Pigmented size press and surface size for coated paper and paperboard

Abstract

A size press composition for paper or paperboard is provided, which includes: binder; pigment; synthetic surface sizing agent; and water; wherein the binder and pigment are present in a binder:pigment weight ratio of about 10:1 to about 1:10; and wherein the synthetic surface sizing is present in a synthetic surface sizing agent:(binder and pigment) weight ratio of about 2:100 to about 10:100.

1 . A size press composition for paper or paperboard, comprising:
 binder;   pigment;   synthetic surface sizing agent; and   water;   wherein the binder and pigment are present in a binder:pigment weight ratio of about 10:1 to about 1:10; and   wherein the synthetic surface sizing is present in a synthetic surface sizing agent:(binder and pigment) weight ratio of about 2:100 to about 10:100.   
     
     
         2 . The size press composition of  claim 1 , wherein the binder comprises one or more of natural product, casein, soy protein, fatty acid salts and copolymers, water soluble polymer, water soluble starch co-binder, polyvinyl alcohol, poly acrylic acid, poly acrylic acid salt, polyvinylpyrrolidone, polyethylene glycol, polyethylene oxide, polymer emulsion, acrylate, styrene acrylate, styrene butadiene, styrene acrylonitrile, polyurethane, polyvinyl acetate, polyethylene emulsion, polyethylene (PE) polymers; polyethylene terephthalate (PET) polymers; polyhydroxyalkanoate (PHA) polymers; polylactic acid (PLA) polymers; polyglycolic acid (PGA) polymers; polyvinyl acetate polymers; waxes; polyurethane polymers; or epoxy resins, starch, high-amylose corn starch, waxy corn starch, tapioca starch, cationic starch, ethylated starch, oxidized starch, corn starch, potato starch, rice starch, dent corn starch, waxy starch, modified starch, FilmKote™ by Ingredion, FilmKote 370™ by Ingredion (modified starch), Aquabloc™ by Aquasol, Aquabloc 403™ by Aquasol (starch), Flex Starch™ by Tate and Lyle, Clear-Cote 640™ by Tate and Lyle (waxy starch), PG270™ by Ingredion (ethylated starch), RAP 810™ by Trinseo (styrene acrylate), XU 31669 SB™ latex by Trinseo (styrene butadiene), XU 31695™ by Trinseo (styrene acrylonitrile), Polyco 3960™ by Dow (poly vinyl acetate), Polyco 2160 IPA™ by Dow (poly vinyl acetate), binder, Hypod 1001™ by Dow (polyethylene emulsion), Hypod 9105™ by Dow (polyethylene emulsion), or a combination thereof. 
     
     
         3 . The size press composition of  claim 1 , wherein the binder comprises one or more natural products such as casein, soy protein, and fatty acid salts and copolymers, water soluble polymers such as polyvinyl alcohol, poly acrylic acid and salts, polyvinylpyrrolidone, polyethylene glycol, polyethylene oxide, etc, and polymer emulsions such as acrylates, styrene acrylates, styrene butadienes, polyurethanes, polyvinyl acetates, polyethylene (PE) polymers; polyethylene terephthalate (PET) polymers; polyhydroxyalkanoate (PHA) polymers; polylactic acid (PLA) polymers; polyglycolic acid (PGA) polymers; polyvinyl acetate polymers; waxes; polyurethane polymers; or epoxy resins, and their copolymers and derivatives. 
     
     
         4 . The size press composition of  claim 1 , wherein the binder comprises a starch selected from the group consisting of high-amylose corn starch, waxy corn starch, tapioca starch, cationic starch, ethylated starch, oxidized starch, corn starch, potato starch, rice starch, dent corn starch, waxy starch, modified starch, FilmKote™ by Ingredion, FilmKote 370™ by Ingredion (modified starch), Aquabloc™ by Aquasol, Aquabloc 403™ by Aquasol (starch), Flex Starch™ by Tate and Lyle, Clear-Cote 640™ by Tate and Lyle (waxy starch), PG270™ by Ingredion (ethylated starch), and a combination thereof. 
     
     
         5 . The size press composition of  claim 1 , wherein the binder comprises a water-soluble polymer binder selected from the group consisting of starch binders, cellulosic binders, polyvinyl alcohol binders, polyacrylic acid binders, polymethacrylic acid binders, polyvinylamine binders, polyacrylamide binders, polyether binders, sulfonated polystyrene binders, carboxylated polystyrene binders, and a combination thereof. 
     
     
         6 . The size press composition of  claim 5 , wherein the water-soluble polymer binder is a starch binder. 
     
     
         7 . The size press composition of  claim 1 , wherein the binder comprises a polymer latex binder selected from the group consisting of styrene butadiene rubber latexes, acrylic polymer latexes, polyvinyl acetate latexes, styrene acrylic copolymer latexes, polyurethane latexes, starch/acrylic copolymer latexes, starch/styrene acrylic copolymer latexes, polyvinyl alcohol (PVOH)/styrene acrylic copolymer latexes, PVOH/acrylic copolymer latexes, and a combination thereof. 
     
