TW201404972A - 紙或板的纖維網及其製造方法 - Google Patents

紙或板的纖維網及其製造方法 Download PDF

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TW201404972A
TW201404972A TW102114177A TW102114177A TW201404972A TW 201404972 A TW201404972 A TW 201404972A TW 102114177 A TW102114177 A TW 102114177A TW 102114177 A TW102114177 A TW 102114177A TW 201404972 A TW201404972 A TW 201404972A
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web
foam
board
pulp
forming fabric
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TWI589752B (zh
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Isto Heiskanen
Karita Kinnunen
Tuomo Hjelt
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Stora Enso Oyj
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/002—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines by using a foamed suspension
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/03—Non-macromolecular organic compounds
    • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
    • D21H17/09—Sulfur-containing compounds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/22—Agents rendering paper porous, absorbent or bulky
    • D21H21/24—Surfactants
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
    • D21H21/56—Foam
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/26—All layers being made of paper or paperboard
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/16—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only modified by a particular after-treatment
    • D21H11/18—Highly hydrated, swollen or fibrillatable fibres

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Abstract

本發明關於纖維網產品，如紙，及製備此纖維網之方法。依照此方法，將微纖維化纖維素(MFC)連同纖維長度較大的紙漿(如化學熱機械漿(CTMP))混合水與界面活性劑的發泡體，將該發泡體供應至造紙或造板機的成形織物，將該發泡體藉由通過該成形織物進行吸氣而脫水，及將該發泡體乾燥成為最終網產品。該方法產生高容積及高史考特黏結值(Scott bond value)，以對該紙及板產品提供改良的濕及乾拉伸強度。

