Filler compositions comprising microfibrillated cellulose and microporous inorganic particulate material composites for paper and paperboard applications with improved mechanical properties

Abstract

Method of making a filler composition comprising microfibrillated cellulose and one or more microporous inorganic particulate material and methods of making papermaking furnishes and paper products comprising microfibrillated cellulose and one or more microporous inorganic particulate material.

1 - 120 . (canceled) 
     
     
         121 . A paper or paperboard filler composition comprising microfibrillated cellulose (MFC) and one or more microporous inorganic particulate material for addition to a papermaking furnish for the manufacture of paper or paperboard, wherein the MFC and the one or more microporous inorganic particulate material impart mechanical properties to the paper or paperboard that are improved compared to paper and paperboard products made from an identical papermaking furnish not containing MFC and the one or more microporous inorganic particulate material. 
     
     
         122 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material is selected from the group consisting of: calcined clay, kaolin, kaolinite, amorphous aluminum silicates, Scalenohedral precipitated calcium carbonate, aragonite precipitated calcium carbonate, chemically aggregated filler materials, diatomaceous earth, and milled expanded perlite. 
     
     
         123 . The filler composition according to  claim 121 , wherein the microporous inorganic material comprises calcined clay. 
     
     
         124 . The filler composition according to  claim 121 , wherein the microporous inorganic material comprises kaolin. 
     
     
         125 . The filler composition according to  claim 121 , wherein the microporous inorganic material comprises kaolinite. 
     
     
         126 . The filler composition according to  claim 121 , wherein the microporous inorganic material comprises calcined clay. 
     
     
         127 . The filler composition according to  claim 121 , wherein the microporous inorganic material comprises amorphous aluminum silicates. 
     
     
         128 . The filler composition according to  claim 121 , wherein the microporous inorganic material comprises Scalenohedral precipitated calcium carbonate. 
     
     
         129 . The filler composition according to  claim 121 , wherein the microporous inorganic particulate material comprises at least two microporous inorganic particulate material selected from the group consisting of: calcined clay, kaolin, kaolinite, amorphous aluminum silicates, Scalenohedral precipitated calcium chloride, aragonite precipitated calcium carbonate, chemically aggregated filler materials, diatomaceous earth, and milled expanded perlite. 
     
     
         130 . The filler composition according to  claim 121 , wherein the papermaking furnish comprises one or more pulp selected from softwood pulps. 
     
     
         131 . The filler composition according to  claim 130 , wherein the softwood pulp is selected from the group consisting of: spruce, pine, fir, larch and hemlock and mixed softwood pulps. 
     
     
         132 . The filler composition according to  claim 121 , wherein the papermaking furnish comprises one or more pulp selected from hardwood pulps. 
     
     
         133 . The filler composition according to  claim 132 , wherein the hardwood pulp is selected from the group consisting of: eucalyptus, aspen and birch, and mixed hardwood pulps. 
     
     
         134 . The filler composition according to  claim 121 , wherein the pulp source for the papermaking furnish is selected from the group consisting of: eucalyptus pulp, spruce pulp, pine pulp, beech pulp, hemp pulp, acacia, cotton pulp, and mixtures thereof. 
     
     
         135 . The filler composition according to  claim 121 , wherein the pulp source for the papermaking furnish is selected from the group consisting of: Nordic Pine, Black Spruce, Radiata Pine, Southern Pine, Enzyme-Treated Nordic Pine, Douglas Fir, Dissolving Pulp, Birch, Eucalyptus, Acacia, Mixed European Hardwood, Mixed Thai Hardwood, Tissue Dust, Cotton, Abaca, Sisal, Bagasse, Kenaf, Miscanthus, Sorghum, Giant Reed and Flax. 
     
     
         136 . The filler composition of  claim 121 , wherein the mechanical property is selected from one or more of Tensile Strength, Tensile Elongation, Bulk, Tensile Stiffness, Bending Stiffness, Porosity, Burst and Tear Strength, and Tensile Strength in the ‘Z’ direction. 
     
