Method of making a paper and paperboard and the paper and paperboard thereof

Abstract

A method of making paper or paperboard using a composition made by the hydrogenation or partial hydrogenation of an alkyl ketene dimer, alkenyl ketene dimer, or ketene multimer (collectively labeled H.sub.2-AKD). Also, relates to a paper or paperboard having increased water and water vapor resistance while maintaining good recyclability and repulpability.

Claims

1. A method of making a paper and paperboard comprising: providing a composition comprising Formula I: ##STR00003## wherein R is a branched or straight chain alkyl that is at least 6 carbon atoms in length; R.sub.1 is a branched or straight chain alkyl containing from 2-34 carbon atoms in length; R.sub.2 is a branched or straight chain alkyl that is at least 6-carbon atoms in length; wherein R, R.sub.1 and R.sub.2 may independently, optionally contain a cyclic functional group; and n is an integer from 1 to 6; and wherein Formula I is the result of the hydrogenation or partial hydrogenation of an alkyl ketene dimer, alkenyl ketene dimer, or ketene multimer; contacting the composition with a pulp material; forming a paper or paperboard; and optionally, applying the composition of Formula I to the surface of the paper or paperboard.

2. The method according to claim 1, wherein the paper or paperboard is formed and the composition comprising Formula I is applied to the surface of the formed paper or paperboard.

3. The method according to claim 1, wherein the composition further comprises at least one additional wax.

4. The method according to claim 1, wherein the composition optionally comprises a thermoplastic polymeric material, hydrocarbon resins, polyethylene acetate, polyethylene, or any combination thereof.

5. A paper or paperboard produced according to the method of claim 1.

6. A method for increasing the repulpability of a paper or paperboard comprising: providing a paper or paperboard; applying to the surface of the paper or paperboard a composition comprising Formula I: ##STR00004## wherein R is a branched or straight chain alkyl that is at least 6-carbon atoms in length; R.sub.1 is a branched or straight chain alkyl containing from 2 to 34 carbon atoms; R.sub.2 is a branched or straight chain alkyl that is at least 6-carbon atoms in length; wherein R, R.sub.1 and R.sub.2 may independently, optionally contain a cyclic functional group; and n is an integer from 1 to 6; and repulping the paper or paperboard; and wherein Formula I is the result of the hydrogenation or partial hydrogenation of an alkyl ketene dimer, alkenyl ketene dimer, or ketene multimer.

7. The method according to claim 6, wherein the composition of Formula I, further comprises at least one additional wax.

8. The method of claim 6, wherein the composition optionally comprises a thermoplastic polymeric material, hydrocarbon resins, polyethylene acetate, polyethylene, or any combination thereof.

9. The method according to claim 6, wherein repulping pH is from about 5 to about 14.

10. The method according to claim 6, wherein the repulping temperature is from about 20 C. to about 100 C.

11. The method according to claim 6, wherein the composition of Formula I comprises from about 1% to 100% of the total weight of the composition.

12. The method according to claim 6, wherein the composition of Formula I comprises from about 15% to about 25% of the total weight of the composition.

13. A coated paper or paperboard comprising: providing a paper or paperboard applying the composition of claim 1 to the surface of the paper or paperboard.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1, illustrates one possible mechanism for the hydrogenation and hydrolysis of an alkyl ketene dimer.

(2) FIG. 2, illustrates one possible alkyl ketene dimer hydrolysis mechanism.

(3) FIG. 3, illustrates a generic chemical structure for the resulting hydrogenated ketene dimer or ketene multimer.

(4) FIG. 4, illustrates a generic chemical structure for hydrolyzed, hydrogenated alkyl ketene dimer, alkenyl ketene dimer, or ketene multimer.

(5) FIG. 5, illustrates various degrees of repulping that was quantified by comparing each sample to a series of repulping standards.

DETAILED DESCRIPTION

(6) In accordance with the present invention, there are provided compositions comprising Formula I:

(7) ##STR00001##
wherein R is a branched or straight chain alkyl that is at least 6-carbon atoms in length; R.sub.1 is a branched or straight chain alkyl containing from 2 to 34 carbon atoms; R.sub.2 is a branched or straight chain alkyl that is at least 6-carbon atoms in length; wherein R, R.sub.1 and R.sub.2 may independently, optionally contain a cyclic functional group; and n is an integer from 0 to 6.

