High-Yield Paper and Methods of Making Same

Abstract

A high-yield paper sheet generally includes at least about 50 weight percent mechanical pulp, wherein the basis weight of the sheet is in the range of about 24 to about 60 pounds, and a surface layer on the sheet including nPCC pigment.

1 . A high-yield paper sheet, comprising:
 (a) at least about 50 weight percent mechanical pulp, wherein the basis weight of the sheet is in the range of about 24 to about 60 pounds; and   (b) a surface layer on the sheet including nPCC pigment.   
     
     
         2 . The high-yield paper sheet of  claim 1 , wherein the surface layer on the sheet includes about 0.5 to about 10 gsm nPCC. 
     
     
         3 . The high-yield paper sheet of  claim 1 , wherein the surface layer on the sheet includes about 1 to about 6 gsm nPCC. 
     
     
         4 . The high-yield paper sheet of  claim 1 , wherein the surface layer on the sheet further includes about 0.1 to about 3 gsm binder. 
     
     
         5 . The high-yield paper sheet of  claim 4 , wherein the binder is selected from the group consisting of a binder component selected from the group consisting starch, latex, polyvinyl alcohol, carboxymethyl cellulose, glucomannan, protein, and other known binders, and any combination thereof. 
     
     
         6 . The high-yield paper sheet of  claim 1 , wherein the particle size of the nPCC is selected from the group consisting of less than about 200 nanometers, less than about 100 nanometers, and about 15 to about 40 nanometers. 
     
     
         7 . The high-yield paper sheet of  claim 1 , wherein the nPCC comprises substantially non-agglomerated particles. 
     
     
         8 . The high-yield paper sheet of  claim 1 , wherein the nPCC has a substantially needle-shaped morphology. 
     
     
         9 . The high-yield paper sheet of  claim 8 , wherein the needle-shaped nPCC has a diameter in the range of about 15 to about 200 nanometers. 
     
     
         10 . The high-yield paper sheet of  claim 8 , wherein the needle-shaped nPCC has a length of greater than 1 microns. 
     
     
         11 . The high-yield paper sheet of  claim 8 , wherein the needle-shaped nPCC has a length of about 4 to about 6 microns. 
     
     
         12 . The high-yield paper sheet of  claim 1 , wherein the surface layer on the sheet further includes other pigments selected from the group consisting of GCC, calcined clay, delaminated clay, plastic pigments, silicates, mica, kaolin, bentonite, alumina trihydrate, phyllosilicant, talc, and any combination thereof. 
     
     
         13 . A high-yield paper sheet, comprising:
 (a) at least about 50 weight percent mechanical pulp, wherein the basis weight of the sheet is in the range of about 35 to about 55 pounds; and   (b) a surface layer on the sheet including nPCC pigment.   
     
     
         14 . The high-yield paper sheet of  claim 13 , wherein the surface layer on the sheet includes about 0.5 to about 10 gsm nPCC. 
     
     
         15 . The high-yield paper sheet of  claim 13 , wherein the surface layer further includes starch binder. 
     
     
         16 . A high-yield paper sheet, comprising:
 (a) at least about 50 weight percent mechanical pulp, wherein the basis weight of the sheet is less than about 45 pounds; and   (b) a surface layer on the sheet including nPCC pigment and binder.   
     
     
         17 . The high-yield paper sheet of  claim 16 , wherein the surface layer on the sheet includes about 0.5 to about 10 gsm nPCC. 
     
     
         18 . The high-yield paper sheet of  claim 16 , wherein the surface layer further includes starch binder.