourdrinier wire. At the time the
embryonic web is subjected to rearrangement on the deflection
member, it must be held together by bonds weak enough to permit
rearrangement of the fibers under the action of the deflection
forces.
[0140] Any of the techniques known to those skilled in the
papermaking art can be used to form the embryonic web, and the
precise method by which the embryonic web is formed is immaterial
to the practice of this invention. Although batch process, such as
handsheet making processes, can be used, continuous papermaking
processes are preferred. Examples of said processes are described,
e.g., U.S. Pat. Nos. 3,301,746, and 3,994,771, each incorporated
herein by reference.
[0141] The third step in the paper making process includes
associating the embryonic web with a deflection member (i.e., the
second foraminous member) to bring the embryonic web into contact
with the deflection member on which it will be subsequently
deflected, rearranged, and further dewatered. The deflection member
can include any physical form known to one skilled in the art, such
as an endless belt, a stationary plate for use in making
handsheets, or a rotating drum.
[0142] The deflection member must be foraminous. As used herein,
"foraminous" is defined as possessing continuous passages
connecting a first surface (i.e., upper surface, working surface,
the surface with which the embryonic web is associated) with a
second surface (i.e., lower surface). The deflection member is
constructed in such a manner that, when water removal from the
embryonic web occurs, it can be discharged from the system in the
direction of the foraminous member without having to again contact
the embryonic web in either the liquid or the vapor state. Water
removal can occur by application of differential fluid pressure
[0143] The embryonic web-contacting surface of the deflection
member can also include a macroscopically monoplanar, patterned,
continuous network surface, which defines within the deflection
member a plurality of discrete, isolated, deflection conduits. When
a portion of the embryonic web-contacting surface of the deflection
member is placed into a planar configuration, the network surface
is essentially monoplanar, meaning that deviations from absolute
planarity are tolerable, but not preferred, as long as the
deviations are not substantial enough to adversely affect the
performance of the product formed on the deflection member. The
network surface is said to be "continuous" because the lines formed
by the network surface form at least one essentially unbroken
net-like pattern. The pattern is said to be "essentially"
continuous because interruptions in the pattern are tolerable, but
not preferred, as long as the interruptions are not substantial
enough to adversely affect the performance of the product made on
the deflection member. The deflection conduits are discrete and
have a finite shape that depends on the pattern selected for the
network surface. The deflection conduits are isolated because there
is no connection within the body of the deflection member between
one deflection conduit and another. Thus, transfer of material from
one deflection conduit to another is not possible unless the
transfer is effected outside the body of the deflection member. An
infinite variety of geometries for the network surface and the
openings of the deflection conduits are possible, and guidelines
for selecting a particular geometry are described in U. S. Pat. No.
4,637,859.
[0144] The fourth step involves deflecting the fibers in the
embryonic web into the deflection conduits and removing water from
the embryonic web, e.g., by the application of differential fluid
pressure to the embryonic web, to form an intermediate web of
papermaking fibers. The deflecting is effected under such
conditions that there is essentially no water removal from the
embryonic web through the deflection conduits after the embryonic
web has been associated with the deflection member prior to the
deflecting of the fibers into the deflection conduits. At the time
the fibers are deflected into the deflection conduits or after such
deflection, water removal from the embryonic web and through the
deflection conduits begins. The third and fourth steps essentially
can be accomplished simultaneously through the use of a technique
analogous to the wet-microcontraction process used in papermaking.
The water removal that occurs both during and after deflection
results in a decrease in fiber mobility in the embryonic web, which
tends to fix the fibers in place after they have been deflected and
rearranged.
[0145] The fifth step includes drying the intermediate web to form
the paper article of the invention. Any means known to one in the
papermaking art can be used to dry the intermediate web. For
example, flow-through dryers and Yankee dryers, alone and in
combination, are satisfactory. Optionally, a predryer can be
used.
[0146] Optionally, but preferably, the dried article is
foreshortened following the first step of the paper making process.
As used herein, "foreshortening" refers to the reduction in length
of a dry paper web which occurs when energy is applied to the dry
web to reduce the length of the web and to rearrange the fibers
with an accompanying disruption of fiber-fiber bonds.
Foreshortening can be accomplished in any of several well-known
ways, such as creping (i.e., adhering the dried web to a surface
and then removing it from that surface with a doctor blade). Other
techniques for foreshortening paper webs include subjecting the web
to compaction between a hard surface and a relatively elastic
surface, as described in U.S. Pat. Nos. 2,624,245, 3,011,545,
3,329,556, 3,359,156, and 3,630,837, each of which are incorporated
herein by reference, and microcreping, as described in U.S. Pat.
Nos. 3,260,778, 3,416,192, 3,426,405, and 4,090,385, each of which
are incorporated herein by reference.
EXAMPLE
Example 1
Preparation of Bio-Polyaminoamide Epichlorohydrin
[0147] About 225 g (2.18 mol) of bio-diethylenetriamine and 100
grams of water is placed in a 3-necked flask equipped with a
mechanical stirrer, thermometer, and condenser. To this is added
290 grams (2.0 mol) of bio-adipic acid. After the acid has
dissolved in the amine, the solution is heated to 185-200.degree.
C. and held there for 1.5 hours. Then, vacuum from a water pump is
applied to the flask during the period required for the contents of
the flask to cool to 140.degree. C. following which 430 grams of
water is added. The bio-polyamide solution contains 52.3% solids
and had an acid number of 2.1.