(8) Therefore, in accordance with the invention, a latent dispersant with the generic structure shown in Formula I, is made by the hydrogenation of an alkyl ketene dimer, alkenyl ketene dimer, or ketene multimer (collectively identified as H.sub.2-AKD). Alkyl ketene dimers, alkenyl ketene dimers, and ketene multimers that have not undergone hydrogenation, (collectively AKD's) are currently used as internal and surface sizing agents by the paper industry. A generic chemical structure for these starting materials can be found in U.S. Pat. No. 5,685,815 (Bottoroff). Other examples can be found in U.S. Pat. No. 6,175,022 (Brungardt) and U.S. Pat. No. 6,207,258 (Varnell), wherein carboxylic acids and dicarboxylic acids are used to make alkyl ketene dimers, alkenyl ketene dimers, and ketene multimers (AMD's).

(9) The hydrogenation reaction acts to reduce the carbon-to-carbon double bond(s) attached to the four-membered lactone ring(s) of the alkyl ketene dimer, alkenyl ketene dimer, or ketene multimer (See FIG. 1). Hydrogenation also acts to reduce any carbon-to-carbon double bonds in the hydrocarbon chains attached to the lactone ring(s). A generic chemical structure for the resulting hydrogenated ketene dimer or ketene multimer is shown in Formula I, wherein n is from 0 to 6, can be 0 to 3 and may be 0. R.sub.1 may contain 2 to 34 carbon atoms and may be a straight or a branched alkyl group, and may contain cyclic functional groups. R and R.sub.2 are at least 6-carbon atoms in length; can contain 10 to about 22 carbons in length; can be from about 10 to about 20 carbons in length; and may be from about 12 to about 18 carbons in length. R and R.sub.2, are selected from straight chain or branched alkyl groups and may also contain cyclic functional groups.

(10) The carboxylic acids used to make the alkyl ketene dimer, alkenyl ketene dimer, or ketene multimer starting materials can contain other functional groups, such as, for example, esters, ethers, tertiary and quaternary amines, carbon-to-carbon double and triple bonds, ketones, aldehydes, aliphatic rings and aromatic rings and any functional groups as described in U.S. Pat. No. 6,175,022. It is also understood that the present invention also contains regia isomers of the compounds of Formula I. It is also understood that the present invention contains regio isomers of the compounds of Formula II.

(11) What is meant by dispersant is a substance that aids in separating and dispersing small, insoluble particles of hydrophobic materials in a substantially aqueous environment. The dispersant can be used in combination with a chemical agent, such as NaHCO.sub.3, Na.sub.2CO.sub.3, and NaOH, which are capable of modifying the carboxylic acid group(s) present on the dispersant.

(12) A further objective is to provide a method of increasing the water and water vapor resistance of paper and paperboard while maintaining recyclability and repulpability. When added to paper or paperboard, or applied as a coating on the paper or paperboard, a composition comprising H.sub.2-AKD; or partially hydrogenated H.sub.2-AKD, increases the water and water vapor resistance of the paper or paperboard. Hereinafter, when referring to H.sub.2-AKD, it is understood that this can mean a partially hydrogenated AKD. The H.sub.2-AKD remains a hydrophobic wax under normal end-use, storage, and shipping conditions. When the H.sub.2-AKD treated paper or paperboard is exposed to hot water and alkaline conditions during recycling or repulping, it is believed to react to form an anionic soap. The anionic soap can then be dispersed in water and separated from the cellulose pulp.

(13) One possible mechanism for the improved repulpability obtained with H.sub.2-AKD is illustrated in FIG. 1 and FIG. 2. Commercially available AKD reacts with water to form a beta-keto carboxylic acid. The beta-keto carboxylic acid loses CO.sub.2 rapidly at room temperature to form a waxy, hydrophobic ketone. This waxy ketone would not be expected to improve the repulpability of a wax coating. However, hydrogenation of AKD yields a hydrophobic wax with a reactive lactone ring. The lactone ring can undergo hydrolysis during repulping to form stable carboxylic acid soap. The anionic soap can be easily dispersed in water and separated from the cellulose pulp.

(14) A generic chemical structure for the hydrolyzed analogue of the hydrogenated alkyl ketene dimer, alkenyl ketene dimer, or ketene multimer is given in Formula II.

