초록

Disclosed herein are compositions and methods to increase paper machine performance and enhance sizing. The compositions include a sizing agent, an emulsifier, and an aqueous component. The emulsifier may be an aldehyde-functionalized polymer.

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1. A sizing emulsion, comprising: a) a sizing agent selected from the group consisting of an alkyl ketene dimer (“AKD”) and an alkenyl succinic anhydride (ASA);b) an emulsifier selected from the group consisting of:glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content;glyoxa

1. A sizing emulsion, comprising: a) a sizing agent selected from the group consisting of an alkyl ketene dimer (“AKD”) and an alkenyl succinic anhydride (ASA);b) an emulsifier selected from the group consisting of:glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content;glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content and further comprising MgSO4.7H2O;glyoxalated poly(DADMAC)/AcAm polymer having a 12 mole % DADMAC monomer content; andglyoxalated poly(DADMAC)/AcAm polymer having a 12 mole % DADMAC monomer content and further comprising MgSO4.7H2O; andc) an aqueous component. 2. The sizing emulsion of claim 1, wherein the emulsifier is glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content. 3. The sizing emulsion of claim 1, wherein the emulsifier is glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content and further comprising MgSO4.7H2O. 4. The sizing emulsion of claim 1, wherein the emulsifier is glyoxalated poly(DADMAC)/AcAm polymer having a 12 mole % DADMAC monomer content. 5. The sizing emulsion of claim 1, wherein the emulsifier is glyoxalated poly(DADMAC)/AcAm polymer having a 12 mole % DADMAC monomer content and further comprising MgSO4.7H2O. 6. The sizing emulsion of claim 1, having a median particle size of less than or equal to 2.5 microns. 7. The sizing emulsion of claim 1, having a median particle size of less than or equal to 2.0 microns. 8. The sizing emulsion of claim 1, having a median particle size of less than or equal to 1.5 microns. 9. The sizing emulsion of claim 1, having a median particle size of less than or equal to 1.4 microns. 10. The sizing emulsion of claim 1, having a median particle size of less than or equal to 1.3 microns. 11. The sizing emulsion of claim 1, having a median particle size of less than or equal to 1.5 microns after 0 minutes of aging, less than or equal to 1.5 microns after 30 minutes of aging, and less than or equal to 1.5 microns after 60 minutes of aging. 12. The sizing emulsion of claim 1, wherein the ratio of emulsifier to sizing agent ranges from 0.6:1.0 to 1.25:1.0, based on volume. 13. A method of enhancing sizing, the method comprising adding an effective amount of a sizing emulsion to a paper machine in a papermaking process, wherein the sizing emulsion comprises: a) a sizing agent selected from the group consisting of an alkyl ketene dimer (“AKD”) and an alkenyl succinic anhydride (ASA);b) an emulsifier selected from the group consisting of:glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content;glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content and further comprising MgSO4.7H2O;glyoxalated poly(DADMAC)/AcAm polymer having a 12 mole % DADMAC monomer content; andglyoxalated poly(DADMAC)/AcAm polymer having a 12 mole % DADMAC monomer content and further comprising MgSO4.7H2O; andc) an aqueous component. 14. The method of claim 13, wherein the sizing emulsion is prepared in a high shear homogenizer emulsification unit and the volume ratio of emulsifier to ASA ranges from 0.6:1.0 to 1.0:1.0. 15. The method of claim 14, wherein the high shear homogenizer emulsification unit comprises a turbine loop, and the percentage of the emulsifier in the turbine loop ranges from 0.3% to 0.9% based on solids. 16. The method of claim 15, wherein the sizing emulsion has a median particle size (D50) of 1.1 micron or less. 17. The method of claim 13, wherein the sizing emulsion is prepared in a high pressure turbine emulsification unit and the volume ratio of emulsifier to ASA ranges from 0.6:1.0 to 1.25:1.0. 18. The method of claim 17, wherein the high pressure turbine emulsification unit comprises a turbine loop, and the percentage of the emulsifier in the turbine loop ranges from 0.6% to 1.8% based on solids. 19. The method of claim 18, wherein the sizing emulsion has a median particle size (D50) of 1.3 micron or less. 20. The method of claim 13, wherein the sizing emulsion is diluted with a secondary carrier solution prior to entering a headbox of the paper machine. 21. The method of claim 20, wherein the secondary carrier solution is an aqueous solution comprising an emulsifier selected from the group consisting of: glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content;glyoxalated poly(DADMAC)/AcAm polymer having a 5 mole % DADMAC monomer content and further comprising MgSO4.7H2O;glyoxalated poly(DADMAC)/AcAm polymer having a 12 mole % DADMAC monomer content; andglyoxalated poly(DADMAC)/AcAm polymer having a 12 mole % DADMAC monomer content and further comprising MgSO4.7H2O. 22. The method of claim 21, wherein the secondary carrier solution comprises about 2 weight % to about 10 weight % of the emulsifier. 23. The method of claim 20, wherein the secondary carrier solution is an aqueous solution free of emulsifiers. 24. The method of claim 20, wherein the ratio of secondary carrier solution added to the sizing emulsion ranges from 2:1 to 20:1. 25. An emulsion comprising: a) a sizing agent;b) a glyoxalated poly(DADMAC)/AcAm polymer; andc) an aqueous component. 26. The emulsion of claim 25, wherein the glyoxalated poly(DADMAC)/AcAm polymer is derived from a poly(DADMAC)/AcAm copolymer comprising 1 to 50 percent DADMAC monomer content. 27. The emulsion of claim 26, wherein the glyoxalated poly(DADMAC)/AcAm polymer is formed by reacting the poly(DADMAC)/AcAm copolymer with glyoxal in a molar ratio of about 0.05 to about 1.5, respectively. 28. The emulsion of claim 25, wherein the sizing agent is alkenyl succinic anhydride (ASA). 29. The emulsion of claim 25, having a median particle size of less than or equal to about 2.5 microns.