Foam formulations for application of dry strength agents

Abstract

Foam formulations and methods for manufacturing paper products using foam formulations are provided. An exemplary method includes producing a foam of a gas, water, a dry strength agent, and a combination of foaming agents including an anionic sulfated/sulfonated surfactant and a polysorbate-type nonionic surfactant; applying the foam to a web; and processing the web to form the product.

What is claimed is: 
     
         1 . A method for manufacturing a paper product, the method comprising:
 producing a foam of a gas, water, a dry strength agent, and a combination of foaming agents including an anionic sulfated/sulfonated surfactant and a polysorbate-type nonionic surfactant;   applying the foam to a web; and   processing the web to form the product.   
     
     
         2 . The method of  claim 1 , wherein the dry strength agent has a cationic functional group. 
     
     
         3 . The method of  claim 1 , wherein the dry strength agent comprises a graft copolymer of a vinyl monomer and functionalized vinyl amine, a vinyl amine containing polymer, or an acrylamide containing polymer. 
     
     
         4 . The method of  claim 1 , wherein the anionic sulfated/sulfonated surfactant comprises a sodium alkyl sulfate. 
     
     
         5 . The method of  claim 1 , wherein the anionic sulfated/sulfonated surfactant comprises sodium dodecyl sulfate (SDS). 
     
     
         6 . The method of  claim 1 , wherein the polysorbate-type nonionic surfactant comprises polysorbate 20. 
     
     
         7 . The method of  claim 1 , wherein the combination of foaming agents has an anionic sulfated/sulfonated surfactant to polysorbate-type nonionic surfactant ratio of from 3:7 to 9:1. 
     
     
         8 . The method of  claim 1 , wherein the combination of foaming agents has an anionic sulfated/sulfonated surfactant to polysorbate-type nonionic surfactant ratio of from 5:5 to 7:3. 
     
     
         9 . The method of  claim 1 , wherein the anionic sulfated/sulfonated surfactant comprises sodium dodecyl sulfate (SDS), wherein the polysorbate-type nonionic surfactant comprises polysorbate 20, and wherein the combination of foaming agents has a sodium dodecyl sulfate to polysorbate 20 ratio of from 3:7 to 9:1. 
     
     
         10 . The method of  claim 1 , wherein the anionic sulfated/sulfonated surfactant comprises sodium dodecyl sulfate (SDS), wherein the polysorbate-type nonionic surfactant comprises polysorbate 20, and wherein the combination of foaming agents has a sodium dodecyl sulfate to polysorbate 20 ratio of from 5:5 to 7:3. 
     
     
         11 . The method of  claim 1 , wherein the anionic sulfated/sulfonated surfactant comprises sodium dodecyl sulfate (SDS), wherein the polysorbate-type nonionic surfactant comprises polysorbate 20, and wherein the combination of foaming agents consists of the sodium dodecyl sulfate (SDS) and the polysorbate 20. 
     
     
         12 . A formulation for producing a foam with a gas content upon incorporation of gas into the formulation, the formulation comprising:
 water;   a dry strength agent having a cationic functional group;   an anionic sulfated/sulfonated surfactant; and   a polysorbate-type nonionic surfactant.   
     
     
         13 . The formulation of  claim 12 , wherein the dry strength agent comprises a graft copolymer of a vinyl monomer and functionalized vinyl amine, wherein the anionic sulfated/sulfonated surfactant comprises sodium dodecyl sulfate (SDS), and wherein the polysorbate-type nonionic surfactant comprises polysorbate 20. 
     
     
         14 . The formulation of  claim 13 , wherein the formulation has a sodium dodecyl sulfate to polysorbate 20 ratio of from 3:7 to 9:1. 
     
     
         15 . The formulation of  claim 13 , wherein the formulation has a sodium dodecyl sulfate to polysorbate 20 ratio of from 5:5 to 7:3. 
     
     
         16 . The formulation of  claim 13 , wherein the formulation is substantially free of surfactants other than the sodium dodecyl sulfate (SDS) and the polysorbate 20. 
     
     
         17 . The formulation of  claim 13 , wherein the formulation consists essentially of:
 water;   the dry strength agent having a cationic functional group;   the anionic sulfated/sulfonated surfactant; and   the polysorbate-type nonionic surfactant.   
     
     
         18 . The formulation of  claim 13 , wherein the formulation is free of starch. 
     
     
         19 . The formulation of  claim 13 , further comprising uncooked starch. 
     
     
         20 . The formulation of  claim 19 , wherein the formulation consists essentially of:
 the uncooked starch;   water;   the dry strength agent having a cationic functional group;   the anionic sulfated/sulfonated surfactant; and   the polysorbate-type nonionic surfactant.