(15) ##STR00002##
Wherein R is a branched or straight chain alkyl that is at least 6-carbon atoms in length; R.sub.1 is a branched or straight chain alkyl containing from 2 to 34 carbon atoms; R.sub.2 is a branched or straight chain alkyl that is at least 6-carbon atoms in length; wherein R, R.sub.1 and R.sub.2 may independently, optionally contain a cyclic functional group; and n is an integer from 0 to 6.

(16) In Formula II, n can be from 0 to 6; can be 0 to 3; and may be 0. R and R.sub.2, are selected from straight chain or branched alkyl groups, and may also independently contain cyclic functional groups. R and R.sub.2 are at least 6-carbon atoms in length; can contain 10 to about 22 carbons in length; can be from about 10 to about 20 carbons in length; and may be from about 12 to about 18 carbons in length. R.sub.1 can contain 2 to 34 carbon atoms and may be a straight chain or branched alkyl group, and may optionally contain cyclic functional groups.

(17) Alternatively, the H.sub.2-AKD wax can be incorporated into a conventional wax coating. The hydrophobic hydrocarbon nature of H.sub.2-AKD and its melting point (56 C.), make it compatible with conventional coating waxes. For example, Paraflex4797A (The International Group, Agincourt, Ontario, Canada) has a melting point of 59 C. When the H.sub.2-AKD/wax coated paper or paperboard is exposed to alkaline repulping conditions, an anionic soap formed from the H.sub.2-AKD helps to disperse the conventional wax, making it easier to separate from the cellulose pulp.

(18) The waxes that can be used with H.sub.2-AKD to coat paper and paperboard are known in the art of papermaking and include: paraffin wax, microcrystalline wax, or any natural or synthetic wax coating compositions, but not limited to plant waxes, animal waxes and petroleum derived waxes. Commercial examples of such waxes are available from The International Group (Agincourt, Ontario, Canada). The waxes currently used to coat paper or paperboard typically contain from about 20 to about 40 carbon atoms in their hydrocarbon chains and have melting points from about 30 C. to about 200 C.; and can have melting points between about 40 C. and about 85 C. In addition to wax, the formulations may also include optional resins, such as thermoplastic polymeric materials, for example hydrocarbon resins, polyethylene vinylacetate, polyethylene and the like to enhance the physical properties of the coating, reduce cost and improve performance.

(19) The H.sub.2-AKD or the H.sub.2-AKD/wax composition can be applied by any of the methods used to apply a coating of wax to paper or paperboard, including, for example, as an emulsion, on a curtain coater, on a wax impregnator or on a cascade coater. U.S. Pat. No. 4,317,756 (Dumas, et. al.), discloses methods for making aqueous emulsions of alkyl ketene dimer (AKD), which can then be used for making emulsions of the hydrogenated compositions of the present invention.

(20) When added by itself or in combination with a conventional wax, the H.sub.2-AKD/wax composition addition level can range from about 1% to about 60% of the total weight of the coated paper or paperboard. H.sub.2-AKD can range from about 1% to about 100% by weight of the coating composition; can be from about 5% to about 50% by weight of the coating composition; and may be about 15% to about 25% by weight of the coating composition.

(21) It should be understood that throughout the specification and claims the term coating is understood to mean coating or impregnation unless otherwise indicated.

(22) A further objective is to provide a method of increasing the repulpability of a coated paper or paperboard. Paper or paperboard coated with a H.sub.2-AKD or H.sub.2-AKD/wax composition can be repulped at a pH of from about 5 to about 14; can be repulped at a pH of from about 7 to about 12; and may be repulped at a pH of from about 9 to about 12.

(23) Paper or paperboard coated with a H.sub.2-AKD or H.sub.2-AKD/wax composition can be repulped at temperatures of from about 20 C. to about 100 C.; can be repulped at temperatures of from about 30 C. to about 70 C.; and may be repulped at a temperature of from about 40 C. to about 60 C. The paper or paperboard coated with the H.sub.2-AKD or H.sub.2-AKD/wax composition may also be repulped at about 50 C.,

(24) While there is no rigid differentiation between paper and paperboard, paperboard is generally thicker (usually over 0.25 mm/0.010 in or 10 points) than paper. The present composition can be used with any paper or paperboard. Examples of paper and paperboard types and classification can be found in TAPPI MethodTIP 0404-36, which is herein incorporated in its entirety.

(25) The following examples are intended to be illustrative of the presently disclosed and claimed inventive concepts. However, these examples are intended to be non-limiting embodiments of the invention.

