Paper substrate containing a functional layer and methods of making and using the same

Abstract

The invention relates to the papermaking art and, in particular, to the manufacture of paper or paperboard substrates, paper-containing articles such as multilayered paper or paperboard or corrugated-based packaging, having a functional layer, as well as methods of making and using the same.

1 - 25 . (canceled) 
     
     
         26 . A paper or paperboard substrate, comprising
 a web of cellulose fibers and a functional layer, wherein
 when the substrate is incorporated into a box, the box has at least a 100 CT (sulfur dioxide concentration in ppm×time in hours) achieved by either a 30-minute treatment or a total utilization treatment of sulfur dioxide; and 
 the functional layer comprises at least one film forming compound and optionally starch. 
   
     
     
         27 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer comprises optionally starch and at least one film forming compound selected from the group consisting of latex and styrene acrylate. 
     
     
         28 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer comprises at least one film forming compound having a Tg that is not greater than 350° C. 
     
     
         29 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer is present in the substrate at a coat weight that ranges from 5 to 15 gsm. 
     
     
         30 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer further comprises at least one member selected from the group consisting of a crosslinker, a clay, a pigment, an anti-blocking agent, and a defoamer. 
     
     
         31 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer and the web of cellulosic fibers have a layer of interpenetration. 
     
     
         32 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer and the web of cellulosic fibers have a layer of interpenetration and the interpenetration layer is less than 25% of the entire cross section of the substrate. 
     
     
         33 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer and the web of cellulosic fibers have a layer of interpenetration and the interpenetration layer is greater than 25% of the entire cross section of the substrate. 
     
     
         34 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer and the web of cellulosic fibers have a layer of interpenetration and the interpenetration layer 100% of the entire cross section of the substrate. 
     
     
         35 . The paper or paperboard substrate according to  claim 26 , wherein the functional layer and the web of cellulosic fibers have a layer of interpenetration and the interpenetration layer is greater than 100% of the entire cross section of the substrate and the functional layer is evenly dispersed throughout the web. 
     
     
         36 . The paper or paperboard substrate according to  claim 26 , wherein the substrate has a Cobb Value of less than 35 g/m 2  as determined by the Cobb Sizing Test, according to ASTM D-3285 (TAPPI T-441). 
     
     
         37 . The paper or paperboard substrate according to  claim 26 , wherein the substrate has an increase in sulfur dioxide holdout that is at least 5% greater than that of a substrate not containing the web of cellulose fibers and the functional layer. 
     
     
         38 . The paper or paperboard substrate according to  claim 26 , further comprising an adhesive layer. 
     
     
         39 . The paper or paperboard substrate according to  claim 38 , wherein the functional layer lies between the adhesive layer and the web. 
     
     
         40 . The paper or paperboard substrate according to  claim 38 , wherein the functional layer lies at least on a surface of the web and between the adhesive layer and the web. 
     
     
         41 . The paper or paperboard substrate according to  claim 40 , wherein the functional layer and the web further create an interpenetration layer. 
     
     
         42 . The paper or paperboard substrate according to  claim 38 , wherein a portion of the functional layer lies at least on a surface of the web and between the adhesive layer and the web. 
     
     
         43 . The paper or paperboard substrate according to  claim 38 , wherein a portion of the functional layer lies at least on a surface of the web and between the adhesive layer and the web; and a surface of the web is also in contact with a portion of the adhesive layer. 
     
     
         44 . The paper or paperboard substrate according to  claim 43 , wherein a portion of the adhesive layer penetrates though a portion of the surface of the web. 
     
     
         45 . A corrugated board, comprising the paper or paperboard substrate according to  claim 26 . 
     
     
         46 . A package, carton, or box, comprising the corrugated board according to  claim 45 . 
     
     
         47 . The package according to  claim 46 , having a sulfur dioxide CT that is at least 2500. 
     
     
         48 . The package according to  claim 46 , having a sulfur dioxide CT that is at least 2700. 
     
     
         49 . The package according to  claim 46 , having a sulfur dioxide CT that is at least 3000.