US2004108081A1PendingUtilityA1

Filler-fiber composite

38
Assignee: SPECIALTY MINERALS MICHIGANPriority: Dec 9, 2002Filed: Dec 9, 2002Published: Jun 10, 2004
Est. expiryDec 9, 2022(expired)· nominal 20-yr term from priority
Inventors:Geoffrey Hughes
D21H 23/04D21H 17/70D21H 17/15D21H 17/675D21H 11/16D21H 3/00
38
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Claims

Abstract

The present invention relates to a filler-fiber composite, a process for its production, the use of such in the manufacture of paper or paperboard products and to paper produced therefrom. More particularly the invention relates to a filler-fiber composite in which the morphology and particle size of the mineral filler are established prior to the development of the bond to the fiber. Even more particularly, the present invention relates to a PCC filler-fiber composite, wherein the desired optical and physical properties of the paper produced therefrom are realized.

Claims

exact text as granted — not AI-modified
We claim:  
     
         1 . A filler-fiber composite comprising: 
 (a) feeding slake containing citric acid to a first stage reactor    (b) reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry    (c) reacting the first partially converted calcium hydroxide calcium carbonate slurry in a second stage reactor in the presence of carbon dioxide to produce a second partially converted calcium hydroxide calcium carbonate slurry and    (d) reacting the second partially converted calcium hydroxide calcium carbonate slurry in a third stage reactor in the presence of carbon dioxide and fibrils to produce a filler-fiber composite.    
     
     
         2 . The filler-fiber composite of  claim 1  wherein the fiber is from about 0.1 microns to about 2 microns in thickness and from about 10 microns to about 400 microns in length.  
     
     
         3 . The filler-fiber composite of  claim 2  wherein the filler is scalenohedral having a specific surface area of from about 5 meters squared per gram to about 11 meters squared per gram.  
     
     
         4 . The filler-fiber composite of  claim 3  wherein the calcium hydroxide calcium carbonate slurry is converted from about 20 percent to about 40 percent.  
     
     
         5 . The filler-fiber composite of  claim 4  wherein the first partially converted calcium hydroxide calcium carbonate slurry is converted from about 41 percent to about 99 percent.  
     
     
         6 . The filler-fiber composite of  claim 5  wherein the second partially converted calcium hydroxide calcium carbonate slurry is converted to a filler-fiber composite.  
     
     
         7 . A method for producing a filler-fiber composite comprising: 
 (a) feeding slake containing citric acid to a first stage reactor    (b) reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry    (c) reacting the first partially converted calcium hydroxide calcium carbonate slurry in a second stage reactor in the presence of carbon dioxide to produce a second partially converted calcium hydroxide calcium carbonate slurry and    (d) reacting the second partially converted calcium hydroxide calcium carbonate slurry in a third stage reactor in the presence of carbon dioxide and fibers to produce a filler-fiber composite.    
     
     
         8 . The method of producing the filler-fiber composite of  claim 7  wherein the fiber is from about 0.1 microns to about 2 microns in thickness and from about 10 microns to about 400 microns in length.  
     
     
         9 . The method of producing the filler-fiber composite of  claim 8  wherein the filler is scalenohedral and has a specific surface area of from about 5 meters squared gram to about 11 meters squared per gram.  
     
     
         10 . The method of producing the filler-fiber composite of  claim 9  wherein the calcium hydroxide calcium carbonate slurry is converted from about 20 percent to about 40 percent.  
     
     
         11 . The method of producing the filler-fiber composite of  claim 10  wherein the first partially converted calcium hydroxide calcium carbonate slurry is converted from about 41 percent to about 99 percent.  
     
     
         12 . The filler-fiber composite of  claim 11  wherein the second partially converted calcium hydroxide calcium carbonate slurry is converted to a filler-fiber composite.  
     
     
         13 . The filler-fiber composite of  claim 1  utilized in paper or paperboard  
     
     
         14 . The filler-fiber composite of  claim 7  utilized in paper or paperboard.  
     
     
         15 . The paper produced utilizing the filler-fiber of  claim 1 .  
     
     
         16 . The paper produced utilizing the filler-fiber of  claim 7 .  
     
     
         17 . A filler-fiber composite comprising: 
 (a) feeding slake containing citric acid to a first stage reactor    (b) reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry    (c) taking a first portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibrils and reacting such in a second stage reactor in the presence of carbon dioxide to produce a calcium carbonate\fibril composite to serve as a heel and    (d) taking a second portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibrils and surfactant and reacting in the presence of CO2 to produce a second partially converted Ca(OH)2/CaCO3/fibril material and    (e) reacting the second partially converted Ca(OH)2/CaCO3/fibril material in the presence of CO2 in a third stage reactor to produce a filler-fiber composite.    
     
     
         18 . The filler-fiber composite of  claim 17  wherein the fiber is from about 0.1 microns to about 2 microns in thickness and from about 10 microns to about 400 microns in length.  
     
     
         19 . The filler-fiber composite of  claim 18  wherein the filler is scalenohedral having a specific surface area of from about 5 meters squared per gram to about 11 meters squared per gram.  
     
     
         20 . The filler-fiber composite of  claim 19  wherein the calcium hydroxide calcium carbonate slurry is converted from about 20 percent to about 40 percent.  
     
     
         21 . The filler-fiber composite of  claim 20  wherein the first partially converted calcium hydroxide calcium carbonate slurry is converted from about 41 percent to about 99 percent.  
     