Description

紙或板的纖維網及其製造方法
本發明關於一種製備紙或板的纖維網(fibrous web)之方法、藉由該方法所得的纖維網、及包含此網作為至少一層之多層板。作為一特定態樣，在用以製造該纖維網之本發明中使用發泡技術。
在造紙工業中，發泡體技術(其中，使用發泡體作為材料的載體相)已被用於網形成法及網塗布法。該技術係揭述於例如以下的刊物：Radvan,B.、Gatward,A.P.J.之The formation of wet-laid webs by a foaming process,Tappi，第55卷(1972)，第748頁；Wiggins Teape Research and Development Ltd.的報告：New process uses foam in papermaking instead of avoiding it,Paper Trade Journal，1971年11月29日；及Smith,M.K.、Punton,V.W.、Rixson,A.G.之The structure and properties of paper formed by a foaming process,TAPPI，1974年1月，第57卷，第1期，第107-111頁。
GB 1 395 757號專利揭述製造製紙用之發泡纖維分散液的設備。將表面活性劑加入纖維長度超過約 3毫米的纖維漿，以提供空氣含量為至少65%之分散液，將其排放在造紙機之成形織物上。該目標為在織物上纖維網的均勻結構(uniform formation)。
在1970年代中期，在生產機台已成功地證明發泡體形成法。在Wiggins TeapeRadfoam法(Arjo Wiggins)中，將纖維以水性發泡體的懸浮液輸送至習知長網造紙機之線材。研發團隊使用該發泡體在以長網造紙機所製的紙中獲得水中纖維濃度非常高(3-5%)的不分層3D結構。
當比較發泡體形成方法與水形成方法則有明確的傾向。使用發泡體形成法的容積較大，但是拉伸指數較小。有較大的結構則該結構為更多孔的，其導致較小的拉伸指數值。自水與發泡體沉降樣品之比較之引起關注的結果為，兩種情形的拉伸剛度指數非常接近，即使發泡體形成的樣品極大。其原因目前未知且需要進一步的研究。
在發泡法所用的界面活性劑對紙網之乾及濕拉伸強度均有負面影響。
拉伸強度損失可藉由紙片的乾拉伸強度之降低而解釋，因界面活性劑被吸附於阻礙纖維間的氫鍵之纖維表面上。由於將濕片保持在一起的主要力量減弱所造成的表面張力降低，起初濕強度因界面活性劑而降低，尤其是在8-25%的乾含量(dry content)。
依照目前的了解，妨礙發泡體形成在紙、紙板及硬紙板製造中成為網標準形成技術的主要問題為： - 在某些應用中，孔隙度太高，- 相較於一般低稠度濕式形成，強度性質降低，- 史考特黏結不良，- 拉伸強度不良，及- 彈性模數不良。
相較於一般濕式形成，發泡體形成可獲得較大的容積(密度較低)。對於典型印刷及包裝紙及板等級，主要缺點為彈性模數(「軟度」)及內部強度(史考特黏結或z-強度)之損失。然而，同樣的特徵對薄紙製造為有利的。因此，發泡體形成在薄紙產品極為常見。
最近改良造紙的方法(以改良在成形織物上所形成的纖維網中的造紙化學物之脫水及保留為目標)為將微纖維化纖維素(MFC)加入紙漿懸浮液。US 6,602,994 B1號專利教示使用具有靜電或立體官能性之衍生化MFC達成目的，其甚至包括網的較佳結構。依照該參考資料，微纖維的直徑為5至100奈米之範圍。
然而，MFC所經歷的缺點為紙之緻密化及高乾燥收縮，以及MFC吸附及保留大量水的傾向，其增加乾燥所需能量且降低造紙機速度及生產力。這些原因使MFC目前尚無法在造紙業中廣為使用。
本發明之目的為藉由發現製造形成發泡纖維網之方法(當保留低密度而給紙及板產品提供實質上增加的強度)而克服或實質上減少關於印刷及包裝紙及板的上述問題。本發明之解決法為經由以下步驟製造網： (i)提供水與界面活性劑之發泡體，(ii)將微纖維化纖維素連同纖維長度較大的紙漿在該發泡體中混合，(iii)將發泡體供應至成形織物，(iv)藉由吸引將成形織物上的發泡體脫水以形成網，及(v)將該網進行最終乾燥。
尤其是現已意外地發現，纖維長度較大的機械或化學漿可結合微纖維化纖維素而有利地用於發泡體形成。即使造紙業已知如此使用MFC，但據申請人所知，先前技術中尚未教示將MFC摻入至發泡體中，且所屬技術領域者尚未預見其益處。
MFC之微纖維一般具有約10奈米至10微米之纖維長度，及約3至50奈米之纖維直徑。用以定義本發明之術語微纖維化纖維素(MFC)亦涵蓋奈米纖維化纖維素(NFC)。根據定義，結合MFC之紙漿具有較大的纖維長度，較佳為約1毫米以上。特別適合用於本發明之紙漿為化學熱機械漿(CTMP)。
除了CTMP，其他可用於本發明的長纖維漿為化學漿、化學機械漿(CMP)、熱機械漿(TMP)、GW，及其他的高產率紙漿，如APMP與NSSC。
不受任何理論限制，據信結合CTMP長纖維等則提供大型結構，且MFC提供長纖維之間的黏結。現已發現，本發明之方法獲得至少2.5cm3/g，較佳為3至7cm3/g之容積。該方法亦證明與CTMP研磨廢品搭配良好，而顯示對例如折疊盒紙板中間層之產品使用較少精製紙漿之可行性。
在發泡體形成中，個別長纖維或MFC單獨均 無法形成毛屑(flock)，然而MFC可建構個別長纖維之間的橋接，此對網提供意外良好的強度性質。
因發泡體形成防止長纖維之間的毛屑形成，故可獲得非常良好的基重形成。如此改良印刷品質之均勻性，因為紙及板中的線規變異(caliber variation)較小。
這些CTMP的堅硬長纖維可在濕式壓製及乾燥時維持大型結構，如此使片產生意外良好的容積。
比較水與發泡體沉降樣品而得的關注結果為，兩種情形的拉伸剛度指數非常接近，即使發泡體所成的樣品極大。其原因目前未知且需要進一步的研究。