EXAMPLES

(26) The following examples are provided to illustrate the production and activity of representative compositions of the present teachings and to illustrate their water and water vapor resistance, and performance in recycling and repulping operations. One skilled in the art will appreciate that although specific reagents and conditions are outlined in the following examples, these reagents and conditions are not a limitation on the present teachings.

Example 1

Hydrogenation of Alkyl Ketene Dimer

(27) A sample of Aquapel364, alkyl ketene dimer (AKD) (available from Ashland Water TechnologiesLexington, Ky.) was hydrogenated using the following method: 25 grams (g) of alkyl ketene dimer was dissolved in 25 g of toluene. The mixture was then loaded into a stainless steel PmT reactor along with 2 mole % of Pd catalyst on carbon (10% palladium on carbon, available from Aldrich-Milwaukee Wis.). The reactor was flushed two times with H.sub.2 gas, sealed under 600 pounds per square inch of H.sub.2 gas pressure, and then stirred for 18 hours at room temperature. Once the reaction was complete, the mixture was filtered to remove the Pd catalyst, and the toluene solvent was removed under vacuum. Twenty four grams of the desired H.sub.2-AKD composition were isolated. The H.sub.2-AKD composition had a melting point of 56 C.

Example 2

Preparation of Paperboard

(28) Paperboard for wax coating was made using the following method. A sample of commercial paperboard was cut into 2.5 centimeter (cm) strips, then refined to a Canadian standard freeness (CSF) of 375 milliliter (mL) using a double disc refiner. 2.5 weight % of GPCTD-15F (Grain Processing CorporationMuscatine, Iowa) was added to the refined pulp.

(29) Recycled paperboard was made from the pulp furnish using a pilot paper machine similar to the one available at Western Michigan University in Kalamazoo, Mich. The temperature of the paper making pulp was set at 50 C. Paper making pH was fixed at 7.5. The following additives were added to the wet-end of the paper machine: 0.5 weight % Stalok300 cationic starch (all addition levels based on pulp furnish, Tate and Lyle-London, United Kingdom), 0.05 weight % Hercon70 alkyl ketene dimer sizing agent emulsion (Ashland Hercules Water TechnologiesLexington Ky.), and 0.0125 weight % Perform8713 cationic polyacrylamide retention aid (Ashland Water TechnologiesLexington Ky.). Basis weight was fixed at 160 grams per meter squared (g/m) Sheet moisture at the reel was controlled to 8%.

Example 3

Preparation of Wax Coated Paperboard

(30) The recycled paperboard made in Example 2 was coated with Paraflex4797A wax using the following method (a commercial cascade wax supplied by the International Group). A 200 g sample of Paraflex4797A was melted using a hot water bath set at 80 C. The recycled paperboard was cut into 6 inch6 inch squares. The squares were then dipped into the molten wax for 5 seconds, removed, and allowed to cool at room temperature for one hour. Paraflex4797A coatings containing 5%, 10%, 15%, 25%, 50% and 100% H.sub.2-AKD were also made by the same method. The H.sub.2-AKD was made using the method described in Example 1. The coated samples were cured in an oven at 85 C. for 30 minutes prior to testing. Wax pick-up averaged 50% of the total weight of the coated paperboard.

Example 4

Repulpability Test Method

(31) The repulpability of the uncoated paperboard, the Paraflex4797A coated paperboard, H.sub.2-AKD coated paperboard, and H.sub.2-AKD/wax coated paperboard described in Example 3 were measured using the following method.

(32) A 342 g aliquot of water was placed into a Waring Blender. An 18 g sample of paperboard was cut into 2.5 cm2.5 cm squares and placed into the blender. An electric motor fitted to the bottom of the blender was used to rotate the blade. The blade was rotated in a reverse direction, to avoid cutting the pulp with the sharp edge of the blade. Stirring rate was fixed at 1500 revolutions per minute (rpm). A 1N solution of sulfuric acid (H.sub.2SO.sub.4) was used to adjust the repulping dispersion to pH 5. NaHCO.sub.3 (1000 ppm) was used to buffer the repulping dispersion to pH 7. Na.sub.2CO.sub.3 (1000 ppm) was used to buffer the repulping dispersion to pH 9, and a mixture of Na.sub.2CO.sub.3 (1000 ppm) and NaOH was used to buffer the repulping dispersion to pH 12. Water temperature was controlled using an electric heating jacket wrapped around the outside of the blender.

