Paper Coating Formulation

Abstract

The present invention relates to a laminate comprising coated or uncoated paperboard coated with a film that comprises a polymeric binder, TiO.sub.2, and tetrapotassium pyrophosphate. Paper or paperboard coated with a film containing tetrapotassium pyrophosphate shows excellent optical properties.

Description

BACKGROUND OF THE INVENTION

[0001] The present invention relates to a pigmented paper coating with improved brightness.

[0002] Titanium dioxide (TiO.sub.2) is used as a pigment in paperboard coatings on darker substrates such as recycled board and unbleached Kraft board to improve the optical properties such as brightness, opacity, and appearance. In addition, TiO.sub.2 is used in lightweight coated paper to improve opacity, or in premium coated paper grades to improve the brightness and appearance. Motivated by the high cost of TiO.sub.2, papermakers are looking for ways to either reduce its usage or improve its efficiency or both.

[0003] In the absence of modifiers such as dispersants, TiO.sub.2 particles will crowd, leading to inefficient hiding. However, even with well dispersed TiO.sub.2 there can be crowding of TiO.sub.2 particles as the level of TiO.sub.2 is increased. Furthermore, it is known, for example, (2001 TAPPI Coating Conference Paper by Imerys on "Optimum Dispersion In Blade Coating Operations;" also, Chapter 3 on "Inorganic Salt Dispersants" in Practical Dispersion: A Guide to Understanding and Formulating Slurries by R. F. Conley, Wiley Press) that over-dispersing of a coating will cause pigment particles to flocculate, which can lead to an improvement in coating brightness on the order of 0.5 to 1.5 points. This improvement in brightness, however, is attributed to an increase in the porosity of the coating, which increases the amount of light scattering from air voids, and not to the increased efficiency of TiO.sub.2 dispersion in the coating. Furthermore, the brightness advantage realized from using high levels of dispersants is greatly reduced after calendaring to less than 1 point because the voids created upon the addition of the dispersant are removed during the calendaring process.

[0004] U.S. Pat. No. 8,043,476 discloses a paper or paperboard coating formulation with improved viscosity stability comprising a phosphate or phosphonate functionalized acrylic polymer binder, TiO.sub.2, and a polyphosphate dispersant. Although the phosphate or phosphonate functionality is known to enhance adsorptivity of the binder to the TiO.sub.2, thereby improving the efficiency of its usage, the presence of phosphates or phosphonates often adversely affect viscosity stability of the binder and water sensitivity of the coating. Moreover, latexes prepared with the commonly used phosphate monomer, phosphoethyl methacrylate (PEM), invariably contain impurities that are of concern to governmental regulatory agencies (e.g., the FDA) that regulate products that may come in contact with food. Accordingly, it would be an advance in the art of paper and paperboard coating formulations to design a coating with enhanced brightness that does not require the presence of phosphate and phosphonate functionalized binders.

SUMMARY OF THE INVENTION

[0005] The present invention addresses a need in the art by providing a laminate comprising coated or uncoated paperboard; and a 5- to 35-.mu.m thick layer of a film adhered to the coated or uncoated paper or paperboard; wherein the film comprises a) from 3 to 25 weight percent of a polymeric binder; b) from 5 to 35 weight percent TiO.sub.2; and c) from 0.05 to 2 weight percent tetrapotassium pyrophosphate; wherein the polymeric binder comprises vinyl acetate, vinyl-acrylic, styrene-acrylic, or styrene-butadiene polymer, and blends thereof; and wherein the weight percentages are all based on the weight of the film.

[0006] In another aspect, the present invention is a method comprising the step of applying a 5- to 35-.mu.m thick layer of a composition to paper or paperboard, wherein the composition comprises an aqueous dispersion of a) from 3 to 25 weight percent polymeric binder particles; b) from 5 to 35 weight percent TiO.sub.2; and c) from 0.05 to 2 weight percent of tetrapotassium pyrophosphate; wherein the polymeric binder particles comprise vinyl acetate, vinyl-acrylic, styrene-acrylic, or styrene-butadiene polymer particles, and blends thereof; and wherein the weight percentages are all based on the weight of total solids of the composition.