     
         137 . The filler composition according to  claim 121 , wherein the microfibrillated cellulose has a modal fibre particle size ranging from about 0.1 μm-500 μm. 
     
     
         138 . The method according to  claim 121 , wherein the one or more microporous inorganic particulate material has a median particle size (d 50 ) ranging from about 3 μm to about 50 μm. 
     
     
         139 . The method according to  claim 121 , wherein the one or more microporous inorganic particulate material has a median particle size (d 50 ) ranging from about 3 μm to about 6 μm. 
     
     
         140 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material and microfibrillated cellulose composite may be associated with one or more dispersing agents selected from the group consisting of: homopolymers or copolymers of polycarboxylic acids and/or their salts or derivatives, esters based on, acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid; acryl amide or acrylic esters, methylmethacrylate, or mixtures thereof; alkali polyphosphates, phosphonic-, citric- and tartaric acids and the salts or esters thereof, and mixtures thereof. 
     
     
         141 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material and microfibrillated cellulose composite is provided in the form of a powder. 
     
     
         142 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material and microfibrillated cellulose composite is provided in the form of a suspension. 
     
     
         143 . The filler composition according to  claim 142 , wherein the suspension is an aqueous suspension. 
     
     
         144 . The filler composition according to  claim 143 , wherein the aqueous suspension is a pumpable liquid. 
     
     
         145 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material comprises a blend of a first and second microporous inorganic particulate material, wherein the ratio of the first microporous inorganic particulate material to the second microporous inorganic particulate material may range from about 10:90 to about 90:10 by weight. 
     
     
         146 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material comprises a blend of a first and second microporous inorganic particulate material, wherein the ratio of the first microporous inorganic particulate material to the second microporous inorganic particulate material may range from about 20:80 to about 80:20 by weight. 
     
     
         147 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material comprises a blend of a first and second microporous inorganic particulate material, wherein the ratio of the first microporous inorganic particulate material to the second microporous inorganic particulate material may range from about 25:75 to about 75:25 by weight. 
     
     
         148 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material comprises a blend of a first and second microporous inorganic particulate material, wherein the ratio of the first microporous inorganic particulate material to the second microporous inorganic particulate material may range from about 40:60 to about 60:40 by weight. 
     
     
         149 . The filler composition according to  claim 121 , wherein the one or more microporous inorganic particulate material, comprises a blend of a first and second microporous inorganic particulate material, wherein the ratio of the first inorganic particulate material to the second inorganic particulate material is about 50:50 by weight. 
     
     
         150 . The filler composition according to  claim 121 , further comprising a binder. 
     
     
         151 . The filler composition according to  claim 150 , wherein the binder is an inorganic or organic binder. 
     
     
         152 . The filler composition according to  claim 151 , wherein the binder is an alkali metal silicate. 
     
     
         153 . The filler composition according to  claim 152 , wherein the alkali metal silicate is sodium silicate. 
     
     
         154 . The filler composition according to  claim 152 , wherein the alkali metal silicate is potassium silicate. 
     
     
         155 . The filler composition according to  claim 121 , wherein the weight ratio of microfibrillated cellulose to the one or more microporous inorganic particulate material on a dry weight basis is from about 1:5 to about 5:1. 
     
     
         156 . The filler composition according to  claim 121 , wherein the total content of the one or more microporous inorganic particulate material is present in an amount of from about 10 wt-% to about 95 wt-% on a dry weight basis of the filler composition. 
     
     
         157 . A method of making a paper or paperboard with improved mechanical properties, the method comprising the steps of: preparing a papermaking furnish for production of paper or paperboard; adding one or more microporous inorganic particulate material to the papermaking furnish; adding microfibrillated cellulose (MFC) to the papermaking furnish; wherein the MFC and the one or more microporous inorganic particulate material are added separately to the papermaking furnish or as a filler composition comprising the MFC and the one or more microporous inorganic particulate material; manufacturing the paper or paperboard from the papermaking furnish by dewatering and drying the papermaking furnish; wherein the MFC and the one or more microporous inorganic particulate materials impart mechanical properties to the paper or paperboard that are improved compared to paper and paperboard products made from an identical papermaking furnish not containing MFC and microporous inorganic particulate material. 
     
