Compositions containing expandable microspheres and an ionic compound, as well as methods of making and using the same

Abstract

This invention relates to composition containing expandable microspheres and at least one ionic compound and having a zeta potential that is greater than or equal to zero mV at a pH of about 9.0 or less at an ionic strength of from 10 −6 M to 0.1M., as well as methods of making and using the composition.

What is claimed is: 
     
         1 . A composition, comprising
 at least one expandable microsphere and   at least one ionic compound,   wherein said composition has a zeta potential that is greater than or equal to zero mV at a pH of about 9.0 or less at an ionic strength of from 10 −6  M to 0.1M.   
     
     
         2 . The composition according to  claim 1 , wherein said zeta potential is greater than zero mV. 
     
     
         3 . The composition according to  claim 1 , wherein said zeta potential ranges from greater than zero to +150 mV. 
     
     
         4 . The composition according to  claim 1 , wherein said zeta potential ranges from greater than +20 to +130 mV. 
     
     
         5 . The composition according to  claim 1 , wherein said ionic compound is at least one compound selected from the group consisting of an organic and inorganic ionic compound. 
     
     
         6 . The composition according to  claim 1 , wherein said ionic compound is at least one polyorganic compound. 
     
     
         7 . The composition according to  claim 1 , wherein said ionic compound is at least one polyamine compound. 
     
     
         8 . The composition according to  claim 1 , wherein said ionic compound is crosslinked, branched, or combinations thereof. 
     
     
         9 . The composition according to  claim 1 , wherein said ionic compound is at least one polyethyleneimine compound. 
     
     
         10 . The composition according to  claim 1 , wherein said ionic compound is at least one polyethyleneimine compound having a molecular weight of at least 600 weight average molecular weight. 
     
     
         11 . The composition according to  claim 1 , wherein said ionic compound is at least one polyethyleneimine compound having a molecular weight of from 600 to 40,000 weight average molecular weight. 
     
     
         12 . The composition according to  claim 1 , wherein said ionic compound is cationic. 
     
     
         13 . The composition according to  claim 1 , wherein said ionic compound comprises at least one member selected from the group consisting of alumina and silica. 
     
     
         14 . The composition according to  claim 1 , wherein said ionic compound comprises a colloid comprising at least one member selected from the group consisting of silica, alumina, tin oxide, zirconia, antimony oxide, iron oxide, and rare earth metal oxides. 
     
     
         15 . The composition according to  claim 1 , wherein said ionic compound comprises a sol comprising at least one member selected from the group consisting of silica, alumina, tin oxide, zirconia, antimony oxide, iron oxide, and rare earth metal oxides. 
     
     
         16 . The composition according to  claim 1 , wherein the composition is a particle. 
     
     
         17 . The composition according to  claim 16 , wherein an outside surface of the at least one expandable microsphere is bound to the ionic compound. 
     
     
         18 . The composition according to  claim 16 , wherein an outside surface of the at least one expandable microsphere is non-covalently bound to the ionic compound. 
     
     
         19 . The particle according to  claim 16 , wherein the outside surface of at least one expandable microsphere is anionic. 
     
     
         20 . The particle according to  claim 16 , wherein the ionic compound is cationic. 
     
     
         20 . A method of making the composition according to  claim 1 , comprising
 contacting the at least one expandable microsphere with the at least one ionic compound to form a mixture.   
     
     
         21 . The method according to  claim 20 , further comprising
 centrifuging the mixture to form a first phase comprising at least one ionic compound and a second phase comprising the particle.   
     
     
         22 . A method of making the composition according to  claim 1 , comprising
 adsorbing at least one ionic compound to at least one expandable microsphere   
     
     
         23 . The composition according to  claim 1 , further comprising a plurality of cellulose fibers. 
     
     
         24 . The composition according to  claim 23 , wherein an outside surface of the at least one expandable microsphere is bound to the ionic compound. 
     
     
         25 . The composition according to  claim 23 , wherein an outside surface of the at least one expandable microsphere is non-covalently bound to the ionic compound. 
     
     
         26 . A method of making the composition according to  claim 23 , comprising
 contacting the at least one expandable microsphere with the at least one ionic compound to form a particle, and   contacting said particle with said plurality of cellulose fibers.   
     
     
         27 . A method of making the composition according to  claim 23 , comprising
 contacting the at least one expandable microsphere with the at least one ionic compound to form a particle; and   injecting the particle into a solution comprising a plurality of cellulose fibers.   
     
     
         28 . A paper or paperboard substrate, comprising
 a plurality of cellulose fibers;   from 0.1 to 5 wt % of a plurality of expandable microspheres; wherein the substrate has a Sheffield Smoothness of less than 250 SU as measured by TAPPI test method T 538 om-1; and   a scanning 2 nd  cyan print mottle of not more than 6.   
     
     
         29 . The substrate according to  claim 28 , wherein an outside surface of the expandable microspheres are bound to an ionic compound. 
     
     
         30 . The substrate according to  claim 28 , comprising from 0.1 to 3 wt % of a plurality of expandable microspheres. 
     
     
         31 . The substrate according to  claim 28 , comprising from 0.1 to 2 wt % of a plurality of expandable microspheres. 
     
     
         32 . The substrate according to  claim 28 , further comprising at least one coating layer. 
     
     
         33 . The substrate according to  claim 28 , wherein the coating layer comprises at least one top coat and at least one base coat. 
     
     
         34 . The substrate according to  claim 28 , wherein the Sheffield Smoothness is less than 250 SU and the scanning print mottle is less than 6 after calendaring said substrate, as measured by TAPPI test method T 538 om-1. 
     
     
         35 . The substrate according to  claim 28 , wherein the substrate has a Parker Print Surface Smoothness of from about 1.0 to 0.5 as measured by TAPPI test method T 555 om-99 
     
     
         36 . An article, comprising the substrate according to  claim 28 . 
     
     
         37 . The article according to  claim 33 , wherein the article is a folding carton. 
     
     
         38 . An article, comprising
 at least one paper or paperboard substrate wherein as least one substrate comprises a web of cellulose fibers and a bulking agent; wherein the article weighs equal to or less than one ounce; and wherein the article has a weight whose difference from 1 ounce is an absolute value that is more than that of a conventional package having the same number of layers.