Volatile debonder formulations for papermaking

Abstract

Formulations and methods for papermaking use one or more volatile debonders, where the volatile debonder forms a solution or an emulsion with water in a paper precursor, and where the volatile debonder is evaporable from the paper precursor before the paper precursor is completely dried to form a paper sheet during papermaking. Two volatile debonders having different boiling points can be used, where they are miscible in water and in each other, and where one volatile debonder has a higher molecular weight and the other volatile debonder has a lower boiling point.

What is claimed: 
     
         1 . A formulation for use in papermaking, comprising a volatile debonder, wherein the volatile debonder forms a solution or an emulsion with water in a paper precursor, and wherein the volatile debonder is evaporable from the paper precursor before the paper precursor is completely dried to form a paper sheet during papermaking. 
     
     
         2 . The formulation of  claim 1 , wherein the volatile debonder forms an azeotropic mixture with water. 
     
     
         3 . The formulation of  claim 2 , wherein the azeotropic mixture is a positive azeotropic mixture. 
     
     
         4 . The formulation of  claim 1 , wherein the volatile debonder comprises a hydrophobic molecule. 
     
     
         5 . The formulation of  claim 1 , wherein the volatile debonder forms an emulsion with water. 
     
     
         6 . The formulation of  claim 1 , wherein the volatile debonder comprises a molecule having a lower boiling point than a drying temperature to form the paper precursor into the paper sheet. 
     
     
         7 . The formulation of  claim 1 , wherein the volatile debonder comprises a glycol ether. 
     
     
         8 . The formulation of  claim 7 , wherein the glycol ether comprises at least one of an aliphatic and an aromatic side chain. 
     
     
         9 . A formulation to be added to a paper precursor during papermaking, comprising a first volatile debonder and a second volatile debonder, wherein the first and the second volatile debonders are soluble in each other and in water, wherein the first and second volatile debonders evaporate from the paper precursor without leaving residua in the paper precursor after drying, and wherein the first and second volatile debonders have different boiling points. 
     
     
         10 . The formulation of  claim 9 , wherein one of the first and second volatile debonders is a lower molecular weight debonder and the other of the first and second volatile debonders is a higher molecular weight debonder. 
     
     
         11 . The formulation of  claim 9 , wherein the first and the second volatile debonders are mixed together in a water solution that is added to the paper precursor. 
     
     
         12 . The formulation of  claim 9 , wherein one of the first and second volatile debonders is mixed with water and added to the paper precursor separately from the other volatile debonder. 
     
     
         13 . The formulation of  claim 9 , wherein neither the first nor the second volatile debonder forms an azeotropic mixture with water. 
     
     
         14 . A formulation for use in a process of papermaking, comprising a volatile debonder, wherein the volatile debonder is formulated in an aqueous solution or emulsion for dispersal on a paper precursor, and wherein the volatile debonder is evaporable from the paper precursor before the paper precursor is completely dried to form a paper sheet. 
     
     
         15 . The formulation of  claim 14 , wherein the volatile debonder evaporates from the paper precursor without leaving residua in the paper sheet. 
     
     
         16 . The formulation of  claim 14 , wherein the volatile debonder is formulated in an aqueous solution or emulsion for dispersal by spraying on the paper precursor. 
     
     
         17 . The formulation of  claim 14 , further comprising a second volatile debonder that is evaporable from the paper precursor before the paper precursor is completely dried to form the paper sheet. 
     
     
         18 . A method for making a debonded paper sheet, comprising:
 preparing a volatile debonder formulation compatible with the aqueous environment of a paper precursor, wherein the volatile debonder formulation comprises at least one volatile debonder,   applying the volatile debonder formulation to the aqueous environment to form a debonded paper precursor, and   processing the debonded paper precursor through a papermaking process, wherein the papermaking process has a drying step as its final stage, and wherein the at least one volatile debonder evaporates from the debonded paper precursor during the drying step, thereby forming the debonded paper sheet.   
     
     
         19 . The method of  claim 18 , wherein the volatile debonder formulation comprises at least two volatile debonders, each having a different boiling point. 
     
     
         20 . The method of  claim 19 , wherein the at least two volatile debonders comprise a first volatile debonder having a higher molecular weight and a second volatile debonder having a lower molecular weight. 
     
     
         21 . The method of  claim 18 , wherein the step of preparing the volatile debonder formulation comprises preparing an emulsion that disperses the volatile debonder formulation in the aqueous environment. 
     
     
         22 . The method of  claim 18 , wherein the step of applying the volatile debonder formulation to the aqueous environment comprises mixing the volatile debonder formulation with the paper precursor before the drying step. 
     
     
         23 . The method of  claim 22 , wherein the step of mixing the volatile debonder formulation with the paper precursor comprises forming an azeotropic mixture. 
     
     
         24 . The method of  claim 18 , wherein the step of applying the volatile debonder formulation to the aqueous environment comprises spraying or topically applying the volatile debonder to the paper web. 
     
     
         25 . A method for making a debonded paper sheet without debonder residua, comprising:
 adding a first volatile debonder to a paper precursor in an aqueous environment to form a debonded paper precursor, wherein the first volatile debonder is evaporable during a drying process without leaving debonder residua; and   processing the debonded paper precursor through the drying process, thereby evaporating the volatile debonder without leaving debonder residua, and thereby making the debonded paper sheet without debonder residua.   
     
     
         26 . The method of  claim 25 , further comprising adding a second volatile debonder to the paper precursor in an aqueous environment, wherein the second volatile debonder is evaporable during the drying process without leaving debonder residua. 
     
     
         27 . The method of  claim 26 , wherein the first volatile debonder and the second volatile debonder have different boiling points. 
     
     
         28 . The method of  claim 27 , wherein one of the first volatile debonder and the second volatile debonder has a lower molecular weight, and the other of the first volatile debonder and the second volatile debonder has a higher molecular weight.