     
         158 . The method according to  claim 157 , wherein the one or more microporous inorganic particulate material is selected from the group consisting of: calcined clay, kaolin, kaolinite, amorphous aluminum silicates, Scalenohedral precipitated calcium chloride, aragonite precipitated calcium carbonate, chemically aggregated filler materials, diatomaceous earth, milled expanded perlite, and mixtures thereof. 
     
     
         159 . The method according to  claim 157 , wherein the microporous inorganic material comprises calcined clay. 
     
     
         160 . The method according to  claim 157 , wherein the microporous inorganic material comprises kaolin. 
     
     
         161 . The method according to  claim 157 , wherein the microporous inorganic material comprises kaolinite. 
     
     
         162 . The method according to  claim 157 , wherein the microporous inorganic material comprises calcined clay. 
     
     
         163 . The method according to  claim 157 , wherein the microporous inorganic material comprises amorphous aluminum silicates. 
     
     
         164 . The method according to  claim 157 , wherein the microporous inorganic material comprises Scalenohedral precipitated calcium carbonate. 
     
     
         165 . The method according to  claim 157 , wherein the microporous inorganic particulate material comprises at least two of calcined clay, kaolin, kaolinite, amorphous aluminum silicates, Scalenohedral precipitated calcium chloride, aragonite precipitated calcium carbonate, chemically aggregated filler materials, diatomaceous earth, milled expanded perlite and mixtures thereof. 
     
     
         166 . The method according to  claim 157 , wherein the papermaking furnish comprises one or more pulp selected from softwood pulps. 
     
     
         167 . The method according to  claim 166 , wherein the softwood pulp is selected from the group consisting of: spruce, pine, fir, larch and hemlock and mixed softwood pulps. 
     
     
         168 . The method according to  claim 157 , wherein the papermaking furnish comprises one or more pulp selected from hardwood pulps. 
     
     
         169 . The method according to  claim 168 , wherein the hardwood pulp is selected from the group consisting of: eucalyptus, aspen and birch, and mixed hardwood pulps. 
     
     
         170 . The method according  claim 157 , wherein the pulp source for the papermaking furnish is selected from the group consisting of: eucalyptus pulp, spruce pulp, pine pulp, beech pulp, hemp pulp, acacia, cotton pulp, and mixtures thereof. 
     
     
         171 . The method according to  claim 157 , wherein the pulp source for the papermaking furnish is selected from the group consisting of: Nordic Pine, Black Spruce, Radiata Pine, Southern Pine, Enzyme-Treated Nordic Pine, Douglas Fir, Dissolving Pulp, Birch, Eucalyptus, Acacia, Mixed European Hardwood, Mixed Thai Hardwood, Tissue Dust, Cotton, Abaca, Sisal, Bagasse, Kenaf, Miscanthus, Sorghum, Giant Reed, Flax, and mixtures thereof. 
     
     
         172 . The method according to  claim 157 , wherein the mechanical property is selected from one or more of Tensile Strength, Tensile Elongation, Bulk, Tensile Stiffness, Bending Stiffness, Porosity, Burst and Tear Strength, and Tensile Strength in the ‘Z’ direction. 
     
     
         173 . The method according to  claim 157 , wherein the microfibrillated cellulose has a modal fibre particle size ranging from about 0.1 μm-500 μm. 
     
     
         174 . The method according to  claim 157 , wherein microfibrillated cellulose has a modal fibre particle size of at least about 0.5 μm. 
     
     
         175 . The method according to  claim 157 , wherein the one or more microporous inorganic particulate material has a median particle size (d 50 ) ranging from about 3 μm to about 50 μm. 
     
