Paper substrates useful in wallboard tape applications

Abstract

This invention relates to paper products and/or substrates suitable for being made and/or converted into wallboard tape; which also may be known as joint tape and/or drywall tape, having a pH of at least 7.0 and containing a plurality of cellulose fibers, a wet strength additive, an alkaline sizing agent, and an anionic promoter, as well as methods of making and using the same.

What is claimed is: 
     
         1 . A paper substrate, comprising
 a plurality of cellulose fibers,   a wet strength additive, and   an alkaline sizing agent,   wherein said substrate has a pH of from 7.0 to 14.0.   
     
     
         2 . The paper substrate according to  claim 1  having a basis weight of from 50 to 120 lbs/3000 sq. ft. 
     
     
         3 . The paper substrate according to  claim 1 , having an apparent density of from 5.0 to 20 lb/1000 sq. ft. per 0.001 inch thickness. 
     
     
         4 . The paper substrate according to  claim 1 , having a MD Tensile of from 25 to 100 lbf/inch width. 
     
     
         5 . The paper substrate according to  claim 1 , having a CD Tensile of from 5 to 50 lbf/inch width. 
     
     
         6 . The paper substrate according to  claim 1 , wherein at least a majority of the plurality of cellulose fibers is softwood fibers. 
     
     
         7 . The paper substrate according to  claim 1 , further comprising calcium carbonate. 
     
     
         8 . The paper substrate according to  claim 1 , wherein the alkaline sizing agent is at least one member selected from the group consisting of alkyl ketene dimer, alkenyl ketene dimer and alkenyl succinic anhydride. 
     
     
         9 . The paper substrate according to  claim 1 , further comprising an anionic promoter. 
     
     
         10 . The paper substrate according to  claim 9 , wherein the anionic promoter is at least one member selected from the group consisting of a polyacrylate, sulfonate, carboxymethyl cellulose, galactomannan hemicellulose and polyacrylamide. 
     
     
         11 . The paper substrate according to  claim 1 , further comprising at least one member selected from the group consisting of a binder, filler, thickener, and preservative. 
     
     
         12 . The paper substrate according to  claim 1 , wherein the substrate is abraded. 
     
     
         13 . The paper substrate according to  claim 1 , wherein the substrate is sanded. 
     
     
         14 . A paper substrate according to  claim 1 , wherein said substrate has a width off a winder of a paper machine of from 15 to 100 inches. 
     
     
         15 . A paper substrate according to  claim 1 , wherein said paper substrate is abraded or sanded and has a cut width of from 1.5 to 3.25 inches. 
     
     
         16 . The paper substrate according to  claim 1 , wherein the wet strength agent is at least one member or combinations selected from the group consisting of a polymeric amine epichlorohydrin, urea formaldehyde, melamine formaldehyde and glyoxylated polyacrylamide resins. 
     
     
         17 . The paper substrate according to  claim 1 , further comprising calcium carbonate in at least one form selected from the group consisting of precipitated calcium carbonate and ground calcium carbonate. 
     
     
         18 . The paper substrate according to  claim 1 , wherein the alkaline sizing agent is at least one unsaturated hydrocarbon having from 16 to 20 carbon atoms. 
     
     
         19 . The paper substrate according to  claim 1 , further comprising a binder. 
     
     
         20 . A method of making the paper substrate according to  claim 1 , comprising
 contacting a plurality of cellulose fibers with a wet strength additive, an alkaline sizing agent, and optionally an anionic promoter consecutively and/or simultaneously.   
     
     
         21 . The method according to  claim 20 , wherein said contacting occurs within an aqueous environment having a pH of from 7.0 to 14.0. 
     
     
         22 . A paper substrate, comprising
 a plurality of cellulose fibers;   a wet strength additive;   an alkaline sizing agent; and   optionally an anionic promoter, wherein   said substrate has a pH of from 7.0 to 14.0; and   said substrate has an internal bond of from about 25 to about 350 milli ft-lb/sq. in. as measured by TAPPI method 541.   
     
     
         23 . The paper substrate according to  claim 22 , wherein the substrate has an internal bond of from about 50 to about 250 milli ft-lb/sq. in. as measured by TAPPI method 541. 
     
     
         24 . A method of making the paper substrate according to  claim 22 , comprising
 contacting a plurality of cellulose fibers with a wet strength additive, an alkaline sizing agent, and optionally an anionic promoter consecutively and/or simultaneously.