Coated substrate comprising a surface-treated, aqueous-based polymer coating and methods of making and using the same

Abstract

Disclosed herein are, for instance, coated substrates comprising cellulose-based substrates with surface-treated aqueous-based polymer coatings. In some embodiments, the aqueous-based polymer coatings are surface-treated using corona treatment. Methods of making and using the same are also disclosed.

1 .- 45 . (canceled) 
     
     
         46 . A paper cup, comprising:
 a side portion and a bottom portion, and   a first aqueous-based polymer coating on a first surface of the paper cup, the first surface comprising one or more of an interior surface of the side portion or an interior surface of the bottom portion,
 wherein the first aqueous-based polymer coating has been surface treated with a high energy discharge, and 
 wherein a bottom edge of the side portion is bonded to a side edge of the bottom portion via a seal comprising the first aqueous-based polymer coating. 
   
     
     
         47 . The paper cup according to  claim 46 , wherein the first aqueous-based polymer coating comprises a pure acrylic copolymer, a styrene-acrylic copolymer, a styrene-butadiene copolymer, a vinyl acrylic copolymer, or a combination thereof. 
     
     
         48 . The paper cup according to  claim 46 , wherein the first surface comprises both an interior surface of the side portion and an interior surface of the bottom portion. 
     
     
         49 . The paper cup according to  claim 46 , wherein the first aqueous-based polymer coating is surface treated using corona treatment. 
     
     
         50 . The paper cup according to  claim 46 , further comprising a second coating comprising a semicrystalline polymer on a second surface of the paper cup, the second surface comprising an interior surface of the bottom portion of the cup when the first surface is the interior surface of the side portion or the second surface comprising an interior surface of the side portion of the cup when the first surface is the interior surface of the bottom portion, and wherein a bottom edge of the side portion is bonded to a side edge of the bottom portion via a seal comprising the first aqueous-based polymer coating and the second coating. 
     
     
         51 . The paper cup according to  claim 50 , wherein the semicrystalline polymer comprises low density polyethylene homopolymer or low density polyethylene copolymer. 
     
     
         52 . The paper cup according to  claim 50 , wherein the semicrystalline polymer has polar functionality. 
     
     
         53 . The paper cup according to  claim 50 , wherein the semicrystalline polymer includes a low density polyethylene copolymer that is a copolymer of ethylene and a monomer comprising methyl acrylate, methacrylic acid, or a combination thereof. 
     
     
         54 . The paper cup according to  claim 50 , wherein the second coating has a thickness of 0.5 mils to 2 mils. 
     
     
         55 . The paper cup according to  claim 50 , wherein the semicrystalline polymer has a melting point temperature of 95° C. to 105° C. 
     
     
         56 . The paper cup according to  claim 50 , wherein the second coating has a density of 0.65 g/cm 3  to 1.1 g/cm 3 . 
     
     
         57 . The paper cup according to  claim 50 , wherein the first aqueous-based polymer coating further comprises a pigment that has been treated with a material selected from the group consisting of surfactants; hydrophobically-modified polymers; styrene-acrylic resin emulsions;
 styrene-butadiene latex emulsions; silanes, siloxanes, siloxane/silicone resin blends, and their carbon-based analogs; and combinations thereof to form a treated pigment.   
     
     
         58 . The paper cup according to  claim 50 , wherein the side portion of the paper cup is adhered to itself along a side edge. 
     
     
         59 . The paper cup according to  claim 50 , wherein the paper cup does not exhibit a leak along the seal of the paper cup for thirty minutes after substantially filling the cup with hot coffee at an initial temperature of 90° C. 
     
     
         60 . A method of producing a treated, coated substrate, the method comprising:
 coating a cellulose-based substrate with an aqueous-based polymer coating to form a coated substrate, and   corona treating the coated substrate to form a treated, coated substrate.   
     
     
         61 . The method according to  claim 60 , wherein the aqueous-based polymer coating comprises a pure acrylic copolymer, a styrene-acrylic copolymer, a styrene-butadiene copolymer, a vinyl acrylic copolymer, or a combination thereof. 
     
     
         62 . The method according to  claim 60 , wherein the corona treatment is conducted at 1 to 4 watts per square foot per minute. 
     
     
         63 . A method of producing a paper cup, comprising:
 forming a side wall and/or a bottom from a first cellulose-based substrate, at least a portion of a surface of the first cellulose-based substrate coated with a first aqueous-based polymer coating and then surface treated with a high energy discharge,   bonding the side wall to itself along a side edge; and   bonding the side wall along a bottom edge to the bottom along a side edge to form a seal comprising the first aqueous-based polymer coating.   
     
     
         64 . The method according to  claim 63 , further comprising providing a second cellulose-based substrate, wherein at least a portion of the second cellulose-based substrate is coated with a semicrystalline polymer and the second cellulose-based substrate is formed into a side wall if the first cellulose-based substrate is formed into a bottom and the second cellulose-based substrate is formed into a bottom if the first cellulose-based substrate is formed into a side wall. 
     
     
         65 . The method according to  claim 64 , wherein the semicrystalline polymer comprises low density polyethylene, aliphatic aromatic polyester, nylon, or a combination thereof.