[0007] The potassium pyrophosphate containing film shows improved brightness with a variety of binders and grades of TiO.sub.2 as compared with films containing other ostensibly similar dispersants.

DETAILED DESCRIPTION OF THE INVENTION

[0008] The present invention addresses a need in the art by providing a laminate comprising coated or uncoated paperboard; and a 5- to 35-.mu.m thick layer of a film adhered to the coated or uncoated paper or paperboard; wherein the film comprises a) from 3 to 25 weight percent of a polymeric binder; b) from 5 to 35 weight percent TiO.sub.2; and c) from 0.05 to 2 weight percent tetrapotassium pyrophosphate; wherein the polymeric binder comprises vinyl acetate, vinyl-acrylic, styrene-acrylic, or styrene-butadiene polymer, and blends thereof; and wherein the weight percentages are all based on the weight of the film.

[0009] Preferably, the weight percent of the binder, based on the weight of total solids of the composition, is from 5 to 25 weight percent. The binder may contain up to 8 weight percent phosphate or phosphonate groups but preferably comprises a substantial absence of these groups. As used herein, the term "substantial absence of phosphate or phosphonate groups" means that the binder particles contain, based on the weight of the binder, less than 0.05 weight percent, preferably less than 0.01 weight percent, more preferably less than 0.001 weight percent, and most preferably 0 weight percent phosphate and phosphonate groups.

[0010] The aqueous composition preferably comprises from 5 to 25 weight percent, more preferably to 20 weight percent, and most preferably to 15 weight percent TiO.sub.2, based on the weight of total solids of the composition; the TiO.sub.2 can be rutile or anatase TiO.sub.2 and may be untreated, or treated with inorganic silica or alumina or zirconia or a combination thereof.

[0011] The tetrapotassium pyrophosphate is preferably present in the composition at 0.1 to 0.8 weight percent, based on the weight of the composition.

[0012] The composition of the present invention advantageously includes other additives including auxiliary pigments, such as clays and calcium carbonate; rheology modifiers; hollow sphere pigments, such as ROPAQUE.TM. AF-1055 Hollow Sphere Pigment (A Trademark of The Dow Chemical Company or its Affiliates); natural binders, such as proteins and starch; optical brightening agents; lubricants; antifoamers; crosslinkers; and other dispersants, such as polyacrylic acid based dispersant. The particle size of auxiliary pigments useful for the composition of the present invention is preferably finer than 2 .mu.m, more preferably 80% to 100% by weight finer than 2 .mu.m, as measured using Sedigraph. This preferred size range is considerably smaller than what is typically used in paint formulations.

[0013] The film thickness is preferably in the range of from 5 .mu.m, more preferably from 10 .mu.m, to 35 .mu.m, more preferably to 20 .mu.m, which is about one-third to one-tenth the film thickness of typical paint coatings.

[0014] In a second aspect, the present invention is a method comprising the step of applying a 5- to 35-.mu.m thick layer of a composition to paper or paperboard, wherein the composition comprises an aqueous dispersion of a) from 3 to 25 weight percent polymeric binder particles; b) from 5 to 35 weight percent TiO.sub.2; and c) from 0.05 to 2 weight percent of tetrapotassium pyrophosphate; wherein the polymeric binder particles comprise vinyl acetate, vinyl-acrylic, styrene-acrylic, or styrene-butadiene polymer particles, and blends thereof; and wherein the weight percentages are all based on the weight of total solids of the composition. The binder particles preferably have a volume average particle size in the range of from 50 nm, more preferably from 80 nm, to 500 nm, more preferably to 300 nm.

