JPS6052683A - Production of peater saturated nonwoven floor lining material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION B. Industrial Application Field This invention relates to a method for producing nonwoven floor backings by a beater saturation process in which the white water does not accumulate ammonium sulfate or polyvalent cations that interfere with the precipitation process.

Prior Art Pretzel US Pat. No. 2.375.2115.

The papermaking fiber slurry is pretreated with alum and ammonia so that the later added binder latex precipitates and acts as a binder during the sheeting process without the addition of further precipitants. A method for producing aluminum hydroxide in and around the fibers is disclosed.

Craig, U.S. Pat. No. 2,599,092, describes a method in which calcium chloride is added to a cellulosic fiber stock, followed by carbonation to produce a hard paperboard. is taught.

Kao, US Pat. No. 3.01T 2.1115, teaches a method for simultaneously coating tenon particles and fibers with a coating material (such as rubber latex). The method requires pretreatment with a salt (such as alum), the addition of an alkali (sodium carbonate or sodium hydroxide) to a pH' of about 5, and does not appear to produce aluminum hydroxide. The latex is then added, followed by the latex coagulant, such as alum. Eckert, U.S. Patent No. 3.5119.11
No. 5 produces mineral fiber M1-viscosity ceramic paperboard by adding aluminum sulfate to a slurry of mineral fibers and clay and then first adding a peptizer such as thorium carbonate or sodium hydroxide. It teaches how to mold. Furthermore, Tj dated February 13, 1872,
US Patent No. 123,7117 to Emann. This patent states that the papermaking slurry is pretreated with alum and then "pre-slaked, freshly calcined" to produce a precipitate of "alumina water" (which is undoubtedly aluminum hydroxide). Discloses a method for treating with "green lime".

C1 Problems that the invention attempts to solve The present invention has been made in view of the above.

A slurry of manufactured fibers is treated with alum and a mixture of sodium carbonate or sodium bicarbonate and sodium hydroxide to a pr-r2 of about 7 to 9, and a binder latex is added to precipitate the latex into the fibers. Ii(◇′
An object of the present invention is to provide (5) a method for manufacturing a beater-saturated nonwoven sheet, which comprises a step of forming a sheet from the obtained slurry.

The water wash prevents the formation of ammonium sulfate in the white water that occurs in the conventional alum-ammonium process described in connection with the Pretzel patent. Ammonium sulfate is harmful to water products such as rivers and lakes. Additionally, polyvalent cations gradually accumulate in recycled white water as water gradually extracts them from clay and other fillers. Eventually, the accumulated polyvalent cations interfere with the precipitation of the binder latex, thus requiring the white water to be drained and replaced more often than is economically desirable.

20 Means and Effects for Solving the Problems According to the present invention, a slurry of papermaking fibers IJ- is formed with water, irrespective of the order (1) adding alum to said slurry, (2) sodium carbonate or water. Addition of sodium oxide and sodium bicarbonate to produce total aluminum hydroxide and T) I'1l-7-9 after addition of said alum and carbonate.
The binder latex (6) is added to the carbonate-treated slurry, and the latex-containing slurry is stirred to precipitate the binder on the fibers while also carbonating the polyvalent cations. A process for making a beater-saturated nonwoven flooring material is provided, comprising forming a sheet from a slurry precipitated as a salt.

A slurry of papermaking fibers consists of fibers, fillers, and additives commonly used in the manufacture of nonwoven floor backing phases. Among the cellulose fibers, mention may be made of sulfite pulp, kraft, soda pulp, cotton aid, cotton linters, paperboard and newspaper. glass.

Inorganic fibers such as mineral wool, asbestos, and wollastonite are used along with organic polymeric fibers (eg, polyethylene, polypropylene, polyester, polyvinyl chloride, etc.). The raw material 1 is prepared with desired fillers such as viscosity, some silicates, carbon black and other suitable fillers 42.
It is produced by adding silk paste to water. A swelling agent for cellulose fibers.

Added with additives such as antioxidants, colorants and titanium dioxide to increase the opacity of the final sheet.

