Controllable filler prefloculation using a dual polymer system

1. A method of preparing a stable dispersion of flocculated filler particles having a specific particle size distribution for use in papermaking processes comprising

a) providing an aqueous dispersion of filler particles;

b) adding a first flocculating agent to the dispersion in an amount sufficient to mix uniformly in the dispersion without causing significant flocculation of the filler particles, and the first flocculating agent being amphoteric;

c) adding a second flocculating agent to the dispersion in an amount sufficient to initiate flocculation of the filler particles in the presence of the first flocculating agent wherein the second flocculating agent has opposite charge to the net charge of the first amphoteric flocculating agent;

d) shearing the flocculated dispersion to provide a dispersion of filler flocs having the desired particle size;

e) flocculating the filler particles prior to adding them to a paper stock and wherein no paper stock is present during the flocculation; and

t) adding the filler particles to a paper stock.

2. The method of claim 1 wherein the filler flocs have a median particle size of 10-100 μm.

3. The method of claim 1 wherein the filler is selected from the group consisting of precipitated calcium carbonate, ground calcium carbonate, kaolin clay, talc, titanium dioxide, alumina trihydrate, barium sulfate and magnesium hydroxide, and mixtures thereof.

4. The method of claim 1 wherein the first flocculating agent has net anionic charge.

5. The method of claim 4 wherein the second flocculating agent is cationic, selected from the group consisting of copolymers and terpolymers of (meth)acrylamide with dimethylaminoethyl methacrylate (DMAEM), dimethylaminoethyl acrylate (DMAEA), diethylaminoethyl acrylate (DEAEA), diethylaminoethyl methacrylate (DEAEM) or their quaternary ammonium forms made with dimethyl sulfate, methyl chloride or benzyl chloride, and mixtures thereof.

6. The method of claim 5 wherein the second flocculating agent is acrylamide-dimethylaminoethyl acrylate methyl chloride quaternary copolymer having a cationic charge of 10-50 mole percent and a RSV of at least 15 dL/g.

7. The method of claim 4 wherein the second flocculating agent is a homopolymer of diallyl dimethyl ammonium chloride having an RSV of 0.1-2 dL/g.

8. The method of claim 1 further comprising adding one or more microparticles to the flocculated dispersion after addition of the second flocculating agent.

9. The method of claim 1 wherein the filler is anionically dispersed and a low molecular weight, cationic coagulant is added to the dispersion to at least partially neutralize its anionic charge prior to the addition of the first flocculating agent.

10. A method of papermaking comprising the use of filler, the method comprising the steps of:

providing an aqueous dispersion of filler particles, at least one dry strength aid, and cellulose fiber stock,

treating the filler particles by the steps of:

a) adding a first flocculating agent to the dispersion in an amount sufficient to mix uniformly in the dispersion without causing significant flocculation of the filler particles, and the first flocculating agent being amphoteric;

b) adding a second flocculating agent to the dispersion in an amount sufficient to initiate flocculation of the filler particles in the presence of the first flocculating agent wherein the second flocculating agent has opposite charge to the net charge of the first amphoteric flocculating agent;

c) shearing the flocculated dispersion to provide a dispersion of filler flocs having the desired particle size;

d) flocculating the filler particles prior to adding them to a paper stock and wherein no paper stock is present during the flocculation,

then combining the filler particles with the cellulose fiber stock,

treating the combination with at least one dry strength aid, and

forming a paper mat from the combination,

wherein at least 10% of the filler particles are in a dispersed form using a high anionically charged dispersant,

the cellulose fiber stock comprises a plurality of cellulose fibers and water, and

the treatment enhances the performance of the dry strength aid in the paper mat.

11. The method of claim 10 wherein the filler flocs have a median particle size of 10-100 μm.

12. The method of claim 10 wherein the filler is selected from the group consisting of precipitated calcium carbonate, ground calcium carbonate, kaolin clay, talc, titanium dioxide, alumina trihydrate, barium sulfate and magnesium hydroxide, and mixtures thereof.

13. The method of claim 10 wherein the first flocculating agent has net anionic charge.

14. The method of claim 13 wherein the second flocculating agent is cationic, selected from the group consisting of copolymers and terpolymers of (meth)acrylamide with dimethylaminoethyl methacrylate (DMAEM), dimethylaminoethyl acrylate (DMAEA), diethylaminoethyl acrylate (DEAEA), diethylaminoethyl methacrylate (DEAEM) or their quaternary ammonium forms made with dimethyl sulfate, methyl chloride or benzyl chloride, and mixtures thereof.

15. The method of claim 13 wherein the second flocculating agent is acrylamide-dimethylaminoethyl acrylate methyl chloride quaternary copolymer having a cationic charge of 10-50 mole percent and a RSV of at least 15 dL/g.

16. The method of claim 13 wherein the second flocculating agent is a homopolymer of diallyl dimethyl ammonium chloride having an RSV of 0.1-2 dL/g.

17. The method of claim 10 further comprising adding one or more microparticles to the flocculated dispersion after addition of the second flocculating agent.

18. The method of claim 10 wherein the filler is anionically dispersed and a low molecular weight, cationic coagulant is added to the dispersion to at least partially neutralize its anionic charge prior to the addition of the first flocculating agent.