Paper coating composition containing high starch levels

Abstract

Described herein is coating starch composition comprising a starch and a plasticizer, as well as a paper coating composition comprising said coating starch composition, where the paper coating composition contains at least 2% starch, a dry solids content of at least 40%, and a viscosity of less than about 1200 cPs, as well as methods of using and making such compositions, such as, for example, in paper manufacturing processes.

1 . A coating starch composition comprising a starch and a plasticizer, wherein said composition has a starch and plasticizer solids level of at least 40% dry solids basis. 
     
     
         2 . The coating starch composition of  claim 1 , wherein said composition contains 1 part of a starch for each 1, 1.5, 2, 2.5, 3, 3.5, or 4 parts of a plasticizer. 
     
     
         3 . The coating composition of  claim 1 , where said plasticizer is a non-carbohydrate derived plasticizer, a carbohydrate derived plasticizer, or a mixture thereof. 
     
     
         4 . The coating composition of  claim 3 , where said non-carbohydrate derived plasticizer is selected from urea, glycerin/glycerol, formamide, citric acid or other carboxylic acids, ethylene glycol, and a mixture of any two or more of the foregoing. 
     
     
         5 . The coating composition of  claim 3 , where said carbohydrate derived plasticizer is (i) a sugar; (ii) a sucrose, a starch derived syrup, a maltodextrin, a dextrin, a sugar alcohol, or a mixture of any two or more of the foregoing; (iii) a starch derived syrup selected from a corn syrup, a low sugar syrup, dextrose, or a mixture of any two or more of the foregoing; (iv) a maltose corn syrup or a high fructose corn syrup; or (v) a sorbitol. 
     
     
         6 . The coating composition of  claim 5 , wherein said starch derived syrup has a dextrose equivalency of about 20 to about 90, about 20 to about 100, about 40 to about 75, about 40 to about 70, about 40 to about 44, about 49 to about 55, about 53 or 53. 
     
     
         7 . The coating starch composition of  claim 1 , wherein said plasticizer is a corn syrup selected from maltose corn syrup, high fructose corn syrup, and a mixture thereof. 
     
     
         8 . The coating starch composition of  claim 1 , wherein the starch is a modified starch selected from a nonionic starch, an anionic starch, an amphoteric starch, an etherified starch, an acetylated starch, a sulfonated starch, and a mixture of any two or more of the foregoing:
 optionally, wherein the starch is selected from corn starch, dent corn starch, waxy corn starch, wheat starch, potato starch, tapioca starch, pea starch, sorghum starch, manioc starch, sago starch, rice starch, and a mixture of any two or more of the foregoing.   
     
     
         9 . (canceled) 
     
     
         10 . A paper coating composition comprising the coating starch composition of  claim 1 , wherein said composition contains at least about 2%, from about 2% to about 30%, from about 2% to about 25%, from about 2% to about 22%, or from about 2% to about 10% starch. 
     
     
         11 . The paper coating composition of  claim 10 , wherein the composition has (i) a viscosity of less than 1200 cPs, about 100 to about 1200 cPs, about 200 to about 1200 cPs, or about 300 to about 600 cPs and a solids content of at least 40%, 45%, 50%, 55%, 60%, 65% or 70% dry solids basis, or (ii) a viscosity of about 300 to about 600 cPs and a solids content of at least 60% dry solids basis; and, optionally, wherein the viscosity is measured on a Brookfield Viscometer at 20 rpm at 18.3° C. 
     
     
         12 . The paper coating composition of  claim 10 , wherein said composition contains from 2 to 20 parts of the starch and from 5 to 35 parts of the plasticizer, from 2 to 10 parts of the starch and from 5 to 25 parts of the plasticizer, or 10 parts of the starch and 25 parts of the plasticizer. 
     
     
         13 . The paper coating composition of  claim 10 , wherein said composition further comprises (i) a pigment, a latex, or a mixture thereof; or (ii) about 100 parts pigment and about 10 to about 25 parts latex. 
     
     
         14 . A method of manufacturing a dry-finished, coated paper or paperboard product comprising applying the paper coating composition of  claim 10  to at least one side of a paper or paperboard; and obtaining a dry finished, coated paper or paperboard. 
     
     
         15 . The method of  claim 14 , wherein no starch is applied to the paper or paperboard prior to or after the application of the paper coating composition. 
     
     
         16 . The method of  claim 14 , with the proviso that the method does not comprise a wet stack calendering step prior to applying the paper coating composition. 
     
     
         17 . The method of  claim 14 , wherein the coating composition is applied to the paper or paperboard at a coater. 
     
     
         18 . A dry-finished, coated paper or paperboard product produced from the method of  claim 14 . 
     
     
         19 . The dry-finished, coated paper or paperboard product of  claim 18 , wherein the dry-finished paper or paperboard is characterized by a surface strength equivalent to that of a wet-finished paper or paperboard product as measured by an IGT pick and blister test. 
     
     
         20 . The dry-finished, coated paper or paperboard product of  claim 19 , wherein the dry-finished paper or paperboard is characterized by an IGT average increase of at least 50%, 55%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, or 70% as compared to a dry-finished paper or paperboard product coated with a standard coating. 
     
     
         21 . A paper substrate comprising, on at least one surface, the paper coating composition of  claim 10 .