[0015] It has surprisingly been discovered that the laminate of the present invention imparts brightness to the paper or paperboard without additional loadings of TiO.sub.2, and preferably using binder that contains a substantial absence or complete absence of phosphate and phosphonate groups. Moreover, as the following examples demonstrate, it has surprisingly been discovered that paper or paperboard coated with pigmented films containing TKPP consistently provide superior brightness compared to films containing ostensibly similar dispersants (TSPP or KTPP). This trend of superiority was generally observed across a variety of binders and TiO.sub.2 types.

Abbreviations

TABLE-US-00001 [0016] Product Name Abbreviation Kaomax Clay Clay RPS Vantage TiO.sub.2 RPS TiO.sub.2 Kronos 2063 TiO.sub.2 2063 TiO.sub.2 Ti-Pure R-746 TiO.sub.2 R-746 TiO.sub.2 POLYCO .TM. 3960 Vinyl Acrylic Vinyl Acrylic Latex latex RHOPLEX .TM. NW-1715K Styrene Acrylic Styrene Acrylic Latex latex RHOPLEX .TM. RM-232D RM-232D HASE Rheology Modifier ROPAQUE .TM. AF-1055 AF-1055 Hollow Sphere Pigment Tetrasodium Pyrophosphate TSPP Tetrapotassium Pyrophosphate TKPP Potassium Tripolyphosphate KTPP

POLYCO, RHOPLEX, and ACUMER are all Trademarks of The Dow Chemical Company or its Affiliates.

EXAMPLES

Example 1

Preparation of Coating with Vinyl Acrylic Latex and TKPP

[0017] RPS TiO.sub.2 (10.5 parts by weight, 70.58% solids) was added to Clay (89.5 parts by weight, 68.24% solids), followed by addition of Vinyl Acrylic Latex (20 parts by weight, 49.8% solids), then TKPP (0.3 parts by weight, 5% solids). Additional DI water was added to adjust percent solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of RM-232D (0.6 parts by weight, 28.27% solids).

Comparative Example 1

Preparation of Vinyl Acrylic Latex Coating without Dispersant

[0018] RPS TiO.sub.2 (10.5 parts by weight, 70.58% solids) was added to Clay (89.5 parts by weight, 68.24% solids), followed by addition of Vinyl Acrylic Latex (20 parts by weight, 49.8% solids). Additional DI water was added to adjust percent solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition RM-232D (0.6 parts by weight, 28.27% solids).

Comparative Example 2

Preparation of Vinyl Acrylic Latex Coating with TSPP

[0019] The method of Example 1 was used except that TSPP (0.3 parts by weight, 5% solids) was used as the dispersant instead of TKPP.

Comparative Example 3

Preparation of Vinyl Acrylic Latex Coating with KTPP

[0020] The method of Example 1 was used except that KTPP (0.3 parts by weight, 5% solids) was used as the dispersant instead of TKPP.

Example 2

Preparation of Coating with Styrene Acrylic Latex and TKPP

[0021] RPS TiO.sub.2 (10.5 parts by weight, 70.58% solids) was added to Clay (89.5 parts by weight, 68.24% solids), followed by the addition of Styrene Acrylic Latex (20 parts by weight, 46.5% solids), then TKPP (0.8 parts by weight, 5% solids). Additional DI water was added to adjust solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of RM-232D (0.2 parts by weight, 28.27% solids).

Comparative Example 4

Preparation of Styrene Acrylic Latex Coating without Dispersant

[0022] RPS TiO.sub.2 (10.5 parts by weight, 70.58% solids) was added to Clay (89.5 parts by weight, 68.24% solids), followed by addition of Styrene Acrylic Latex (20 parts by weight, 46.5% solids). Additional DI water was added to adjust solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of 0.2 parts of RM-232D (28.27% solids).

Comparative Example 5

Preparation of Styrene Acrylic Latex Coating with TSPP

[0023] The method of Example 2 was used except that TSPP (0.8 parts by weight, 5% solids) was used as the dispersant instead of TKPP.

