Fibrous sheet binders

Abstract

A method and composition are disclosed for providing a two-part polymer binder additive for a fibrous sheet for improving both its strength and durability. The two-part polymer binder may be added to augment organic binders to increase board strength and durability or to reduce the amount of organic binder required. The polymers may also be added in place of conventional organic binders or added in addition to organic binders to improve sag resistance and fibrous sheet performance.

1. A polymer binder for a fibrous sheet comprising:
 a polyanion having a negative charge of between about 4 to about 12 milliequivalents per gram; and  
 polycation having a positive charge of between about 6 to about 12 milliequivalents per gram.  
 
     
     
       2. The binder of  claim 1 , wherein the polyanion has a plurality of negatively charged anionic groups and the polycation has a plurality of positively charged cationic groups, the molar ratio of total negatively charged anionic groups to total positively charged cationic groups being between about 10:1 and about 1.1:1. 
     
     
       3. The binder of  claim 2 , wherein the negatively charged anionic groups are acids. 
     
     
       4. The binder of  claim 3 , wherein the anionic acid groups are weakly acidic. 
     
     
       5. The binder of  claim 2 , wherein the positively charged cationic groups are amines. 
     
     
       6. The binder of  claim 2 , wherein the molar ratio of total negatively charged anionic groups to total positively charged cationic groups is about 3:1. 
     
     
       7. The binder of  claim 1 , wherein the molecular weight of the polyanion is between about 10,000 to about 900,000 grams per mole. 
     
     
       8. The binder of  claim 1 , wherein the polyanion is crosslinked. 
     
     
       9. The binder of  claim 1 , wherein the polyanion has a plurality of negatively charged anionic groups, the total negatively changed anionic groups having a cross-link ratio of up to about 1:50. 
     
     
       10. The binder of  claim 1 , wherein the molecular weight of the polycation is between about 10,000 to about 900,000 grams per mole. 
     
     
       11. The binder of  claim 1 , wherein the binder forms a interpolyelectrolyte complex. 
     
     
       12. The binder of  claim 1 , wherein the binder further comprises a spacer selected from the group consisting of a polysaccharide, a hydrogel, a latex and combinations thereof . 
     
     
       13. The binder of  claim 1 , wherein the polysaccharide  binder further comprises a starch spacer. 
     
     
       14. The binder of  claim 1 , wherein the binder further comprises a surfactant. 
     
     
       15. The binder of  claim 14 , wherein the surfactant is selected from the group consisting of alkylamines, fatty amines and combinations thereof. 
     
     
       16. The binder of  claim 1 , wherein the polyanion to polycation charge ratio is about 1:1. 
     
     
       17. The binder of  claim 1 , wherein the polyanion is selected from the group consisting of polycarbohydrates, polyphosphates, polysulfonates, polysulfates and combinations thereof. 
     
     
       18. The binder of  claim 1 , wherein the polycation is a polyamine. 
     
     
       19. The binder of  claim 18 , wherein the polyamine is a quaternary amine. 
     
     
       20. The binder of  claim 1 , wherein the polycation has a positive charge of between 6 to about 12 milliequivalents per gram. 
     
     
       21. The binder of  claim 12 , wherein the spacer is selected from the group consisting of a polysaccharide, a hydrogel, a latex and combinations thereof. 
     
     
       22. A polymer binder for a fibrous sheet comprising:
   a spacer; and        an interpolyelectrolyte complex, the interpolyelectrolyte complex being formed around the spacer.     
     
     
       23. The polymer binder of  claim 22 , wherein the interpolyelectrolyte complex includes a two- part polymer additive, the two - part polymer additive including a polyanion and a polycation, wherein the ratio of polyanion to polycation is between  10 : 1  and  1 . 1 : 1 .   
     
     
       24. The polymer binder of  claim 22 , wherein the binder further includes a surfactant, the interpolyelectrolyte complex and surfactant form a polyelectrolyte- surfactant complex, wherein the polyelectrolyte - surfactant complex is formed around the spacer.   
     
     
       25. A polymer binder for a fibrous sheet comprising:
   a polyanion;        a polycation; and        a surfactant;        wherein the polyanion, polycation and surfactant form a polyelectrolyte - surfactant complex.     
     
     
       26. The polymer binder of  claim 25 , wherein the ratio of polyanion to polycation is between  10 : 1  and  1 . 1 : 1 .