The consistency of the slurry is approximately 0.5-5%. Once the raw material is of suitable consistency, it is subjected to mechanical refinement to obtain the desired degree of freeness. The freeness of the papermaking slurry used in this invention is generally within the range of about 200 to 1100.

The slurry is then treated with paper-grade alum or sodium carbonate. The amount of alum added to the slurry is generally about 10-90% based on the weight of dry latex solids. One of the control points for this precipitation process is the amount of alum added initially; using smaller amounts within this range will increase the size of the precipitated flocs and generally increase the settling time of the latex.

On the other hand, the use of larger amounts will reduce the size of the settling flocs and generally shorten the settling time of the latex.

The latex precipitation time is generally desired to be about 2 to 5 minutes. Once the alum has been added in solid or aqueous form and is sufficiently dissolved in the slurry, in one embodiment, the sodium carbonate is added. Sodium carbonate is added in the form of a solid or an aqueous solution. Then, it is added to the paper making slurry at a pTT of about 7 to 9. A preferred embodiment is pH
It is to add 8.

The reaction between sodium carbonate and the previously added alum produces aluminum hydroxide and sodium sulfate. Aluminum hydroxide precipitates in and around the fibers and filler of the papermaking slurry. and results in smooth and uniform precipitation of latex particles upon addition of the binder to the latex emulsion. In addition, the carbonate ions of the thorium carbonate react with the polyvalent ions, 'IW' and calcium to produce a calcium carbonate precipitate which later serves as a finely divided filler in the final sheet. An advantage of using sodium carbonate in place of ammonium hydroxide in the Pretzel process is that ammonium sulfate is not friendly to fish waterways, whereas sulfuric acid is tolerated.

Furthermore, the removal of calcium ions from the white water allows (9) more of the white water to be recycled than when ammonium hydroxide is added to the alum-treated slurry. Ammonium hydroxide causes unreacted calcium ions and other ions in the white water to accumulate in unwanted water lines. The other divalent ion present in white water is iron.

Magnesium, manganese nickel, copper and zinc. When these aggregated ions accumulate in white water, they all have a detrimental effect on the subsequent precipitation of latex particles.

Sodium bicarbonate can be used in place of sodium carbonate as a treatment agent for the alum-treated slurry.

However, when adding sodium bicarbonate alone, the pH'
e cannot be reduced to about 7 or more. Although latex and cation precipitation occurs at pH 7, that is not the preferred embodiment. The sodium bicarbonate-sodium hydroxide mixture can again be added out of order to the alum addition, since the addition of IJ alum to the sodium bicarbonate provides the desired pH of about 8. I can do it. In such cases, it is sufficient to convert all polyvalent cations to carbonate.

(10) It is necessary to use IJum (bicarbonate). The action of IJium hydroxide is simply to reach the desired pH.

The use of IJum (carbonate) makes it possible to keep the latex precipitation time and floc size unchanged throughout. Fiber and filler retention is increased and the final sheet has higher tensile strength.

In contrast to the alum/ammonia method of the Pretzel patent, p IT control of the slurry is improved.

Elimination of polyvalent cations allows the use of binder latexes that are too sensitive to ions for use in the alum/ammonia process.

Some rubber latexes are significantly more stable than others, increasing the precipitation time in one method. This increased stability may be due to surfactants in the latex or to the introduction of carboxyl groups into the polymer chain. What is the precipitation time?

It can be brought back to normal by adding sodium carbonate first. This results in p T■ of approximately 10. Then +, p T('(Il - 7 O added to the alum to produce the appropriate aluminum hydroxide. After bringing the pH of the carbonate-treated slurry to the desired value, a suitable binder latex is added to the slurry with stirring. Over several minutes, the particles in the binder latex settle on and around the fibers and filler, producing large and uniform composite flocs and a clear supernatant liquid.

Binder latex is a sticky synthetic latex well known in the paper making and split felting arts. Copolymers of butadiene and styrene, copolymers of butadiene and acrylonitrile, many neorenes, acrylic latexes, etc. are used. The binder latex is simply poured into the slurry with stirring to cause precipitation. The amount of latex added depends on the amount of binder needed in the final sheet. This typically amounts to about 30% to 30% binder by weight, based on the dry weight of fibers and filler.

