Cellulose-based substrates encapsulated with polymeric films and adhesive

Abstract

A cellulose based substrate ( 20 ) generally includes a cellulose based sheet having a corrugated medium ( 48 ) spanning between first and second linerboards ( 44 and 46 ), wherein the corrugated medium includes at least one sizing agent for moisture wicking resistance. The cellulose based substrate further includes a polymeric film ( 43 ) encapsulating at least a portion of the cellulose based sheet.

1 . A cellulose based substrate, comprising: 
 (a) a cellulose based sheet having a corrugated medium spanning between first and second linerboards, wherein the corrugated medium includes at least one sizing agent for moisture wicking resistance; and    (b) a polymeric film encapsulating at least a portion of the cellulose based sheet.    
     
     
         2 . The cellulose based substrate of  claim 1 , wherein the at least one sizing agent includes alum for sizing the natural resins of the cellulose.  
     
     
         3 . The cellulose based substrate of  claim 1 , wherein the at least one sizing agent includes a reactive sizing additive.  
     
     
         4 . The cellulose based substrate of  claim 1 , wherein the at least one sizing agent is a reactive sizing agent selected from the group consisting of alkyl ketene dimer, alkenyl ketene dimer emulsion, alkenyl succinic anhydride (ASA), and any blends thereof.  
     
     
         5 . The cellulose based substrate of  claim 4 , wherein the reactive sizing agent is present in the corrugated medium in an amount within the range of about 0.1 to about 4.0 lb/ton.  
     
     
         6 . The cellulose based substrate of  claim 1 , wherein the corrugated medium further includes a cationic crosslinking-type wet strength resin.  
     
     
         7 . The cellulose based substrate of  claim 6 , wherein the resin is selected from the group consisting of urea-formaldehyde condensation products, melamine-urea-formaldehyde condensation products, and polyamide-epichlorohydrin reaction products.  
     
     
         8 . The cellulose based substrate of  claim 1 , wherein the corrugated medium includes about 0 to about 30% virgin cellulosic fiber.  
     
     
         9 . The cellulose based substrate of  claim 1 , wherein the polymeric film encapsulating at least a portion of the cellulose based sheet is adhesively bonded to the first and second linerboards.  
     
     
         10 . The cellulose based substrate of  claim 1 , wherein corrugated medium spanning between first and second linerboards is bonded to the first and second linerboards using a water-resistant adhesive.  
     
     
         11 . A container, comprising: 
 (a) a cellulose based sheet having a corrugated medium spanning between first and second linerboards, wherein the corrugated medium includes at least one sizing agent for moisture wicking resistance; and    (b) a polymeric film encapsulating at least a portion of the cellulose based sheet.    
     
     
         12 . A container, comprising: 
 (a) a cellulose based sheet having a corrugated medium spanning between first and second linerboards, wherein the corrugated medium includes a sizing agent for moisture wicking resistance and a reactive cationic cross-linking type resin for improved wet strength; and    (b) a polymeric film encapsulating at least a portion of the cellulose based sheet.    
     
     
         13 . The container of  claim 12 , wherein the sizing agent is alum for sizing the natural resins of the cellulose.  
     
     
         14 . The container of  claim 12 , wherein the sizing agent is a reactive sizing agent selected from the group consisting of alkyl ketene dimer, alkenyl ketene dimer emulsion, alkenyl succinic anhydride (ASA), and any blends thereof.  
     
     
         15 . The container of  claim 14 , wherein the reactive sizing agent is present in the corrugated medium in an amount in the range of about 0.1 to about 4.0 lb/ton.  
     
     
         16 . The container of  claim 12 , wherein the corrugated medium includes about 0 to about 30% virgin cellulosic fiber.  
     
     
         17 . The container of  claim 12 , wherein corrugated medium spanning between first and second linerboards is bonded to the first and second linerboards using a water-resistant adhesive.  
     
     
         18 . The container of  claim 12 , wherein the polymeric film encapsulating at least a portion of the cellulose based sheet is adhesively bonded to the first and second linerboards.