     
         22 . The filler-fiber composite of  claim 21  wherein the second partially converted calcium hydroxide calcium carbonate slurry is converted to a filler-fiber composite.  
     
     
         23 . A method for producing a filler-fiber composite comprising: 
 (a) feeding slake containing citric acid to a first stage reactor    (b) reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry    (c) taking a first portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibrils and reacting such in a second stage reactor in the presence of carbon dioxide to produce a calcium carbonate\fibril composite to serve as a heel and    (d) taking a second portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibrils and surfactant and reacting in the presence of CO2 to produce a second partially converted Ca(OH)2/CaCO3/fibril material and reacting the second partially converted Ca(OH)2/CaCO3/fibril material in the presence of CO2 in a third stage reactor to produce a filler-fiber composite.    
     
     
         24 . The method for producing filler-fiber composite of  claim 23  wherein the fiber is from about 0.1 microns to about 2 microns in thickness and from about 10 microns to about 400 microns in length.  
     
     
         25 . The method for producing filler-fiber composite of  claim 24  wherein the filler is scalenohedral having a specific surface area of from about 5 meters squared per gram to about 11 meters squared per gram.  
     
     
         26 . The method for producing filler-fiber composite of  claim 25  wherein the calcium hydroxide calcium carbonate slurry is converted from about 20 percent to about 40 percent.  
     
     
         27 . The method for producing filler-fiber composite of  claim 26  wherein the first partially converted calcium hydroxide calcium carbonate slurry is converted from about 41 percent to about 99 percent.  
     
     
         28 . The method for producing filler-fiber composite of  claim 27  wherein the second partially converted calcium hydroxide calcium carbonate slurry is converted to a filler-fiber composite.  
     
     
         29 . The filler-fiber composite of  claim 17  utilized in paper or paperboard  
     
     
         30 . The filler-fiber composite of  claim 23  utilized in paper or paperboard.  
     
     
         31 . The paper produced utilizing the filler-fiber of  claim 17 .  
     
     
         32 . The paper produced utilizing the filler-fiber of  claim 23 .  
     
     
         33 . A filler-fiber composite comprising: 
 (a) feeding slake containing citric acid to a first stage reactor    (b) reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry    (c) taking a first portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibrils and reacting such in a second stage reactor in the presence of carbon dioxide to produce a calcium carbonate/fibril composite to serve as a heel and    (d) taking a second portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibrils and polyacrylamide and reacting in the presence of CO 2  to produce a second partially converted Ca(OH) 2 /CaCO 3 /fibril material and    (e) reacting the second partially converted Ca(OH) 2 /CaCO 3 /fibril material in the presence of CO 2  in a third stage reactor to produce a filler/fiber composite.    
     
     
         34 . The filler-fiber composite of  claim 33  wherein the fiber is from about 0.1 microns to about 2 microns in thickness and from about 10 microns to about 400 microns in length.  
     
     
         35 . The filler-fiber composite of  claim 34  wherein the filler is scalenohedral having a specific surface area of from about 5 meters squared per gram to about 11 meters squared per gram.  
     
     
         36 . The filler-fiber composite of  claim 35  wherein the calcium hydroxide calcium carbonate slurry is converted from about 20 percent to about 40 percent.  
     
     
         37 . The filler-fiber composite of  claim 36  wherein the first partially converted calcium hydroxide calcium carbonate slurry is converted from about 41 percent to about 99 percent.  
     
     
         38 . The filler-fiber composite of  claim 37  wherein the second partially converted calcium hydroxide calcium carbonate slurry is converted to a filler-fiber composite.  
     
     
         39 . A method of producing a filler-fiber composite comprising: 
 (a) feeding slake containing citric acid to a first stage reactor    (b) reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry    (c) taking a first portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibrils and reacting such in a second stage reactor in the presence of carbon dioxide to produce a calcium carbonate\fibril composite to serve as a heel and    (d) taking a second portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibrils and polyacrylamide and reacting in the presence of CO 2  to produce a second partially converted Ca(OH) 2 /CaCO 3 /fibril material and    (e) reacting the second partially converted Ca(OH) 2 /CaCO 3 /fibril material in the presence of CO 2  in a third stage reactor to produce a filler/fiber composite.    
     
     
         40 . The method for producing filler-fiber composite of  claim 39  wherein the fiber is from about 0.1 microns to about 2 microns in thickness and from about 10 microns to about 400 microns in length.  
     
     
         41 . The method for producing filler-fiber composite of  claim 40  wherein the filler is scalenohedral having a specific surface area of from about 5 meters squared per gram to about 11 meters squared per gram.  
     
     
         42 . The method for producing filler-fiber composite of  claim 41  wherein the calcium hydroxide calcium carbonate slurry is converted from about 20 percent to about 40 percent.  
     
     
         43 . The method for producing filler-fiber composite of  claim 42  wherein the first partially converted calcium hydroxide calcium carbonate slurry is converted from about 41 percent to about 99 percent.  
     
     
         44 . The method for producing filler-fiber composite of  claim 43  wherein the second partially converted calcium hydroxide calcium carbonate slurry is converted to a filler-fiber composite.  
     
     
         45 . The filler-fiber composite of  claim 33  utilized in paper or paperboard  
     
     
         46 . The filler-fiber composite of  claim 39  utilized in paper or paperboard.  
     
     
         47 . The paper produced utilizing the filler-fiber of  claim 33 .  
     
     
         48 . The paper produced utilizing the filler-fiber of  claim 39.

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