The final step of water spraying is to form the resulting mixture into a sheet. The sheet is formed by feeding the mixture into a paper making machine, such as a Fourdrinier machine, wet machine, etc., to form a fibrous sheet in a conventional manner. The sheet is dried in conventional manner.

E, Example The following examples illustrate 2.3 embodiments of the invention.

Example 1 Two types of 》nd sea) each having the following components:
Il 535 and 50118 were produced. All parts listed are parts by weight unless otherwise specified. Calcium chloride was added to simulate a slurry containing a rather large amount of calcium ions.

Misu Rashi Craft 11.6 11.6 Newspaper 2.
U 2.3'IA (032cm) DE670-6 glass fiber 14
U91-U9 Akira (052m) Polyester no Akira t1. Depression 1. U9(15) Pulpex EA, polyethylene fiber. 83 o,
8 Wollastonite P-11, 51) 1.5 KWW clay from the Klondike region 14.5 11 ■, 5
Sellit 321. Diatomaceous earth 1゜5 10.5TINO
X, antioxidant (substituted cresol) a, o66 o,
o66 carbon black 0.0125 0.0125
Water 2500cc 2500cc Alum 0.5 2.75 NH40HpH7- Na2 COa -pHg CaCJ2 (0.1M) 100cc 1oOec Sedimentation time 115 seconds 2.5 minutes Canadian standard freeness 510 660 Sheet weight 519 55.3 Tensile strength K7) (23℃) B, u -15,6 (Ill) Ingredients +15u5 50+18 (177℃) 5.61b 9.3 Ca value in white water (ppm) 20u 10 examples 2゜Contains the following components ) Manufactures one type of non-end sheet. Except for increasing the ion concentration of calcium, the purpose of this example is to
It is to show the effect on Canadian freeness, settling time, and calcium ions remaining in white water of the prior art alum-ammonium method. Excess ammonia addition at pH above 7 does not change either parameter.

Unsold craft 2.76 tt tt tt Newspaper 2.76 〃tt tt Glass fiber (bi-670-6) 1. ], 2 tt
u tt component 51li 51+14 5145 51
116 Clay of the Klondike region 11.6 〃u tt
Cerit 321 (diatomaceous earth) 811〃〃〃TI:NOX
(Acid opener) 0,0528 // // // Carbon black 0,01 tt tt ttH20 (2
%consistency) 2000ce tt tt t
t alum U, Ott tt n CaC12 (0,1M) -20cc 1LOcc 3
0ccNI-I3 pH7/l tt tt Canadian Freeness 6606206 0520 Precipitation Time (min) 2 1,75 1.75 1 Example 5 A series of one type having the same components except for the difference in the amount of calcium ions in the slurry hand sheets were manufactured. This example shows the results using sodium carbonate at pH 7. Precipitation of binder latex can be controlled in 1 case 2
Although the increase in adducts using the alum-ammonia method shown in (JJn) is not very large, calcium and
Increased ion content.

Unsarashi Craft 2.76 tt tt Newspaper
2.76tt u tt Glass fiber (QC-670-6) 1.12 tt t
t, tt wollastonite P-111, 6tt tt tt Klondike fat clay 1],, 6 p tt tt Cerit 321 (diatomaceous earth) 8. It p tt tt
Kymene 20611 0.276 tt 〃pT
INOX O,0528p tt ttCarbon black 0.01 tt tt ttPolysar PL
-2556, Ott tt ttH20 (2% consistency) 2000 memories 〃〃〃Alum U:O/
/ // tt (17) Component 51117 51118 '51ヰ9 '51
50CaC7!2 (0,1M) -20cc 1lo
cc 80ccNa2 co31.9 2.0 2.0
21 Canadian freeness 690 611t0 680 6
60 Precipitation time (min) 1.5 2.0 1.75 1.
5pH7////11 Example) 1゜This example shows that the pH in the slurry is adjusted before adding the binder latex.
A preferred embodiment in which sodium carbonate is added to increase the temperature to 8 will be described. Since considerably more calcium ions are removed by precipitation as calcium carbonate,
The precipitation time remained constant despite the increase in calcium ions.