     
         8 . The size press composition of  claim 7 , wherein the polymer latex binder is a styrene-acrylic latex binder. 
     
     
         9 . The size press composition of  claim 1 , wherein the binder is ethylated starch. 
     
     
         10 . The size press composition of  claim 1 , wherein the pigment is selected from the group consisting of ground calcium carbonate (GCC), precipitated calcium carbonate (PCC), clay, kaolin clay, talc, mica, calcium sulfate, absorbent plastic pigment particles, calcined clay pigment particles, titanium dioxide pigment particles, barium sulfate pigment particles, silica pigment particles, zeolite pigment particles, fumed silica pigment particles, alumina pigment particles, bentonite clay pigment particles, HC (Hydrocarb) 90™ by Omya (ground calcium carbonate), HC (Hydrocarb) 60™ by Omya (ground calcium carbonate), Hydrafine 90W™ by KaMin (clay), and a mixture thereof. 
     
     
         11 . The size press composition of  claim 1 , wherein the pigment is ground calcium carbonate (GCC). 
     
     
         12 . The size press composition of  claim 1 , wherein the synthetic surface sizing agent is selected from the group consisting of styrene maleic anhydride (SMA), alkyl ketene dimer (AKD), AKD (IP Size 2000)™ by Solenis (alkyl ketene dimer), Scripset 745™ by Solenis (styrene maleic anhydride), styrene acrylic emulsion (SAE), polymer emulsions with a surface energy of 50 dynes or less after drying, and a combination thereof. 
     
     
         13 . The size press composition of  claim 1 , wherein the synthetic surface sizing agent is styrene maleic anhydride (SMA). 
     
     
         14 . The size press composition of  claim 1 , wherein the synthetic surface sizing agent is Scripset™. 
     
     
         15 . The size press composition of  claim 1 , further comprising one or more water soluble salt. 
     
     
         16 . The size press composition of  claim 15 , wherein the water soluble salt is one or more of a multivalent cationic metal salt, an inorganic salt, an organic salt, or a combination thereof. 
     
     
         17 . The size press composition of  claim 15 , wherein the water soluble salt is one or more multivalent cationic metal salt, inorganic salt, organic salt, or combination thereof selected from the group consisting of calcium chloride, calcium acetate, calcium magnesium acetate, calcium nitrate, calcium hydroxide, magnesium chloride, magnesium sulfate, magnesium nitrate, magnesium sulfate, aluminum chloride, aluminum nitrate, aluminum chlorohydrate, aluminum sulfate, sodium aluminum sulfate, vanadium chloride, and a combination thereof. 
     
     
         18 . The size press composition of  claim 15 , wherein the water soluble salt is calcium chloride. 
     
     
         19 . The size press composition of  claim 15 , wherein the water soluble salt is a metal drying salt, multivalent metal drying salt, monovalent metal drying salt, or a combination thereof. 
     
     
         20 . The size press composition of  claim 19 , wherein the multivalent metal drying salt is selected from the group consisting of calcium chloride, calcium acetate, calcium hydroxide, calcium nitrate, calcium sulfate, calcium sulfite, magnesium chloride, magnesium acetate, magnesium nitrate, magnesium sulfate, magnesium sulfite, aluminum chloride, aluminum nitrate, aluminum sulfate, aluminum chlorohydrate, sodium aluminum sulfate, vanadium chloride, and a combination thereof. 
     
     
         21 . The size press composition of  claim 19 , wherein the monovalent metal drying salt is selected from the group consisting of sodium chloride, sodium acetate, sodium carbonate, sodium bicarbonate, sodium hydroxide, sodium silicates, sodium sulfate, sodium sulfite, sodium nitrate, sodium bromide, potassium chloride, potassium acetate, potassium carbonate, potassium bicarbonate, potassium hydroxide, potassium silicates, potassium sulfate, potassium sulfite, potassium nitrate, potassium bromide, lithium chloride, lithium acetate, lithium carbonate, lithium bicarbonate, lithium hydroxide, lithium silicates, lithium sulfate, lithium sulfite, lithium nitrate, lithium bromide, or a combination thereof. 
     
     
         22 . The size press composition of  claim 15 , wherein the water soluble salt is present in an amount of 3 to 30 parts by weight, based on the weight of the composition. 
     
     
         23 . The size press composition of  claim 15 , wherein the water soluble salt is present in an amount of 5 to 20 parts by weight, based on the weight of the composition. 
     
     
         24 . The size press composition of  claim 15 , wherein the water soluble salt is present in an amount such that the metal anion of the water soluble salt has the same equivalent weight as the calcium anion based on 3 to 30 parts by weight of calcium chloride, based on the weight of the composition. 
     