[0148] To 60 grams of this bio-polyamide solution in a round bottom
flask is added 225 grams of water. This solution is heated to
50.degree. C. and 12.5 grams of bio-epichlorohydrin is added
dropwise over a period of 11 minutes. The contents of the flask are
then heated to 60-70.degree. C. until it has attained a Gardner
viscosity of greater than E. Then 150 grams of water is added to
the product, and it is cooled to 25.degree. C. Eleven mL of 10% HCl
is then added to adjust the pH to 5.0. The product contains 9.0%
solids and has a Gardner viscosity of C-D.
Example 2
Handsheet Preparation
[0149] Northern softwood kraft (NSK) dry lap is repulped by soaking
in distilled water (25 bond dry grams (BDG) in about 500 mL of
water for 1 hour at ambient conditions). The slurry is added to a
Tappi beaker that contains about 1500 mL of tap water pretreated
with sodium thiosulfate antichlor (0.5 mL of a stock solution
containing 86 g/L Na.sub.2S.sub.2O.sub.3 required at 1 ppm
AvCl.sub.2). The pulp slurry disintegrates in about 10 minutes. The
slurry is then added to 17 L of dechlorinated tap water in a
proportioner. A weigh sheet is then formed using 2.543 L of
well-mixed slurry (1.3% consistency). This slurry is added to a
deckle box, which contains 54 mL of dechlorinated tap water (giving
0.04% consistency). Formation is effected via vacuum filtration
through a wire. The wet sheet is passed over a vacuum slit
(2.times.) and a drum dryer (3.times.). The proportioner pulp
consistency is then adjusted to 1.0%, based on the bone dry weight
of the sheet. The solution pH is adjusted as desired (e.g., pH 8)
in both the proportioner and the deckle box. The Pulp Filtration
Rate (PFR) is then measured by methods known to one skilled in the
art. A solution of polyaminoamide epichlorohydrin from Example 1
(69.57 g of a 0.2% solution based on solids) is added to the
proportioner and allowed to mix for about 5 minutes. The resulting
6 handsheets are placed in a 105.degree. C. oven for 5 min.
[0150] The handsheets are characterized by methods known to one
skilled in the art. Tensile strength is measured on 1''.times.4''
sections using a Model 1122 Instron controlled by a Hewlett-Packard
86B computer. Handsheet caliper is measured using a Thwing-Albert
VIR Electronic Thickness Tester. Wet burst is evaluated using a
Thwing-Albert Burst Tester. A 4'' square handsheet section is
soaked briefly in distilled water prior to obtaining wet burst
values. All handsheets are equilibrated in a constant
temperature-humidity room for 24 hours prior to testing.
[0151] Nitrogen levels in handsheets are determined by Kjeldahl
analysis performed at either Huffman Laboratories (Wheatridge,
Colo.) or Hazleton Laboratories (Madison, Wis.). The latter
typically provided "micro-Kjeldahl" analyses. Nitrogen levels are
related to the level of polyaminoamide epichlorohydrin from Example
1 by assuming an elemental nitrogen content of 12.8% in the
polyaminoamide epichlorohydrin.
[0152] A fully extended polymer of Example 1 monomer unit has an
estimated surface area of 50 .ANG..sup.2 (based on Pauling
interatomic distances). The maximum surface area for 0.01 g of
fully extended polymer from Example 1 is calculated according to
the following equation: 50 .ANG..sup.2.times.0.01 g/270
g/mol.times.1 m.sup.2/10.times.10.sup.20
.ANG..sup.2.times.6.02.times.10.sup.23 molecules/mole
m.sup.2/0.01g, which expresses the potential surface area coverage
of the polymer of Example 1 at 1% usage. One gram of unbeaten pulp
has a surface area of about 1 m.sup.2 accessible to a dye of
surface area 141 .ANG..sup.2. This increases to about 7 m.sup.2
upon beating to the point where tensile levels off (about pfr
10).
Example 3
Paper Preparation
[0153] A pilot scale papermaking machine is obtained. The headbox
is a fixed roof suction breast roll former and the Fourdinier wire
is 33 by 30 (filaments per centimeter) five-shed. The furnish
comprises 100% northern softwood Kraft pulp fibers with about 4
kilograms of the wet strength resin from Example 1 per 1000 kg bone
dry fibers. The deflection member is an endless belt and is formed
about a foraminous woven element made of polyester and having 17
(MD) by 18 (CD) filaments per centimeter in a simple (2S) weave.
Each filament is 0.18 mm in diameter; the fabric caliper is 0.42 mm
and it has an open area of about 47%. The deflection member is
about 1.1 mm thick. The blow-through predryer operates at a
temperature of about 93.degree. C. The Yankee drum dryer rotates
with a surface speed of about 244 meters (800 feet) per minute. The
paper web is wound on a reel at a surface speed of 195 meters (640
feet) per minute. The consistency of the embryonic web at the time
of transfer from the Fourdinier wire to the deflection member is
about 10%; and the consistency of the predried web at the time of
impression of the continuous network surface into the web by the
impression nip roll against the surface of the Yankee dryer is
between about 60% and about 70%. The imprinted web is adhered to
the surface of the Yankee dryer with polyvinyl alcohol adhesive and
is creped therefrom with a doctor blade having an 81.degree. angle
of impact.
[0154] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0155] Every document cited herein, including any cross referenced
or related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0156] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *