Microemulsified functionalized polymers

Abstract: Functionalized polymer microparticles having particle diameters of from about 200 to about 4000Å are prepared and are useful in facilitating a variety of flocculation and thickening of dispersions of suspended solids applications.

Description: The present invention relates to the manufacture of dry and/or wet strength paper using functionalised, water-soluble polymers as strength-imparting agents. Functionalised, water-soluble polymers are well known and are useful in a variety of applications, including paper-making. A major drawback of many functionalised polymers is their tendency to crosslink, this problem becoming more severe as the polymer solids content or the molecular weights thereof is increased. In particular, water-soluble, glyoxalated acrylamide polymer wet strength agents are disclosed in US-A-3556932. These wet strength agents are made from polymers with molecular weights ranging from less than about 1,000,000, preferably less than about 25,000. The polymers are reacted with glyoxal in a dilute, aqueous solution to impart -CONHCHOHCHO functionalities onto the polymer and to increase the molecular weight of the polymer through glyoxal crosslinks. Low molecular weight polymers and dilute solutions are required to impart at least a 6 percent -CONHCHOHCHO functionality to the polymers without infinitely crosslinking, or gelling, them, in which condition the polymers are useless for wet strength applications. Even at these low solids concentrations (dilute conditions), crosslinking continues and limits the shelf life of the product. For example, commercial products, supplied as 10% solids solutions, gel within about 8 days at room temperature. In our European Patent No. 0374478 (Application No. 89121217.7), from which the present application has been divided, we describe and claim, inter alia, (alk)acrylamide-based polymers having -CONHCHOHCHO substituents which can be prepared at high solids levels or at high molecular weight without extensive interpolymer crosslinking such that they may be economically transported and easily handled by the end user without the need for any on site preparation. Such polymers are useful as dry and/or wet strength agents in paper-making and as such satisfy a long felt need in the art. The present invention is directed to the use of such polymers for making dry and/or wet strength paper. In accordance with this invention there is provided a method of making dry and/or wet strength paper, which comprises absorbing in an aqueous pulp of paper-making fibers an effective amount, as a latent strengthening agent, of a composition comprising an (alk)acrylamide-based polymer having glyoxal-reactive amide substituents and -CONHCHOHCHO substituents which have a tendency to crosslink the polymer, said -CONHCHOHCHO substituents being present in an excess of 0.5 weight percent, wherein said polymer is present as micelles having particle diameters of from 20 to 400 nm (200 to 4000 Å) and wherein said micelles are obtainable from a microemulsion, and recovering the resultant paper. The present invention also provides a method of making dry and/or wet strength paper which comprises: forming a dilute aqueous solution from micelles comprising water and an (alk)acrylamide-based polymer, said polymer having glyoxal-reactive amide substituents and -CONHCHOHCHO substituents which have a tendency to crosslink the polymer, said -CONHCHOHCHO substituents being present in an excess of 0.5 weight percent and said micelles having particle diameters of from 20 to 400 nm (200 to 4000 Å); adding said solution to an aqueous pulp of paper-making fibers in an amount effective to be absorbed by said fibers; and recovering the resultant paper. Further, the present invention provides a method of making dry and/or wet strength paper wherein an (alk)acrylamide-based polymer is added to an aqueous pulp of paper-making fibers and the resultant slurry is laid down as a web, characterized in that it comprises forming micelles of water and an (alk)acrylamide-containing polymer having glyoxal-reactive amide substituents and -CONHCHOHCHO substituents which have a tendency to crosslink, said -CONHCHOHCHO substituents being present in an excess of 0.5 weight percent and said micelles having particle diameters in the range of 20 to 400 nm (200 to 4000 Å); forming said micelles into a dilute aqueous solution; adding said solution to said aqueous pulp; and recovering the resultant paper. Still further, the present invention provides dry and/or wet strength paper comprised of water-laid, cellulosic paper-making fibers bonded together by an absorbed and at least partially cellulose-reacted composition comprising a glyoxalated (alk)acrylamide-containing polymer having (1) glyoxal-reactive amide substituents and -CONHCHOHCHO substituents which have a tendency to crosslink, said -CONHCHOHCHO substituents being present in an excess of 0.5 weight percent, and (2) being present as micelles of particle diameters ranging from 20 to 400 nm (200 to 4000 Å). In contrast to the functionalised polymers used in the prior art for paper-making which contain large quantities of polymer molecules in the same aqueous environment, the functionalised polymers used in the present invention are isolated as individual, or a limited number of polymer molecules in each aqueous emulsion micelle. Thus, the problem of large scale interpolymer crosslinking inherent in the solution and inverse emulsion products of the prior art is overcome, resulting in polymers which, even though crosslinked, are useful for their intended purpose in paper-making, thereby allowing the polymer to maintain performance on crosslinking and to be prepared at high polymer solids content. Water-soluble polymers which comprise the basis for the polymers used in the present invention are (alk)acrylamide-containing polymers having glyoxal-reactive amide substituents. Examples of suitable glyoxal-reactive monomers are the acrylamides such as acrylamide and methacrylamide; and N-alkyl acrylamides, such as N-methylacrylamide and N-octylacrylamide. The polymers may also contain units derived from such monomers are N,N-dialkylaminoalkyl(alk)acrylamides such as N,N-dimethylaminomethyl acrylamide and N,N-dimethylaminopropylmethacrylamide; the hydroxyalkyl(alk)-acrylates such as hydroxyethyl acrylate and hydroxyethylmethacrylate; N,N-dialkylaminoalkyl(alk)acrylates such as N,N-dimethylaminoethyl acrylate and methacrylate, N,N-diethylaminoethyl acrylate and methacrylate; and unsaturated primary, secondary and tertiary amines such as allyl amine, diallylamine, N-alkyldiallyl amines and mixtures thereof. These water-soluble polymers may be prepared, via known polymerization procedures, by polymerization of the above-enumerated monomers, alone or in conjunction with up to about 99.5%, by weight, based on the total weight of the polymer, of additional non-ionic cationic or anionic comonomers such as acryloylmorpholine; N-vinyl pyrrolidone; N-vinylformamide; the N,N-dialkylacrylamides such as N,N-dimethylacrylamide and N,N-dipropylacrylamide; the N,N-dialkylalkacrylamide such as N,N-dimethylmethacrylamide, N,N-dipropylmethacrylamide; diallyldialkyl ammonium chlorides; the salts and quaternaries of N,N-dialkylaminoalkyl(alk)-acrylates, N,N-dialkylaminoalkyl(alk)acrylamides etc; acrylic acid; methacrylic acid; fumaric acid; itaconic acid; maleic acid; 2-acrylamido-2-methylpropanesulfonic acid; styrene sulfonic acid and their salts. Up to about 10%, by weight, same basis, of water-insoluble comonomers may also be included in the base polymers discussed above. Such monomers include styrene; acrylonitrile; methyl acrylate; methyl methacrylate and vinyl acetate. The -CONHCHOHCHO functional groups possessed by the polymer particles of the present invention may be imparted thereto by (1) reacting a water-soluble (alk)acrylamide-containing polymer with glyoxal, or (2) polymerizing a monomer capable of forming a water-soluble (alk)acrylamide-containing polymer in the presence of glyoxal, or (3) polymerizing a monomer already possessing a -CONHCHOHCHO group and capable of forming, alone or in conjunction with another monomer, a water-soluble (alk)acrylamide polymer; or (4) polymerizing a monomer containing a group capable of being transformed into a -CONHCHOHCHO group and capable of forming a water-soluble (alk)acrylamide polymer, (1) alone or in conjunction with another monomer, or (2) after said group has been transformed into said glyoxalated functional group. In the first process, a water-soluble (alk)acrylamide polymer is reacted with glyoxal. As regards the second process discussed above, glyoxal can be added to the monomers used to prepare the (alk)acrylamide polymer particles before or during the polymerization to add the -CONHCHOHCHO functional group to the resultant polymer. In the third process, glyoxylation reaction can be carried out on the (alk)acrylamide monomer first and then the resultant functionalised monomer may be polymerized under known conditions. In the fourth process of preparation, the (alk)acrylamide monomer being polymerized contains, or is made to contain, a group which is capable of being transformed into a -CONHCHOHCHO functional group. For the purposes of the present invention, it is necessary that the resulting (alk)acrylamide polymers should contain in an excess of 0.5 weight percent of -CONHCHOHCHO substituent groups. In each of the above polymer-forming procedures, the resultant polymers tend to undergo crosslinking. If the polymers are not produced as micelles having particle diameters of from 20 to 400 nm (200 to 4000 Å), they result in compositions which are not useful for their intended purpose due to the crosslinking which occurs. Preferably, the micelles have particle diameters of from 30 to 200 nm (300 to 2000 Å) and even more preferably from 35 to 100 nm (350 to 1000 Å). The polymer micelles used in the present invention may be obtained by the inverse emulsion and microemulsion polymerization processes which are described in detail in the parent European Patent No. 0374478, supra. The glyoxylated (alk)acrylamide polymer particle can be employed in the present invention as dilute aqueous solutions formed by inverting the emulsions, optionally in the presence of a breaker surfactant, or by recovering the particles from the emulsion such as by stripping or by adding the emulsion to a solvent which precipitates the polymer, e.g. isopropanol, filtering off the resultant solids, drying and redispersing in water. The invention is illustrated by the Examples which follow. In the examples: Bulk Viscosity (BV) of emulsions is measured at 25±1° in a Brook viscometer (LVT model) with a #2 spindle at 12 rpm. Standard Viscosity (SV) is measured by adding 50 gms of a 0.2% aqueous polymer solution and 5.84 gms of sodium chloride to 48 gm of water, stirring the resulting mixture for 5 minutes to completely dissolve the salt, adjusting the pH to 5 and determining the viscosity at 25±0.1°C using a Brookfiled viscometer (LVT model) with UL adapter at 60 rpm. Cationic equivalent (CEQ) is measured by the technique described in J.CHem. Ed., 62 (7), 627 (1985). EXAMPLE 1 To a suitable reactor are added 96 gms of an isoparaffinic solvent having a b.p. of 207-254°C (IPS), 10.61 gms of polyoxyethylene sorbitan trioleate (POST) and 6.37 gms of the reaction product of diethanolamine and oleic acid (DOA). To the clear solution is added a solution of 28.61 gms of acrylamide (AMD), 5.05 gms of diallyldimethyl ammonium chloride (DADM), 0.017 gms of the disodium salt of ethylenediaminetetracetic acid (EDTA) 0.0034 gms of NaBrO 3 and 46.32 gms of deionized water with stirring to produce a clear microemulsion. The solution pH is adjusted to 4.0 with sulfuric acid and the microemulsion is nitrogen sparged to reduce its oxygen content to less than 0.1 ppm. SO 2 gas is then passed into the microemulsion to initiate polymerization. The emulsion temperature is held at 25°C during the polymerization until 96% of the AMD and about 40% of the DADM is converted to polymer. The resultant clear product has a bulk viscosity of 15 mPa·s (15 cps) a particle size of about 42 nm (about 420Å) and a Standard Viscosity of 2.9 mPa (2.9 cps) (3x10 6 M.W.) and a solids content of 17.39%. To 50g of the above microemulsion are added 5.45 gms of a 40% aqueous glyoxal solution at pH 4.0. After standing at room temperature for 17 to 31 days, respectively, 2 portions of the emulsion are inverted by adding them to deionized water and the resultant solutions are added to paper pulp at 0.5% and 1.0% based on the dry fiber. See Table 1 for the paper test results. The acronyms given the various materials in Example 1 apply equally to all the following examples as well as others expressed therein. PAPER TEST Example 1 1 Tensile Strength/kg/cm (lbs.in) 0.5%, weight 17 days, 0.55 (3.1) 0.62 (3.5) 31 days, 0.52 (2.9) 0.59 (3.3) 1.0%, weight 17 days, 0.71 (4.0) 0.82 (4.6) 31 days 0.73 (4.1) 0.84 (4.7) As can be seen by the wet-strength data, AMD/DADM/glyoxal microemulsion products provide greater wet strength than AMD/DADM/ glyoxal wet strength agents described in the prior art as represented by a commercially available sample. The AMD/DADM/glyoxal is also seen to be of higher solids content and prepared with higher molecular weight polymers. EXAMPLES 2 - 6 Examples 2 - 6 describe a series of microemulsion compositions prepared from monomer microemulsions containing AMD/DADM (90/10 by weight), but with varying amounts of glyoxal. EXAMPLE 2 28.74 gms of POST, 6.74 gms of sorbitan monooleate (SM) and 0.071 gm of benzoin isobutyl ether are dissolved in 191.93 gms of IPS to produce an oil solution. Separately, an aqueous solution of 51.34 gms of AMD, 5.68 gms of DADM, 14.20 gms of glyoxal, 0.028 gm of EDTA and 89.27 gms of water is prepared and adjusted to pH 3.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. The resulting microemulsion is sparged with nitrogen and polymerization of the monomers thereof is initiated with UV light at 25°C. The polymerization is continued for approximately one half hour and produces a clear, stable microemulsion containing a glyoxalated copolymer of AMD/DADM. The microemulsion possesses a bulk viscosity of 16 mPa·s (16 cps). EXAMPLE 3 28.74 gms of POST, 6.74 gms of SM and 0.071 gm of benzoin isobutyl ether are dissolved in 191.93 gms of IPS to product an oil solution. Separately, an aqueous solution of 42.58 gms of AMD, 4.74 gms of DADM, 23.66 gms of glyoxal, 0.028 gm of EDTA and 89.27 gms of water is prepared and adjusted to pH 3.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. The resulting microemulsion is sparged with nitrogen and polymerization is initiated as in Example 2. The microemulsion of glyoxalated copolymer of AMD/DADM possesses a bulk viscosity of 15 mPa·s (15 cps). EXAMPLE 4 31.51 gms of POST, 3.97 gms of SM and 0.071 gm of benzoin isobutyl ether are dissolved in 191.93 gms of IPS to produce an oil solution. Separately, an aqueous solution of 36.5 gins of AMD, 4.06 gins of DADM, 30.42 gms of glyoxal, 0.028 gins of EDTA and 89.27 gms of water is prepared and adjusted to pH 3.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. Polymerization is conducted as in Example 2 to produce a clear, stable microemulsion containing a glyoxalated copolymer of AMD/DADM having a bulk viscosity of 20 mPa·s (20 cps ). EXAMPLE 5 31.51 gms of POST, 3.97 gins of SM and 0.071 gms of benzoin isobutyl ether are dissolved in 191.93 gms of IPS to produce an oil solution. Separately, an aqueous solution of 31.94 gms of AMD, 3.54 gms of DADM, 35.48 gms of glyoxal, 0.028 gms of EDTA and 89.27 gms of water is prepared and adjusted to pH 3.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. The resulting microemulsion is sparged with nitrogen. Polymerization is conducted as in Example 2 to produce a clear, stable microemulsion containing a glyoxalated copolymer of AMD/DADM having a bulk viscosity of 5 mPa·s (5.0 cps ) EXAMPLE 6 31.51 gms of POST, 3.97 gms of SM and 0.071 gm of benzoin isobutyl ether are dissolved in 191.93 gms of IPS to produce an oil solution. Separately, an aqueous solution of 28.4 gms of acrylamide, 3.16 gins of DADM, 39.44 gins of glyoxal, 0.028 gins of EDTA and 89.27 gms of water is prepared and adjusted to pH 3.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. The resulting microemulsion is sparged with nitrogen and then polymerization is conducted as in Example 2 to produce a clear, stable microemulsion containing a glyoxalated copolymer of AMD/DADM having a bulk viscosity of 17.5 mPa·s (17.5 cps). EXAMPLES 7 - 9 Examples 7 - 9 describe a series of compositions prepared from monomer microemulsions possessing varying ratios of AMD/DADM while maintaining a 25%, by weight, glyoxal concentration. EXAMPLE 7 14.56g of POST, 3.18g of SM and 0.0354g of benzoin isobutyl ether are dissolved in 95.95g of IPS to produce an oil solution. Separately, an aqueous solution of 22.71g of AMD, 5.68g of DADM, 7.10g of glyoxal, 0.014g of EDTA and 44.64g of water is prepared and adjusted to pH 3.5 with 0.5N HC1. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. The resulting microemulsion is sparged with nitrogen and polymerization is conducted as in Example 2 to produce a clear, stable microemulsion containing a glyoxalated copolymer of AMD/DADM. EXAMPLE 8 15.36 gms of POST, 2.38 gms of SM and 0.0354 gms of benzoin isobutyl ether are dissolved in 95.95 gms of IPS to produce an oil solution. Separately, an aqueous solution of 19.87 gms of AMD, 8.52 gms of DADM, 7.10 gms of glyoxal, 0.014 gms of EDTA and 44.54 gins of water is prepared and adjusted to pH 3.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. Polymerization is effected as in Example 2 to produce a clear, stable microemulsion containing a glyoxalated copolymer of AMD/DADM. EXAMPLE 9 16.94 gms of POST, 0.97 gm of SM and 0.0354 gm of benzoin isobutyl ether are dissolved in 95.95 gms of IPS to produce an oil solution. Separately, an aqueous solution of 14.2 gms of AMD, 14.2 gms of DADM, 7.10 gins of glyoxal, 0.014 gms of EDTA and 44.64 gms of water is prepared and adjusted to pH 3.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. Polymerization is effected as in Example 2 to produce a clear, stable microemulsion containing a glyoxalated copolymer of AMD/DADM. EXAMPLE 10 Example 10 is an example of a process utilizing redox initiation and post-addition of glyoxal to the polymerized AMD/DADM microemulsion. 12.85 gms of POST and 3.57 gins of SM are dissolved in 96.0 gms of IPS to produce an oil solution. Separately, an aqueous solution of 28.61 gms of AMD, 5.05 gms of DADM, 0.017 gm of EDTA 0.12 gm of a 2.83 percent solution of sodium bromate and 44.66g of water is prepared and adjusted to pH 4.0 with l.ON sulfuric acid. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. The resulting microemulsion is sparged with nitrogen and SO 2 gas is bubbled into the microemulsion initiating polymerization at 25°C. The SO 2 bubbling is continued until the polymerization is complete producing a clear, stable microemulsion containing a copolymer of AMD/DADM. To 50 gins of this emulsion is added 5.45 gins of a 40% aqueous glyoxal solution at pH 4. The resulting clear microemulsion contains a glyoxalated copolymer of AMD/DADM. EXAMPLES 11 - 14 Examples 11 - 14 are systems in which a portion of the acrylamide is replaced with another nonionic monomer (N,N-dimethylacrylamide (DMA) or N-vinyl-2-pyrrolidone (VP)). EXAMPLE 11 12.44 gms of POST, 5.30 gms of SM and 0.0354 gm of benzoin isobutyl ether are dissolved in 95.96 gms of IPS to produce an oil solution. Separately, an aqueous solution of 12.78 gms of AMD 12.78 gms of VP, 2.84 gms of DADM, 7.10 gms of glyoxal, 0.014 gms of EDTA, 1.42 gms of sodium acetate buffer and 43.07 gms of water is prepared at pH 5.5. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. The resulting microemulsion is polymerized as in Example 2 to produce a clear, stable microemulsion containing a glyoxalated terpolymer of AMD/VP/DADM. EXAMPLE 12 7.15 gms of POST, 10.59 gms of SM and 0.0354 gms of benzoin isobutyl ether are dissolved in 95.96 gms of IPS to produce an oil solution. Separately, an aqueous solution of 5.68 gms of AMD, 19.88 gms of VP, 2.84 gms of DADM, 7.10 gms of glyoxal, 0.014 gms of EDTA, 1.42 gms of sodium acetate buffer and 43.07 gms of water is prepared at pH 5.5. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. Polymerization as in Example 2 produces a clear, stable microemulsion containing a glyoxalated terpolymer of AMD/VP/DADM. EXAMPLE 13 2.96 gins of polyoxyethylene sorbitan monololeate (POSO), 14.78 gms of polyoxyethylenesorbitol hexaoleate (MESH) and 0.0354 gms of benzoin isobutyl ether are dissolved in 95.46 gms of IPS to produce an oil solution. Separately, an aqueous solution of 2.56 g of AMD, 23.09 gms of DMA, 2.84 gins of DADM, 7.10 gms of glyoxal, 0.014 gm of EDTA, 1.42 gms of sodium acetate buffer and 43.07 gms of water is prepared at pH 5.5. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. Polymerization, as in Example 2 produces a clear, stable microemulsion containing a glyoxalated terpolymer of AMD/DMA/DADM. EXAMPLE 14 17.14 gms of PESH, 0.60 gm of SM and 0.0354 gm of benzoin isobutyl ether are dissolved in 95.96 gins of IPS to produce an oil solution. Separately, an aqueous solution of 12.78 gins of AMD, 12.78 gms of DMA, 2.84 gms of DADM, 7.10 gms of glyoxal, 0.014 gms of EDTA, 1.42 gms of sodium acetate buffer and 43.07 gms of water is prepared at pH 5.5. Following Example 2, polymerization results in a clear, stable microemulsion containing a terpolymer of AMD/DMA/DADM. EXAMPLES 15 - 22 Examples 15 - 22 describe the preparation of a series of microemulsion and standard inverse emulsions with varying particle sizes to determine the effect of particle size on wet strength performance. All products are produced from (90/10) AMD/DADM starting monomer (micro)emulsions which are charged with 25%, by weight, of glyoxal based on AMD/DADM. EXAMPLE 15 8.63 gms of POST, 2.02 gms of SM and 0.0354 gm of benzoin isobutyl ether are dissolved in 95.96 gins of I?S to produce an oil solution. Separately, an aqueous solution of 25.55 gms of AMD, 2.84 gms of DADM, 7.10 gins of glyoxal, 0.014 gm of EDTA, 1.42 gm of sodium acetate buffer and 43.08 gms of water is prepared at pH 5.5. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion as in Example 1. Polymerization as in Example 2 produces a clear, stable microemulsion containing a glyoxalated copolymer of AMD/DADM. The particle size of the polymer is about 63 nm (about 630Å). EXAMPLE 16 The procedure of Example 15 is again followed except that 28.75 gins of POST and 6.74 gms of SM are used. A glyoxalated copolymer of AMD/DADM with a particle size of about 31 nm (about 310Å) is produced. EXAMPLE 17 Following the procedure of Example 15, except that 11.5 gms of POST and 2.7 gms of SM are used, a glyoxalated copolymer of AMD/DADM having a particle size of about 52 nm (about 520Å). EXAMPLE 18 Again following the procedure of Example 15 except that 14.37 gms of POST and 3.37 gms of SM are used, a glyoxalated copolymer of AMD/DADM is produced. The particle size of the polymer particles produced is about 36 nn (about 360Å). EXAMPLE 19 7.5 gms of DOA and 1.25 gms of an A/B/A block copolymer of about 5000 m.w. wherein the A units comprise palmitic acid and 12-hydroxystearic acid (1:5) and the B units are polyethylene oxide (m.w. 1500) (hereinafter identified as PHP) are dissolved in 70.71 qms of a mixed hydrocarbon solvent having a b.p. range of 187.8-270°C (370-518°F) (MH). Separately, an aqueous solution of 59.20 gins of AND, 6.58 gms of DADM, 16.45 gms of glyoxal, 0.039 gm of EDTA, 3.29 gms of sodium acetate buffer, 0.27 gm of sodium sulfate, 0.0822 gm of 2,2'-azobis(2-amidinopropane)-dihydrochloride (A3DC) and 99.42 gins of water is prepared and adjusted to pn 5.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution and emulsified. The resulting white, inverse emulsion is sparged with nitrogen and then initiated at 25°C with U.V. light. The polymerization is continued for approximately one hour and produces an inverse emulsion containing a glyoxalated copolymer of AMD/DADM possessing a bulk viscosity of 67 mPa·s (670 cps). The particle size of the polymer is about 326 nm (about 3260Å). EXAMPLE 20 (comparative) 3.97 gms of DOA, 0.79 gm of PHP and 0.0822 gm of benzoin isobutyl ether are dissolved in 74.70 gms of PHP and 0.0822 gm of benzoin isobutyl ether are dissolved in 74.70 gms of MH. Following Example 19 except that the ABDC is omitted, an aqueous solution is prepared and adjusted to pH 5.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution and emulsified. The resulting white, inverse emulsion is sparged with nitrogen and then initiated with UV light at 25°C. The polymerization is continued for approximately one hour and produces an inverse emulsion containing a glyoxalated copolymer of AMD/DADM possessing a bulk viscosity of 193 mPa·s (193 cps). The particle size of the emulsion is about 782 nm (about 7820Å). EXAMPLE 21 The procedure of Example 19 is again followed except that benzoin isobutyl ether is used in place of the ABDC in equivalent amounts. The resultant polymer has a particle size of 209 nm (2090Å). EXAMPLE 22 15.49 gms of POST and 2.29 gins of SM are dissolved in 95.96 gins of IPS and 0.0354 gm of benzoin isobutyl ether to produce an oil solution. Separately, an aqueous solution of 18.40 gins of AMD, 2.05 gms of DADM, 5.11 gins of glyoxal, 0.012 gm of EDTA, 1.02 gins of sodium acetate and 53.41 gms of water is prepared and adjusted to pH 5.5. The aqueous monomer solution is added to the oil solution producing a clear microemulsion. The resulting emulsion is sparged with nitrogen and initiated with UV light at 25°C. The polymerization is continued for about one half hour and produces a clear, stable microemulsion with a bulk viscosity of 30 mPa·s (30 cps). The particle size of the glyoxalated AMD/DADM copolymer is 55 nm (550Å). EXAMPLE 23 (Comparative) 52.59 gms of POST and 31.56 gins of DOA are dissolved in 96 gms of IPS to produce an oil solution. Separately, an aqueous solution of 28.61 gms of AMD, 5.05 gms of DADM, 0.017 gm of EDTA, 0.0034 gm of ABDC and 46.32 gms of water is prepared. The aqueous monomer solution is added to the oil solution producing a clear microemulsion. The microemulsion is sparged with nitrogen and then initiated with UV light at 25°C. The polymerization is continued for about 2 hours and produces a clear, stable microemulsion containing a copolymer of AMD/DADM. The bulk viscosity is 213 mPa·s (213 cps) and the polymer particle size is 22 nm (220Å). EXAMPLE 24 71.78 gms of POST, and 16.86 gms of SM and 0.0354 gms of benzoin isobutyl ether are dissolved in 95.96 gms of MH resulting in an oil solution. Separately, an aqueous solution of 25.55 gms of AMD, 2.84 gins or DADM, 7.10 gins of glyoxal, 0.014 gm of EDTA 1.42 gins of sodium acetate, and 43.08 gins of water is prepared and adjusted to pH 5.5 with 0.5N HCl. The aqueous monomer solution is then added to the oil solution producing a clear microemulsion. The microemulsion is then treated as in Example 15 resulting in a glyoxalated copolymer of AMD/DADM possessing a bulk viscosity of 105 cps. The particle size of the polymer is about 30 nm (300Å). EXAMPLE 25-44 In order to determine the ability of the compositions of this invention to impart wet strength to paper, the products prepared in Examples 2 - 6 (Table 2) (various levels of glyoxal), Examples 7 and 10 (Table 3) (increased levels of DADM), (redox initiation and post addition of glyoxal), Examples 11 and 13 (Table 4) (AMD/VP/DADM and AMD/DMA/DADM terpolymers), and Examples 15-24 and 1 (effect of particle size on performance) (Table 5) were used to make wet strength paper and the resulting properties of the paper examined. The following describes the method used for making the wet-strength paper. To an aqueous pulp at 0.6% consistency and pH 6.5 composed of bleached Astracell/Albacell hardwood/softwood 50/50, by weight, kraft paper-making fibers beaten to a Canadian standard freeness of about 500 ml is added the cationic resin solution of one of the examples, as a 0.1% solution of broken emulsion, to provide 0.5% of the glyoxalated polymer based on the dry weight of the fibers. The pulp is readjusted to pH 6.5 and is stirred briefly to permit the polymer to be absorbed by the fibers. The fibers are formed into a water-laid web having a basis weight of 22.68 kg (50 lbs) 63.5 x 101.6 cm (25" x 40"/500 ream) in a Nash handsheet machine. The web is pressed between blotters and dried for 1 minute on a rotary laboratory drum drier having a drum temperature of 116°C (240°F). The immediate wet strength of the resulting paper is measured after brushing both sides of the paper with water at 20°C and pH 7. The wet strength results are shown in the Tables 2 - 5 as the performance of the various polymers of the examples specified as a percent of performance of a commercially available 25% glyoxalated polymer of AMD and DADM (90/10). Example Polymer of Example Percentage of Commercial Product Immediate Wet Strength Performance % Glyoxal AMD/DADM 25 2 118 25 90/10 26 3 120 50 do 27 4 124 75 do 28 5 126 100 do 29 6 124 125 do Example Polymer of Example Percentage of Commercial Product Immediate Wet Strength Performance % Glyoxal(a) AMD/DADM 30 7 106 25 80/20 31 10 106 25 85/15 The results in Table 2 show that a variety of glyoxal levels can be employed while achieving improved performance of the instant polymers relative to the prior art. Table 3 shows that the benefits of the instant invention are achieved at a variety of AND/DADM compositions (80/20, by weight, in Example 30, 85/15, by weight, in Example 31 and 90/10, by weight, in Example 25, Table 2). Table 4 shows the invention utilizing terpolymers containing a second nonionic monomer (N,N-dimethylacrylamide and vinyl pyrrolidone) in addition to acrylamide. As can be readily appreciated, these results show that immediate wet strength improvement is maintained while the dry strength is reduced by the increase in the wet/dry ratio. Table 5 shows the effect of particle size on the optimum performance of the product. The compositions of Examples 34-37, 40, 41 and 44 clearly show the improved results in that these compositions show an increase of 9-32% in wet strength performance over the commercially available compositions of the same basic components and concentrations. EXAMPLE 45 The procedure of Example 1 is followed except that no DADM is added to the monomer mixture. A composition comprising microparticles of a cross-linked glyoxalated acrylamide homopolymer is formed similar to that of Example 1. EXAMPLES 46 - 48 The procedure of Example 1 is repeated except that 46) methacryamide, 47) N-methyl acrylamide and 48) N-methyl methacrylamide are substituted for the acrylamide monomer. Compositions comprising microparticles of glyoxalated cationic acrylamide copolymers are formed similar to those of Example 1. EXAMPLE 49-51 The procedure of Example 1 is followed except that 50) methacryloxyethyltrimethylammonium chloride, 51) methacrylamidopropyltrimethylammonium chloride, and 52) acryloxyethyltrimethyl ammonium chloride are used to replace the DADM. Similar results are achieved. Many other embodiments of the present invention will suggest themselves to those skilled in this art in light of the above detailed description. For example, instead of employing acrylamide as the (alk)acrylamide monomer; methacrylamide and ethacrylamide may be used. Polymerization may be initiated by any known method such as ionizing radiation in addition to ultraviolet or redox initiation. Although the above discussion is directed primarily to the use of (meth)acrylamide-based polymers which, before functionalization, are substantially linear, it is also possible to use lightly to moderately cross-linked (meth)acrylamide-based polymers which can be prepared by adding small amounts of cross-linking monomers such as methylenebisacrylamide etc. to the aqueous acrylamide monomer solutions of either of the processes described above prior to polymerization.

Claims: A method of making dry and/or wet strength paper, which comprises absorbing in an aqueous pulp of paper-making fibers an effective amount, as a latent strengthening agent, of a composition comprising an (alk)acrylamide-based polymer having glyoxal-reactive amide substituents and -CONHCHOHCHO substituents which have a tendency to crosslink the polymer, said -CONHCHOHCHO substituents being present in an excess of 0.5 weight percent, wherein said polymer is present as micelles having particle diameters of from 20 to 400 nm (200 to 4000 Å) and wherein said micelles are obtainable from a microemulsion, and recovering the resultant paper. A method of making dry and/or wet strength paper which comprises: forming a dilute aqueous solution from micelles comprising water and an (alk)acrylamide-based polymer, said polymer having glyoxal-reactive amide substituents and -CONHCHOHCHO substituents which have a tendency to crosslink the polymer, said -CONHCHOHCHO substituents being present in an excess of 0.5 weight percent and said micelles having particle diameters of from 20 to 400 nm (200 to 4000 Å); adding said solution to an aqueous pulp of paper-making fibers in an amount effective to be absorbed by said fibers; and recovering the resultant paper. A method of making dry and/or wet strength paper wherein an (alk)acrylamide-based polymer is added to an aqueous pulp of paper-making fibers and the resultant slurry is laid down as a web, characterized in that it comprises forming micelles of water and an (alk)acrylamide-containing polymer having glyoxal-reactive amide substituents and -CONHCHOHCHO substituents which have a tendency to crosslink, said -CONHCHOHCHO substituents being present in an excess of 0.5 weight percent and said micelles having particle diameters in the range of 20 to 400 nm (200 to 4000 Å); forming said micelles into a dilute aqueous solution; adding said solution to said aqueous pulp; and recovering the resultant paper. A method according to any preceding claim, wherein said particle diameters are from 30 to 200 nm (300 to 2000 Å). A method according to Claim 4, wherein said particle diameters are from 35 to 100 nm (350 to 1000 Å). Dry and/or wet strength paper comprised of water-laid, cellulosic paper-making fibers bonded together by an absorbed and at least partially cellulose-reacted composition comprising a glyoxalated (alk)acrylamide-containing polymer having (1) glyoxal-reactive amide substituents and -CONHCHOHCHO substituents which have a tendency to crosslink, said -CONHCHOHCHO substituents being present in an excess of 0.5 weight percent, and (2) being present as micelles of particle diameters ranging from 20 to 400 nm (200 to 4000 Å). Dry and/or wet strength paper according to Claim 4, wherein said particle diameters are from 30 to 200 nm (300 to 2000 Å). Dry and/or wet strength paper according to Claim 7, wherein said particle diameters are from 35 to 100 nm (350 to 1000 Å).

Inventors: DUPLAISE DAVID L, KOZAKIEWICZ JOSPEH J, DUPLAISE, DAVID L., KOZAKIEWICZ, JOSPEH J.
Applicants: CYTEC TECH CORP, CYTEC TECHNOLOGY CORP.
Application year: 1989
Main classification: C08F8
IPC codes: D21H17, C08J3, C08F8, D21H21