     
         25 . The size press composition of  claim 1 , which further comprises a % solids of about 10-30% solids by weight. 
     
     
         26 . The size press composition of  claim 1 , which further comprises a % solids of about 20-30% solids by weight. 
     
     
         27 . The size press composition of  claim 1 , wherein the binder and pigment are present in a binder:pigment weight ratio of about 4:1 to about 1:1. 
     
     
         28 . The size press composition of  claim 1 , wherein the synthetic surface sizing is present in a synthetic surface sizing agent:(binder and pigment) weight ratio of about 3:100 to about 6:100. 
     
     
         29 . A sized web, for paper or paperboard, comprising:
 a dried web comprising cellulosic fibers; and   the size press composition of  claim 1  on one or both sides of the dried web.   
     
     
         30 . A coated or uncoated paper or paperboard, comprising the sized web of  claim 29 . 
     
     
         31 . A paper or paperboard, comprising:
 a sized web, comprising:
 a dried web comprising cellulosic fibers; and 
 a size press composition on one or both sides of the dried web, the size press composition comprising:
 binder; 
 pigment; 
 synthetic surface sizing agent; and 
 substantially no water; 
 
   wherein the binder and pigment are present in a binder:pigment weight ratio of about 10:1 to about 1:10; and   wherein the synthetic surface sizing is present in a synthetic surface sizing agent:(binder and pigment) weight ratio of about 2:100 to about 10:100.   
     
     
         32 . The paper or paperboard of  claim 31 , which is uncoated. 
     
     
         33 . The paper or paperboard of  claim 31 , further comprising one or more coatings in contact with one or both sides of the sized web. 
     
     
         34 . The paper or paperboard of  claim 33 , wherein the one or more coatings are C1S (coated on one side), C2S (coated on both sides), coated C1S, or coated C2S. 
     
     
         35 . The paper or paperboard of  claim 31 , further comprising a base coat in contact with one or both sides of the sized web. 
     
     
         36 . The paper or paperboard of  claim 35 , wherein the base coat is a C1S or C2S coating in contact with sized web. 
     
     
         37 . The paper or paperboard of  claim 35 , further comprising a top coat in contact with the base coat on one or both sides of the sized web. 
     
     
         38 . The paper or paperboard of  claim 37 , wherein the top coat is a C1S or C2S coating. 
     
     
         39 . The paper or paperboard of  claim 31 , having a basis weight of from about 8 pt to about 30 pt. 
     
     
         40 . The paper or paperboard of  claim 31 , having a basis weight of from about 10 pt to about 24 pt. 
     
     
         41 . An article, comprising the paper or paperboard of  claim 31 . 
     
     
         42 . The article of  claim 41 , which is suitable for one or more of inkjet, flexo, gravure, or offset printing, or a combination of two or more thereof. 
     
     
         43 . The article of  claim 41 , which is selected from the group consisting of packaging, food service item, cup, plate, and a combination thereof. 
     
     
         44 . The article of  claim 41 , which has improved barrier properties, improved smoothness for flexo, gravure, and offset printing, or a combination thereof. 
     
     
         45 . A method, comprising contacting, on a papermaking machine:
 a dried web comprising cellulosic fibers; and   the size press composition of  claim 1 ;   to form a sized web.   
     
     
         46 . The method of  claim 45 , wherein the contacting is carried out at a size press selected from the group consisting of rod-metered size press, puddle size press, blade-metered size press, curtain coater size press, vertical size press, horizontal size press, metering size press, gated roll metering size press, doctor blade metering size press, and a combination thereof. 
     
     
         47 . The method of  claim 45 , wherein the contacting is carried out at a rod-metered size press. 
     
     
         48 . The method of  claim 45 , further comprising applying a base coat to one or both sides of the sized web, to form a coated paper or paperboard. 
     
     
         49 . The method of  claim 48 , wherein the base coat is applied from a base coat formulation comprising a standard pigment containing coating designed for flexo and offset printing, comprised of 10 to 20 parts latex binder and 100 parts pigment; a barrier coating containing a higher proportion of binder; or a specialty coating containing only latex. 
     
     
         50 . The method of  claim 49 , wherein the pigment comprises one or more of clay and calcium carbonate. 
     
     
         51 . The method of  claim 48 , further comprising applying a top coat to the base coat on one or both sides of the sized web, to form a coated paper or paperboard. 
     
     
         52 . The method of  claim 51 , wherein the top coat is applied from a top coat formulation comprising a standard pigment containing coating designed for flexo and offset printing, comprised of 10 to 20 parts latex binder and 100 parts pigment; a barrier coating containing a higher proportion of binder; or a specialty coating containing only latex. 
     
     
         53 . The method of  claim 52 , wherein the pigment comprises one or more of clay and calcium carbonate. 
     
     
         54 . The method of  claim 45 , further comprising one or more of drying, coating, or calendaring the sized web, or a combination of two or more thereof.