Compositions comprising kaolin treated with a styrene-based polymer and related methods

Patent metadata

Field	Value
Publication number	US-9903072-B2
Application number	US-201514656563-A
Country	US
Kind code	B2
Filing date	Mar 12, 2015
Priority date	Sep 15, 2011
Publication date	Feb 27, 2018
Grant date	Feb 27, 2018

Abstract

A mineral composition and related methods may include a mineral treated with a styrene-based polymer. The mineral treated with a styrene-based polymer may be used for a coating on a paper product having a first Cobb value that is less than a second Cobb value of the paper product with the coating devoid of the mineral composition.

First claim

What is claimed is:

1. A mineral composition for use in a water barrier coating, the composition comprising:
a mineral coated with 1.25% to 5.0% by weight of a styrene-based polymer, with respect to the total weight of the mineral; and
an aqueous solution comprising a binder, wherein the aqueous solution is devoid of sodium, and wherein the mineral composition has a solids content ranging from 40% to 60% by weight.

2. The mineral composition of claim 1 , wherein a substrate comprising the composition as a coating has a Cobb value ranging from 1 g/m 2 to 25 g/m 2 .

3. The mineral composition of claim 2 , wherein the substrate comprises paper, paperboard, or corrugated linerboard, and wherein the coating is printable.

4. The mineral composition of claim 1 , wherein the mineral has a shape factor of at least 20.

5. The mineral composition of claim 1 , wherein the aqueous solution further comprises a pH adjuster chosen from potassium hydroxide, ammonium hydroxide, a carbonate, or a combination thereof.

6. The mineral composition of claim 5 , wherein the pH adjuster comprises ammonium hydroxide.

7. The mineral composition of claim 1 , wherein the mineral comprises kaolin, the binder comprises latex, and the styrene-based polymer is styrene maleic anhydride.

8. The mineral composition of claim 7 , wherein the kaolin is coated with 1.5% to 2.5% by weight styrene maleic anhydride, with respect to the total weight of the kaolin.

9. The mineral composition of claim 1 , the mineral is selected from the group consisting of kaolin, talc, gypsum, diatomaceous earth, calcium carbonate, attapulgite, bentonite, montmorillonite, natural clays, and synthetic clays.

10. The mineral composition of claim 1 , further comprising a dispersant selected from the group consisting of phosphate, silicate, and acrylate, wherein the dispersant is devoid of sodium.

11. The mineral composition of claim 1 , wherein the mineral comprises kaolin and talc.

12. The mineral composition of claim 1 , wherein the mineral has a steepness of at least 50, a d 50 diameter ranging from 0.2 μm to 1.5 μm, and a d 90 diameter ranging from 1 μm to 10 μm.

13. The mineral composition of claim 1 , wherein the mineral composition has a Brookfield viscosity ranging from 200 cP to 500 cP when measured at 20 rpm and at less than or equal to 65% solids by weight.

14. A mineral composition comprising:
kaolin coated with styrene maleic anhydride; and
an aqueous solution devoid of sodium, the aqueous solution comprising:
at least 20% water by weight, with respect to the total weight of the composition;
3% to 50% binder by weight, with respect to the total weight of the composition; and
a dispersing agent.

15. The mineral composition of claim 14 , wherein the kaolin has a shape factor of at least 45, a d 50 diameter ranging from 0.2 μm to 1.5 μm, and a d 90 diameter ranging from 1 μm to 10 μm.

16. The mineral composition of claim 14 , wherein the kaolin is coated with 1.5% to 2.5% by weight styrene maleic anhydride, with respect to the total weight of the kaolin.

17. The mineral composition of claim 14 , wherein the aqueous solution further comprises ammonium hydroxide, and the aqueous solution has a pH ranging from 6.5 to 8.5.

18. The mineral composition of claim 14 , wherein the kaolin has a steepness of at least 40.

19. The mineral composition of claim 14 , wherein a substrate comprising the composition as a coating has a Cobb value ranging from 1 g/m 2 to 10 g/m 2 .

20. A mineral composition comprising:
kaolin coated with 1.5% to 2.5% by weight styrene maleic anhydride, with respect to the total weight of the kaolin, the kaolin having a shape factor of at least 70, a steepness of at least 50, a d 50 diameter ranging from 0.2 μm to 1.5 μm, and a d 90 diameter ranging from 1 μm to 10 μm; and
an aqueous solution devoid of sodium, the aqueous solution comprising:
at least 20% water by weight, with respect to the total weight of the composition;
3% to 50% binder by weight, with respect to the total weight of the composition;
a dispersing agent; and
ammonium hydroxide;

wherein the mineral composition has a solids content ranging from 20% to 70% by weight and a pH ranging from 6.5 to 8.5.

21. The mineral composition of claim 20 , wherein about 70% by weight of the solids is kaolin coated with styrene maleic anhydride.

22. The mineral composition of claim 20 , wherein the aqueous solution comprises from 0.1% to 0.5% dispersing agent by weight and from 0.025% to 0.25% ammonium hydroxide by weight, with respect to the total weight of the composition.

23. The mineral′composition of claim 20 , wherein the binder comprises acrylic latex or vinyl acetate latex.

24. The mineral composition of claim 20 , wherein a paper, paperboard, or corrugated linerboard substrate comprising the composition as a coating has a Cobb value ranging from 1 g/m 2 to 25 g/m 2 .

25. The mineral composition of claim 24 , wherein the coating is a water barrier coating having a thickness of 8 g/m 2 .

Assignees

• Imerys Pigments Inc
• Imerys Usa Inc

Inventors

• Yildirim Ismail
• Pruett Robert J
• Meizanis Paul M

Classifications

• D21H17/67

  Water-insoluble compounds, e.g. fillers, pigments · CPC title

• D21H19/40

  siliceous, e.g. clays · CPC title

• D21H17/69

  modified, e.g. by association with other compositions prior to incorporation in the pulp or paper · CPC title

• D21H21/16 Primary

  Sizing or water-repelling agents · CPC title

• D21H19/58

  Polymers or oligomers of diolefins, aromatic vinyl monomers or unsaturated acids or derivatives thereof · CPC title