Aldehyde-Functionalized Polymer Emulsifiers for Paper Sizing

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Solution Overview

Problem

The papermaking industry faces challenges in improving sizing performance and machine efficiency, with existing sizing formulations and methods requiring multiple chemistries and struggling to achieve optimal internal sizing and dewatering in paper production.

Innovation Solution

The use of aldehyde-functionalized polymers as emulsifiers in sizing emulsions, specifically glyoxalated poly(DADMAC)/AcAm polymers, which are combined with sizing agents like alkyl ketene dimer (AKD) and alkenyl succinic anhydride (ASA), to create stable emulsions with controlled particle sizes for enhanced paper production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cationic emulsifiers (derivitized starches and synthetic acrylamide-based polymers) are used for ASA emulsion, then emulsion stability and ASA retention are improved, but sizing performance and machine efficiency cannot be optimized further

Engineering Contradiction:

Improveemulsion stabilityVSAvoidmachine efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the chemical parameters of the emulsifier by using aldehyde-functionalized polymers with specific functional groups that can react with ASA. This chemical parameter change enables both improved emulsion stability through better cationizing and enhanced sizing performance through reactive bonding, resolving the contradiction between reliability and productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite emulsifier systems that combine aldehyde-functionalized polymers with specific molecular weights and charge densities. These composite materials provide multiple functions simultaneously: emulsion stabilization, ASA retention, and sizing enhancement, thereby improving both emulsion stability and machine efficiency

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If multiple chemistries are used in sizing formulations, then comprehensive papermaking process control is achieved, but formulation complexity and processing steps increase

Engineering Contradiction:

Improveprocess control capabilityVSAvoidformulation complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The aldehyde-functionalized polymer emulsifiers perform multiple functions simultaneously: they act as emulsifiers to stabilize the ASA emulsion, as retention aids to keep ASA on the fiber, and as sizing agents to provide water resistance. This multi-functionality eliminates the need for multiple separate chemistries while maintaining comprehensive process control

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the functions of emulsification, retention, and sizing into a single integrated formulation system. By combining these functions into one emulsifier product, the formulation complexity is reduced while maintaining the adaptability and versatility needed for papermaking process control

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If internal sizing is enhanced, then liquid penetration resistance is improved, but dewatering performance may be compromised

Engineering Contradiction:

Improveliquid penetration resistanceVSAvoiddewatering performance

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The aldehyde-functionalized polymers provide localized functionality by concentrating sizing activity at the fiber surface through reactive bonding. This localized sizing enhancement provides excellent liquid penetration resistance without creating a uniform coating that would impede dewatering, thus resolving the contradiction between sizing effectiveness and dewatering performance

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach results in significant increases in internal sizing and papermachine dewatering, improving paper production efficiency and reducing the need for multiple chemistries, with improved sizing performance and reduced steam demands on paper machines.

Implementation Method 1

Emulsification of ASA produces an oil in water emulsion and also cationizes the ASA emulsion droplets

Methodology Applied

Scientific EffectEmulsion: Emulsion

Implementation Method 2

Cationizing the ASA droplets helps to promote emulsion stability and aids in ASA retention

Methodology Applied

Scientific EffectCationizing: Electrostatic Induction

Implementation Method 3

aldehyde-functionalized polymers as emulsion stabilizers for sizing emulsions

Methodology Applied

Scientific EffectChemical reaction (aldehyde functionalization): Chemical Bonding

Data Source

PatentUS9145646B2Method of using aldehyde-functionalized polymers to increase papermachine performance and enhance sizing

Publication Date: 2015.09.29 NALCO CO

AI summary

Disclosed herein are compositions and methods to increase paper machine performance and enhance sizing. The compositions include a sizing agent, an emulsifier, and an aqueous component. The emulsifier may be an aldehyde-functionalized polymer. The sizing agent may be selected from rosin size, an alkyl ketene dimer, an alkenyl succinic anhydride, and any combination of these sizing agents.