Unfiltered craft 2.76 tt tt tt Newspaper 2.76 p 〃p Glass fiber (QC-670-6) 1.12 tt t
t ttPulpex E-A 1,76 p tt
tt(18) Ingredients 5155 51565157 5]58 Wollastonite P-1], i,, 6 tt tt p Klondike region's sticky moon, Fl tt tt p Sellit 321
．． 8) 1tt tt ttKymene 206+1
0.276 tt u nTlN0X O,0528
tt tt u carbon black o, o] tt n
ttPolysar PL-2556, Ott n
ttH20 (2% consistency density) 2000cc alum U, On // tt CaC1!2 (0,1M) -20cc 1lQcc
8 (JccNa2 co3 2u 2.11 2.5
2.7 Canada Rosuisan 700 670 710 680
Precipitation time (min) 2.5 2252.5 2.25p'
f18tt tt tt Example The hand sheet with the 5th component was completely prepared.

Juboshi alum and Ca content 1.60 ppm (11
- After addition of enough CaCA2 to give p HF3
0.65 parts of sodium hydroxide was added to obtain k.

Next, IJum bicarbonate was added to the top. The quality of the obtained slurry is 700. Precipitation time was 2 minutes.

And the residual calcium ion strength is 113 p p
It was m.

Example 6 A hand sea F 5 )s g 7 with the following components:
2 were manufactured.

Ingredients 5uF37 Unsealed kraft fiber 50 New paper 2.2 Glass fiber (QC-670-6) 1.1 + polyester fiber 1.11 Polyethylene fiber 22 Klondike clay 22.5 Wollastonite 115 Diatomaceous earth 60 Minutes 51187 Carbon Black 001 Alum 30 Water (2% consistency) 25 ooce Sodium Carbonate 2) 1 Canadaro Suisan 610 Precipitation Time 35 minutes Sodium carbonate was first added to the slurry.

The pH was approximately 1O. The pH was then brought to 7 by the addition of alum. Forming of the sheet was normal.

(21)

Claims (1)

[Claims] L: forming a slurry of papermaking fibers IJ-'e in water, adding (1) alum to the slurry in any order, and (2)
Sodium carbonate or sulfur hydroxide and sodium bicarbonate are added to form aluminum hydroxide, and p T+ f after addition of said alum and carbonate is 7~
Add the binding agent latex to the carbonate-treated slurry, and stir the latex-containing slurry to precipitate the binder on the fibers and convert the polyvalent cations into carbonates. 1. A process for producing a beater-saturated nonwoven flooring material, comprising precipitation and forming a sheet from the resulting slurry. 2. The manufacturing method according to claim 1, wherein the papermaking fibers are comprised of cellulose fibers, glass fibers, and polyolefin fibers. Step 1: Prepare a slurry of paper fibers with water, add alum to the slurry, add sodium carbonate or sodium hydroxide, and sodium bicarbonate to the alum-treated slurry, and adjust the pH to within the range of 7 to 9. The binder latex was then added to the carbonate-treated slurry to form aluminum hydroxide. A beater-saturated nonwoven characterized in that a slurry containing the latex is kept to precipitate a binder on the fibers and polyvalent cations are precipitated as carbonates, and a sheet is formed from the obtained slurry. Manufacturing method for floor lining materials. 11. The manufacturing method according to claim 1, wherein the papermaking fibers are comprised of cellulose fibers, glass fibers, and polyolefin fibers. 5. The manufacturing method according to claim 1, wherein the papermaking slurry contains a fine filler. 6. The latex of the binder is carboxylated steel 1
7-Butadiene rubber. The manufacturing method according to claim 1, wherein the pH is 8. 8. The fibers are made of cellulose 5 glass and polyolefin fibers, and the carbonate is sodium carbonate,
8. The method according to claim 1, wherein p T ( is 8.) and the latex of the binder is carboxylated styrene-butadiene rubber.