Comparative Example 6

Preparation of Styrene Acrylic Latex Coating with KTPP

[0024] The method of Example 2 was used except that KTPP (0.8 parts by weight, 5% solids) was used as the dispersant instead of TKPP.

[0025] Example 3 and Comparative Examples 7-9 use the Vinyl Acrylic Latex binder with the 2063 TiO.sub.2 which has a lower purity of TiO.sub.2 and a higher concentration of inorganic alumina surface treatment compared to the RPS TiO.sub.2.

Example 3

Preparation of Coating with Vinyl Acrylic Latex, 2063 TiO.sub.2, and TKPP

[0026] 2063 TiO.sub.2 (10.5 parts by weight, 77.8% solids) was added to Clay (89.5 parts by weight, 68.24% solids), followed by addition of Vinyl Acrylic Latex (20 parts by weight, 49.8% solids), then TKPP (0.3 parts by weight, 5% solids). Additional DI water was added to adjust percent solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of RM-232D (0.6 parts by weight, 28.27% solids).

Comparative Example 7

Preparation of Vinyl Acrylic Latex and RPS TiO.sub.2 Coating without Dispersant

[0027] 2063 TiO.sub.2 (10.5 parts by weight, 77.8% solids) was added to Clay (89.5 parts by weight, 68.24% solids), followed by addition of Vinyl Acrylic Latex (20 parts by weight, 49.8% solids. Additional DI water was added to adjust percent solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of RM-232D (0.6 parts by weight, 28.27% solids).

Comparative Example 8

Preparation of Coating with Vinyl Acrylic Latex, 2063 TiO.sub.2, and TSPP

[0028] The method of Example 3 was used except that TSPP (0.3 parts by weight, 5% solids) was used as the dispersant instead of TKPP dispersant.

Comparative Example 9

Preparation of Coating with Vinyl Acrylic Latex, 2063 TiO.sub.2, and KTPP

[0029] The method of Example 3 was used except that KTPP (0.3 parts by weight, 5% solids) was used as the dispersant instead of TKPP dispersant.

[0030] Example 4 and Comparative Examples 10-12 use the Vinyl Acrylic Latex binder with R-746 TiO.sub.2, which is an alumina- and silica-surface treated TiO.sub.2 of reduced purity compared to RPS TiO.sub.2.

Example 4

Preparation of Coating with Vinyl Acrylic Latex, R-746 TiO.sub.2, and TKPP

[0031] R-746 TiO.sub.2 (10.5 parts by weight, 76.81% solids) was added to Clay (89.5 parts by weight, 68.24% solids), followed by addition of Vinyl Acrylic Latex (20 parts by weight, 49.8% solids), then TKPP (0.3 parts by weight, 5% solids). Additional DI water was added to adjust percent solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of RM-232D (0.6 parts by weight, 28.27% solids).

Comparative Example 10

Preparation of Vinyl Acrylic Latex and R-746 TiO.sub.2 Coating without Dispersant

[0032] R-746 TiO.sub.2 (10.5 parts by weight, 76.81% solids) was added to Clay (89.5 parts by weight, 68.24% solids), followed by addition of Vinyl Acrylic Latex (20 parts by weight, 49.8% solids). Additional DI water was added to adjust percent solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of RM-232D (0.6 parts by weight, 28.27% solids).

Comparative Example 11

Preparation of Coating with Vinyl Acrylic Latex, R-746 TiO.sub.2, and TSPP

[0033] The method of Example 4 was used except that TSPP (0.3 parts by weight, 5% solids) was used as the dispersant instead of TKPP dispersant.

Comparative Example 12

Preparation of Coating with Vinyl Acrylic Latex, R-746 TiO.sub.2, and KTPP

[0034] The method of Example 4 was used except that KTPP (0.3 parts by weight, 5% solids) was used as the dispersant instead of TKPP dispersant.