(33) Samples of the pulp slurry were taken every 15 minutes. The degree of repulping was quantified by comparing each sample to the series of repulping standards shown in FIG. 5. A repulping index value of 5 is considered to be acceptable for commercial use.

Example 5

Repulpability of Various Wax/H2-AKD Blends

(34) Samples of Paraflex 4797A, H.sub.2-AKD, and Paraflex4797A/H.sub.2-AKD coated paperboard were made using the methods described in Examples 2 and 3. Total wax pick-ups averaged 50% of the weight of the coated paperboard. Repulpability was measured at pH's ranging from 5 to 12, at repulping temperatures of 40 C., 50 C., and 60 C. using the method described in Example 4 (See Tables 1-3).

(35) The 100% Paraflex4797A wax coated paperboard repulped slowly at temperatures below its melting point of 59 C. The highest repulping index value obtained for the 100% Paraflex4797A wax coated paperboard was only 2.5 at repulping temperatures below its melting point (measured after two hours of repulping at 50 C. and pH 12). Increasing repulping temperature to 60 C., above the melting point of the wax, greatly increased the repulping rate of the 100% Paraflex4797A wax coated paperboard. However, wax becomes sticky and forms heavy deposits at repulping temperatures around its melting point resulting in operational issues.

(36) Adding H.sub.2-AKD to the Paraflex4797A wax improved the repulpability of the wax coated board over the entire range of repulping pH's and temperatures tested.

(37) The amount of improvement (versus 100% Paraflex4797A wax) depended on the repulping pH and the percentage of H.sub.2-AKD added to the wax. In general, the repulpability of the H.sub.2-AKD or H.sub.2-AKD/wax composition improved as pH increased from 5 to 12. At pH 12 and 50 C., the H.sub.2-AKD/Paraflex4797A compositions containing at least 15% H.sub.2-AKD repulped quickly at temperatures below the wax melting point (repulping temperature of 50 C.). Improvements in repulpability were observed at H.sub.2-AKD addition levels as low as about 5% to about 10% of the total wax coating. The repulpability of the H.sub.2-AKD and H.sub.2-AKD/wax coated paperboard also improved as the percentage of H.sub.2-AKD in the coating increased. The 100% H.sub.2-AKD coating repulped the most quickly. At pH 12, the 100% H.sub.2-AKD coated paper board gave acceptable repulpability (Repulpability Index of at least 5) at temperatures as low as 40 C.

(38) TABLE-US-00001 TABLE 1 Repulpability of Wax Coatings- 40 C. % H.sub.2 Repulping Time (Minutes) AKD % Wax 15 30 45 60 75 90 105 120 pH 7 Blank 2 3.5 6 8 N/A N/A N/A N/A 0 100 1 1 1 1 1.5 1.5 2 2 5 95 1 1 1 1 1.5 1.5 2 2 10 90 1 1 1 1 1.5 1.5 2 2 15 85 1 1 1 1.5 1.5 1.5 2 2 25 75 1 1 1.5 1.5 2 2 2 2 50 50 1 1.5 2 2 2.5 2.5 3 3 100 0 1 1.5 2 2 2 3 3 3 pH 9 Blank 2 3 to 4 6 8 N/A N/A N/A N/A 0 100 1 1 1 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 5 95 1 1 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 2 10 90 1 1 1 to 2 1 to 2 1 to 2 1 to 2 2 2 15 85 1 1 1 1 to 2 2 2 2 2 to 3 25 75 1 1 1 to 2 2 2 2 to 3 2 to 3 2 to 3 50 50 1 2 2 to 3 2 to 3 3 3 3 to 4 3 to 4 100 0 1 2 2 to 3 2 to 3 3 3 3 to 4 4 pH 12 Blank 2 3 to 4 6 8 N/A N/A N/A N/A 0 100 1 1 1 1 to 2 1 to 2 2 to 3 2 to 3 2 to 3 5 95 1 1 1 to 2 1 to 2 2 2 2 to 3 3 10 90 1 1 1 to 2 1 to 2 2 2 2 to 3 3 15 85 1 2 2 3 3 3 to 4 3 to 4 3 to 4 25 75 1 1 2 to 3 3 3 3 to 4 3 to 4 3 to 4 50 50 1 2 2 to 3 3 3 to 4 4 4 to 5 5 100 0 1 2 2 to 3 3 3 to 4 4 4 to 5 5