本發明之一具體實施例以工業規模在造紙或造板機的行進成形織物(running forming fabric)上形成連續纖維薄片，通過該薄片與成形織物進行吸引而脫水，最終在造紙或造板機的乾燥段中乾燥。
本發明之另一具體實施例包含以最大0.6巴的壓力通過該薄片與成形織物進行吸引空氣而脫水，接著以最大約0.3巴的壓力進行吸引空氣而預先乾燥。
本發明之一進一步具體實施例為在該發泡體所摻入的纖維成分係由約5至40重量百分比，較佳為10至40重量百分比之MFC，與約60至95重量百分比，較佳為60至90重量百分比之長纖維漿所組成。
本發明之又一進一步具體實施例為使該發泡體在被供應至成形織物之前具有60至70體積百分比之空氣含量。接受發泡的紙漿之稠度(consistency)按水量計可為1至2%。發泡體中的界面活性劑之合適量可為0.05 至2.5重量百分比之範圍，但是其易由所屬技術領域者決定。
用於本發明之較佳界面活性劑為十二基硫酸鈉(SDS)，但是亦可使用其他典型的界面活性劑。
藉由使用長纖維素纖維且在發泡體中添加微纖維化纖維素而形成發泡體，因此非常適合且有前途的用於製造需要兼具最佳結構與最佳抗彎剛度之所有紙及板等級之方法。
此產品包括例如所有紙板等級，如：- 紙板類(cartonboards)，包括折疊盒紙板、掛面白紙板(white line chipboard)、固體漂白板、固體未漂白板、液體包裝板等；- 箱用板類(container boards)，包括箱紙板(linerboard)、瓦楞芯紙等；- 特殊板類，包括心型板(core board)、壁紙基材、書面(book binding)板、木漿板等。
該產品亦包括例如新聞紙、改良的新聞紙、羅托新聞紙(rotonews)、MFC、LWC、WFC、銅版紙(art)、及ULWC之紙等級。
本發明所得的高容積高強度結構亦可用於例如：- 作為多層結構(紙類及板類)之中間層(middle ply)，- 於對其他的紙結構及/或塑膠膜層之積層(lamination)，- 作為具有塑膠的擠壓塗層用之纖維素基質，- 作為隔熱、隔音、液體與水分吸收體， - 作為如盤、杯、容器之模塑結構中的可成形層。
可由上述方法而得的本發明之纖維網包含微纖維化纖維素(MFC)與纖維長度較大的紙漿之混合物，且具有至少2.5cm3/g之容積，較佳為3至7cm3/g之容積。
本發明之纖維薄片可具有至少50J/m2，較佳為120至200J/m2之史考特黏結值。
本發明之纖維薄片之纖維長度較大的紙漿可為機械漿，較佳為CTMP。通常該纖維網包含約5至40重量百分比之MFC、與約60至95重量百分比之纖維長度較大的紙漿。
在將本發明之纖維薄片作為多層紙板或硬紙板中的單層時，其較佳為位於中間層，而外表面層可為容積較該中間層小的纖維網。例如以標準造紙技術製造的彈性模數高的較稠密印刷層可組成此外層。可使用本發明所得的多層產品包括例如折疊盒紙板、液體包裝板及食櫥(cupboards)。然而，藉本發明之發泡體形成技術可製造多層板之所有層。
第1圖為實施例中測量各片之容積及修正史考特黏結而測試乾燥的手抄紙之結果。
〔實施例〕
藉以下步驟製造尺寸為38.5公分×26.5公分的發泡體沉降手抄紙(foam laid handsheets)：使用鑽孔機(3500rpm)，將水與作為界面活性劑之十二基硫酸鈉 (SDS)以0.15-0.2克/升的比例混合而製造發泡體，只要發泡體的空氣含量為60-70%即可。發泡體的目標空氣含量係由發泡體設定決定；在發泡體達到目標空氣含量時，發泡體表面之高度不再提高，且混合開始減小發泡體的泡沫大小。在發泡體已就緒時，將包含CTMP與NFC(Daicel KY-100G,10.7%)的纖維懸浮液混合該預製發泡體。將混合持續直到再度達到目標空氣含量。在安定條件下，發泡體中的纖維粒子之間的距離保持固定，且不再發生絮凝(flocculation)。然後將發泡體傾倒至手抄紙模具中，且使用排氣機及真空室通過線材(wire)而過濾。該線材為習知上用於水系形成之型式。然後將線材及形成於其上的手抄紙從模具移除，且在吸引台上使用排氣機預先乾燥。該吸引台具有寬5毫米的吸引縫(suction slit)，其以0.2巴真空通過該片吸取空氣。
依照以上的步驟而由具有不同的分配量之NFC(即5、10、15、20、30、與40%)混合可接受的CTMP(379 CSF)(廢品或稍微研磨精製)的紙漿製造手抄紙。製造僅100% CTMP(0% NFC)的手抄紙作為比較。
測量各片之容積及改良的史考特黏結而測試乾燥的手抄紙。結果係圖示於第1圖。NFC分配量係標記在各測量結果旁。該圖亦包括由習知非發泡體造紙技術所製造的現有產品之數字作為比較。
該測試顯示，例如將20%之NFC混合可接受的CTMP漿，則史考特黏結值由55增至190J/m2；對應的容積值為6及4g/m3。增加CTMP廢品片則史考特黏 結由50增至127J/m2，且對應的容積值為7.4及5.8g/m3。折疊盒紙板之中間層的目標值為至少2.5g/m3之容積，且史考特黏結>100。結果顯示，藉發泡體形成可由粗纖維材料混合NFC而製造具有所需的內部強度性質之折疊盒紙板的高容積中間層。結果亦顯示以較少的精製CTMP漿形成折疊盒紙板中間層之可行性。本發明的經濟性影響為節省紙漿之精製能量、及發泡形成網之乾燥能量。發泡形成(為無關纖維長度之優良結構)的益處亦可造成折疊盒紙板之表面層及塗層較薄。
該測試亦顯示流動發泡體中纖維粒子之間的距離保持固定，即纖維不絮凝。在由此類發泡體製造網時，例如通過造紙機的成形織物而進行吸引，纖維保存其未絮凝狀態且形成具有優良結構的薄片。在移除時，發泡體施加於該結構之結構壓力遠比習知水移除小，如此造成高容積。通過網進行吸引空氣(例如使用吸引縫槽)而結合發泡體形成及網乾燥可獲得超過70%之網固體含量，且保留高容積。將奈米纖維素(NFC)加入欲發泡的纖維材料則增加所形成的網之內部強度性質。