Example 5

Preparation of Coating with RPS Ti0.sub.2, AF-1055, and TKPP

[0035] RPS TiO.sub.2 (9 parts by weight, 70.58% solids) and AF-1055 (2.16 parts by weight, 26.61% solids) were added to Clay (88.6 parts by weight, 68.24% solids), followed by addition of Vinyl Acrylic Latex (20 parts by weight, 49.8% solids), then TKPP (0.24 parts by weight, 5% solids). Additional DI water was added to adjust percent solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of RM-232D (0.6 parts by weight, 28.27% solids).

Comparative Example 13

Preparation of Coating with RPS TiO.sub.2 and AF-1055 without Dispersant

[0036] RPS TiO.sub.2 (9 parts by weight, 70.58% solids) and AF-1055 (2.4 parts by weight, 26.61% solids) were added to Clay (88.6 parts by weight, 68.24% solids), followed by addition of Vinyl Acrylic Latex (20 parts by weight, 49.8% solids). Additional DI water was added to adjust percent solids to 45%. The pH was then adjusted to 8-8.5 with NaOH followed by addition of RM-232D (0.6 parts by weight, 28.27% solids).

Preparation of Coated Samples

[0037] The coatings were manually applied to a Leneta paint scrub panel substrate using a wire wound rod #12 and then were dried at 83.degree. C. for 3 min. Brightness measurements were performed using Technidyne Micro S-5 Brightmeter. Brightness calibration was done using a standard (84.7 brightness reading) before measurements. Five measurements per sample were recorded and the median values reported in Table 1. The brightness data for Examples 1-2 and Comparative Examples 1-6 (C1-C6) are shown in Table 1:

TABLE-US-00002 TABLE 1 Brightness Comparison for Coatings Containing RPS Vantage TiO.sub.2 and Vinyl Acrylic Latex (VA) or Styrene Acrylic Latex (SA) Ex. # 1 C1 C2 C3 2 C4 C5 C6 Binder VA VA VA VA SA SA SA SA Dispersant TKPP None TSPP KTPP TKPP None TSPP KTPP B.sub.Med 65.1 59.4 63.4 65.4 66.1 59.7 63.1 64.5 stdev 0.3 0.3 0.7 0.3 0.3 0.4 0.2 0.3

[0038] The results show that the films containing TKPP (Examples 1 and 2) exhibits superior brightness as compared with the films containing TSPP (C2 and C5); the results further show that TKPP is better than KTPP for the styrene acrylate binder. The TKPP coatings (Ex 1 and 2) show about 5-6 point improvement in brightness compared to the coating with no dispersant (C1 and C4) while the TSPP coatings show only about a 3-4 point improvement in brightness.

[0039] To compare the effects of a modified TiO.sub.2 on the performance of the coating, coated substrates were prepared using two types of surface treated TiO.sub.2: an alumina treated TiO.sub.2 (2063) and a silica and alumina treated TiO.sub.2 (R 746). 2063 TiO.sub.2 based coatings were made with a) TKPP (Example 3); b) no dispersant (C7); c) TSPP (C8); and d) KTPP (C9). R-746 TiO.sub.2 based coatings were made with a) TKPP (Example 4); b) no dispersant (C10); c) TSPP (C11); and d) KTPP (C12).The results are summarized in Table 2.

TABLE-US-00003 TABLE 2 Brightness Comparisons for Coatings with VA and 2063 TiO.sub.2 or R-746 TiO.sub.2 Ex. # 3 C7 C8 C9 4 C10 C11 C12 TiO.sub.2 type 2063 2063 2063 2063 R-746 R-746 R-746 R-746 Dispersant TKPP None TSPP KTPP TKPP None TSPP KTPP B.sub.med 67.9 65.1 65.4 66.6 66.6 62.7 65.3 65.5 stdev 0.3 0.2 0.3 0.5 0.6 0.5 0.3 0.4

[0040] The data show that the film containing TKPP dispersant and alumina-treated TiO.sub.2 (2063) (Example 3) exhibits brightness superior to the comparative films. The film containing TSPP (C8) exhibits no improvement in brightness compared to the film with no dispersant (C7), while the film containing KTPP (C9) exhibits about a 1 point increase in brightness. By comparison the TKPP film exhibits about a 3 point increase in brightness with this alumina-modified TiO.sub.2.