(39) TABLE-US-00002 TABLE 2 Repulpability of Wax Coatings- 50 C. I % H.sub.2 % Repulping Time (Minutes) AKD Wax 15 30 45 60 75 90 105 120 pH 5 Blank 2 3 to 4 6 8 N/A N/A N/A N/A 0 100 1 1 1 1 1 1 1 1 5 95 1 1 1 to 2 1 to 2 1 to 2 2 2 2 10 90 1 1 1 to 2 1 to 2 1 to 2 2 2 2 to 3 15 85 1 1 1 to 2 2 2 2 to 3 2 to 3 2 to 3 25 75 1 1 2 2 2 to 3 2 to 3 2 to 3 2 to 3 50 50 1 1 to 2 2 2 2 to 3 2 to 3 3 3 100 0 1 1 2 2 2 2 to 3 3 3 pH 7 Blank 2 3 to 4 6 8 N/A N/A N/A N/A 0 100 1 1 1 2 2 2 2 to 3 2 to 3 5 95 1 1 1 to 2 2 2 2 to 3 2 to 3 3 10 90 1 1 to 2 2 2 2 to 3 2 to 3 2 to 3 2 to 3 15 85 1 1 to 2 1 to 2 2 to 3 3 3 3 3 25 75 1 to 2 2 2 to 3 3 3 3 to 4 3 to 4 3 to 4 50 50 1 to 2 2 1 to 3 3 3 3 to 4 4 4 100 0 1 to 2 2 2 to 3 3 3 3 to 4 4 4 pH 9 Blank 2 3 to 4 6 8 N/A N/A N/A N/A 0 100 1 1 1 1 to 2 2 2 2 to 3 2 to 3 5 95 1 1 1 to 2 1 to 2 2 2 2 to 3 2 to 3 10 90 1 1 1 to 2 2 2 2 2 to 3 2 to 3 15 85 1 1 1 to 2 2 2 2 2 to 3 2 to 3 25 75 1 1 1 to 2 2 2 2 to 3 2 to 3 3 50 50 1 1 to 2 2 2 to 3 3 3 to 4 3 to 4 3 to 4 100 0 1 2 2 3 4 4 4 to 5 6 pH 12 Blank 4 8 8 N/A N/A N/A N/A N/A 0 100 1 1 1 to 2 2 2 2 2 to 3 2 to 3 5 95 1 to 2 2 2 to 3 3 3 to 4 4 4 4 10 90 1 to 2 2 2 2 to 3 3 to 4 3 to 4 4 5 15 85 2 3 3 to 4 4 to 5 6 8 8 N/A 25 75 3 4 to 5 6 7 8 N/A N/A N/A 50 50 3 5 6 7 8 N/A N/A N/A 100 0 2 5 6 7 8 N/A N/A N/A

(40) TABLE-US-00003 TABLE 3 Repulpability of Wax Coatings- 60 C. % H.sub.2 % Repulping Time (Minutes) AKD Wax 15 30 45 60 75 90 105 120 pH 5 Blank 1 to 2 4 6 8 N/A N/A N/A N/A 0 100 1 2 3 3 to 4 3 to 4 4 4 4 5 95 1 2 3 3 to 4 3 to 4 4 4 4 10 90 1 2 3 to 4 3 to 4 4 4 to 5 5 5 15 85 1 2 3 to 4 3 to 4 4 4 5 5 25 75 1 to 2 2 to 3 3 3 to 4 4 to 5 5 5 5 50 50 1 to 2 2 to 3 4 5 to 6 8 N/A N/A N/A 100 0 1 to 2 2 to 3 3 to 4 6 8 N/A N/A N/A pH 7 Blank 3 to 4 5 to 6 7 to 8 8 N/A N/A N/A N/A 0 100 1 2 3 3 to 4 4 5 5 6 5 95 1 2 3 3 to 4 4 5 5 6 10 90 1 2 3 4 4 5 5 to 6 6 15 85 1 2 to 3 3 4 4 to 5 5 to 6 6 6 to 7 25 75 1 to 2 2 to 3 3 3 to 4 5 to 6 6 to 7 7 7 50 50 2 3 4 6 8 N/A N/A N/A pH 9 Blank 3 to 4 5 7 8 N/A N/A N/A N/A 0 100 1 2 3 4 4 to 5 6 6 to 7 7 5 95 1 2 to 3 3 3 to 4 4 to 5 6 7 7 10 90 1 2 3 3 to 4 5 6 to 7 7 7 to 8 15 85 1 2 3 4 5 6 to 7 7 7 to 8 25 75 2 3 4 4 5 6 N/A N/A 50 50 2 to 3 5 to 6 7 to 8 8 N/A N/A N/A N/A 100 0 2 to 3 5 to 6 7 to 8 8 N/A N/A N/A N/A pH 12 Blank 3 to 4 5 to 6 7 to 8 8 N/A N/A N/A N/A 0 100 1 2 to 3 4 to 5 5 5 to 6 6 to 7 7 to 8 8 5 95 1 3 4 to 5 5 to 6 6 7 8 N/A 10 90 2 to 3 3 to 4 5 6 to 7 7 to 8 8 N/A N/A 15 85 3 4 5 to 6 6 to 7 7 to 8 8 N/A N/A 25 75 3 4 6 7 8 N/A N/A N/A 50 50 3 to 4 5 to 6 7 to 8 8 N/A N/A N/A N/A 100 0 3 to 4 5 to 6 7 to 8 8 N/A N/A N/A N/A