     
         56 . The method according to  claim 157 , wherein the one or more microporous inorganic particulate material has a median particle size (d 50 ) ranging from about 3 μm to about 6 μm. 
     
     
         177 . The method according to  claim 157 , wherein the one or more microporous inorganic particulate material and microfibrillated cellulose composite may be associated with one or more dispersing agents selected from the group consisting of: homopolymers or copolymers of polycarboxylic acids and/or their salts or derivatives, esters based on, acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid; acryl amide or acrylic esters, methylmethacrylate, or mixtures thereof, alkali polyphosphates, phosphonic-, citric- and tartaric acids and the salts or esters thereof; and mixtures thereof. 
     
     
         178 . The method according to  claim 157 , wherein the one or more microporous inorganic particulate material and microfibrillated cellulose composite is provided in the form of a powder. 
     
     
         179 . The method according to  claim 157 , wherein the one or more microporous inorganic particulate material and microfibrillated cellulose composite is provided in the form of a suspension. 
     
     
         180 . The method according to  claim 179 , wherein the suspension is an aqueous suspension. 
     
     
         181 . The method according to  claim 180 , wherein the aqueous suspension is a pumpable liquid. 
     
     
         182 . The method according to  claim 157 , wherein the one or more microporous inorganic particulate material comprises a blend of a first and second microporous inorganic particulate material, wherein the ratio of the first microporous inorganic particulate material to the second microporous inorganic particulate material may range from about 10:90 to about 90:10 by weight. 
     
     
         183 . The method according to  claim 157 , further comprising a binder. 
     
     
         184 . The method according to  claim 183 , wherein the binder is an inorganic or organic binder. 
     
     
         185 . The method according to  claim 183 , wherein the binder is an alkali metal silicate. 
     
     
         186 . The method according to  claim 183 , wherein the alkali metal silicate is sodium silicate. 
     
     
         187 . The method according to  claim 183 , wherein the alkali metal silicate is potassium silicate. 
     
     
         188 . The method according to  claim 157 , wherein the weight ratio of microfibrillated cellulose to the one or more microporous inorganic particulate material on a dry weight basis is from about 1:5 to about 5:1. 
     
     
         189 . The method according to  claim 157 , wherein the total content of the one or more microporous inorganic particulate material is present in an amount of from about 10 wt-% to about 95 wt-% on a dry weight basis of the filler composition. 
     
     
         190 . The method according to  claim 157 , wherein the total content of the one or more microporous inorganic particulate material is present in an amount of from about 15 wt-% to about 90 wt-% on a dry weight basis of the filler composition. 
     
     
         191 . The method according to  claim 157 , wherein the total content of the one or more microporous inorganic particulate material is present in an amount of from about 20 to about 75 wt-% on a dry weight basis of the filler composition. 
     
     
         192 . The method according to  claim 157 , wherein the total content of the one or more microporous inorganic particulate material is present in an amount of from about 25 wt-% to about 67 wt-% on a dry weight basis of the filler composition. 
     
     
         193 . The method according to  claim 157 , wherein the total content of the one or more microporous inorganic particulate material is present in an amount of from about 33 to about 50 wt.-% on a dry weight basis of the filler composition. 
     
     
         194 . A method of making a papermaking furnish comprising microfibrillated cellulose (MFC) and one or more microporous inorganic particulate material, the method comprising the steps of: adding the one or more microporous inorganic particulate material to the papermaking furnish; adding the MFC to the papermaking furnish; wherein the MFC and the one or more microporous inorganic particulate material are added separately to the papermaking furnish or as a filler composition comprising the MFC and the one or more microporous inorganic particulate material;
 wherein the MFC and the one or more microporous inorganic particulate material impart mechanical properties to the paper or paperboard that are improved compared to paper and paperboard products made from an identical papermaking furnish not containing the microfibrillated cellulose and the one or more microporous inorganic particulate material.