Claims (14)

  1. 一種製備紙或板的纖維網(fibrous web)之方法，其步驟包含：- 提供水與界面活性劑之發泡體，- 將微纖維化纖維素(MFC)連同纖維長度較大的紙漿在該發泡體中混合，- 將發泡體供應至成形織物，- 藉吸力(suction)將成形織物上的發泡體脫水而形成網，及- 將該網進行最終乾燥。
  2. 如申請專利範圍第1項之方法，其中連續纖維網係在造紙或造板機的行進成形織物(running forming fabric)上形成，通過該網與該成形織物進行吸力而脫水，且最終在造紙或造板機的乾燥段中乾燥。
  3. 如申請專利範圍第1或2項之方法，其中該網以空氣最大0.6巴的壓力通過該薄片與成形織物進行吸濾而脫水，接著以最大約0.3巴的壓力進行空氣吸濾而預先乾燥。
  4. 如以上申請專利範圍中任一項之方法，其中在該發泡體混入如化學熱機械漿(CTMP)之機械紙漿。
  5. 如以上申請專利範圍中任一項之方法，其中於該發泡體所混入的纖維成分係由約5至40重量百分比之MFC、與約60至95重量百分比之大纖維漿所組成。
  6. 如以上申請專利範圍中任一項之方法，其中使該發泡體在被供應至成形織物之前具有60至70體積百分比 之空氣含量。
  7. 如以上申請專利範圍中任一項之方法，其中該界面活性劑為十二基硫酸鈉(SDS)。
  8. 一種纖維網，其係藉由如以上申請專利範圍中任一項之方法而得，其特徵為該網包含微纖維化纖維素(MFC)與纖維長度較大的紙漿之混合物，及該網具有至少2.5cm3/g之容積。
  9. 如申請專利範圍第8項之纖維網，其中該網具有3至7cm3/g之容積。
  10. 如申請專利範圍第8或9項之纖維網，其中該網具有至少50J/m2，較佳為120至200J/m2之史考特黏結值(Scott bond value)。
  11. 如申請專利範圍第8至10項中任一項之纖維網，其中該纖維長度較大的紙漿為機械漿，較佳為CTMP。
  12. 如申請專利範圍第8至11項中任一項之纖維網，其中該網包含約5至40重量百分比之MFC、與約60至95重量百分比之大纖維漿。
  13. 一種多層板，其特徵為至少一層為如申請專利範圍第8至12項中任一項之纖維網。
  14. 如申請專利範圍第13項之多層板，其中該板包含如申請專利範圍第8至12項中任一項之纖維網作為中間層，及具有容積小於該中間層之外層。
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