Example 6

Water Resistance of Various Wax/H2-AKD Blends

(41) Thirty (30) minute Cobb testing of the Paraflex4797A, H.sub.2-AKD, and Paraflex4797A/H.sub.2-AKD coated paperboard was carried out using Tappi method T441. The results are shown in Table 4. The unsized or uncoated paperboard gave little or no 30-minute Cobb sizing (value greater than 300 g/m.sup.2). The paperboard coated with 100% Paraflex4797A wax gave high levels of 30-minute Cobb sizing (Cobb sizing value less than 5 g/m.sup.2, Cobb sizing value decreases as water resistance increases). Similar levels of Cobb sizing were maintained at H.sub.2-AKD addition levels as high as 25% in Paraflex4797A. The 50% and 100% H.sub.2-AKD addition levels in Paraflex4797A gave 30-minute Cobb sizing values between 15 and 35 g/m.sup.2, a much higher level of sizing than the uncoated control sample.

(42) MVTR testing of the Paraflex4797A, H.sub.2-AKD, and Paraflex4797A/H.sub.2-AKD coated paperboard was carried out using Tappi method T448. The testing was carried out at 23 C. and 85% relative humidity over a five day period. A saturated potassium bromide solution was used to control the humidity in the test chamber to 85%. The results are shown in Table 4. The MVTR results showed that the uncoated paperboard gave little or no resistance to moisture vapor transmission (MVTR greater than 500 g/m.sup.2/day). Adding the 100% Paraflex4797A coating reduced the moisture vapor transmission rate to less than 25 g/m.sup.2/day. The Paraflex4797A/H.sub.2-AKD coated paperboard gave similar levels of moisture vapor resistance at H.sub.2-AKD addition levels as high as 50%. The 100% H.sub.2-AKD coated paperboard gave a slightly lower level of resistance to moisture vapor. The paperboard coated with 100% H.sub.2-AKD had a higher moisture vapor resistance than the untreated paperboard.

(43) The repulpability, Cobb sizing and MVTR results described in Examples 5 and 6 illustrate that adding H.sub.2-AKD to a commercial wax coating improves the coated boards recyclability and repulpability while maintaining high levels of resistance to water and water vapor. Variations, modifications, and other implementations of what is described herein will occur to those of ordinary skill in the art without departing from the spirit and essential characteristics of the present teachings. Accordingly, the invention is intended to include all such modifications and implementations, and their equivalents.

(44) Each reference cited in the present application, including books, patents, published applications, journal articles and other publications, is incorporated herein by reference in its entirety.

(45) TABLE-US-00004 TABLE 4 Cobb Sizing and Moisture Vapor Transmission (MVTR) of Various Wax Coatings 30 Minute Cobb Sizing MVTR % H.sub.2-Dimer % Wax (g/m.sup.2) (g/m.sup.2/day) Blank 300+ 500 0% 100% 3.5 21 5% 95% 0.6 16 10% 90% 2.6 14 15% 85% 2.6 17 25% 75% 4.2 25 50% 50% 14.9 14 100% 0% 33.0 33