[0041] A similar trend is observed in alumina and silica surface treated TiO.sub.2 (R-746) where the film containing TKPP shows brightness superior to the comparative films. The film containing TKPP dispersant (Example 4) shows about a 4 point increase in brightness compared to the film with no dispersant (C10). By comparison, the films containing TSPP (C11) and KTPP (C12) show about a 3 point increase in brightness.

[0042] To compare the effects of TKPP in films containing TiO.sub.2 and hollow spherical pigment, two coatings were prepared: a) a coating containing RPS TiO.sub.2, AF-1055 and TKPP (Example 5) and b) a coating containing RPS TiO.sub.2 and AF-1055 (C13). The results in Table 3 indicate a superior brightness performance of coatings containing TKPP (Example 3) over the coatings without TKPP (C13). Specifically, the film containing TKPP exhibits a brightness increase of about 4 points over the film without TKPP.

TABLE-US-00004 TABLE 3 Brightness Comparison for Coatings Containing Hollow Spherical Pigment AF-1055 with and without TKPP Ex. # 5 C13 Hollow sphere pigment type AF-1055 AF-1055 Dispersant TKPP None B.sub.med 65.3 61.3 stdev 0.5 0.3

[0043] It has surprisingly been discovered that paper or paperboard coated with pigmented films containing TKPP consistently provided superior brightness compared to films containing ostensibly similar dispersants. This trend of marked superiority was generally observed across a variety of binders and TiO.sub.2.

Claims

1. A laminate comprising coated or uncoated paperboard; and a 5- to 35-.mu.m thick layer of a film adhered to the coated or uncoated paper or paperboard; wherein the film comprises a) from 3 to 25 weight percent of a polymeric binder; b) from 5 to 35 weight percent TiO.sub.2; and c) from 0.05 to 2 weight percent tetrapotassium pyrophosphate; wherein the polymeric binder comprises vinyl acetate, vinyl-acrylic, styrene-acrylic, or styrene-butadiene polymer, and blends thereof; and wherein the weight percentages are all based on the weight of the film.

2. The laminate of claim 1 wherein the polymeric binder contains less than 0.05 weight percent of phosphate and phosphonate groups, based on the weight of the binder.

3. The laminate of claim 2 wherein the concentration of tetrapotassium pyrophosphate is from 0.1 to 0.8 weight percent, based on the weight of total solids in the film.

4. The laminate of Claim 1 wherein the film further includes a clay or calcium carbonate or both.

5. The laminate of claim 1 wherein the binder is a vinyl acetate polymer.

6. The laminate of claim 1 wherein the binder is a styrene-acrylic polymer.

7. The laminate of claim 1 wherein the binder is a styrene-butadiene.

8. The laminate of claim 1 wherein the film comprises one or more additives selected from the group consisting of rheology modifiers; hollow sphere pigments; natural binders; optical brightening agents; lubricants; antifoamers; crosslinkers; and polyacrylic acid.

9. A method comprising the step of applying a 5- to 35-.mu.m thick layer of a composition to paper or paperboard, wherein the composition comprises an aqueous dispersion of a) from 3 to 25 weight percent polymeric binder particles; b) from 5 to 35 weight percent TiO.sub.2; and c) from 0.05 to 2 weight percent of tetrapotassium pyrophosphate; wherein the polymeric binder particles comprise vinyl acetate, vinyl-acrylic, styrene-acrylic, or styrene-butadiene polymer particles and blends thereof; and wherein the weight percentages are all based on the weight of total solids of the composition.