Anti-microbial paper substrates useful in wallboard tape applications

Abstract

This invention relates to paper products and/or substrates suitable for being made into wallboard tape (also may be known as joint tape and/or drywall tape) and having improved reduction or inhibition in the growth of microbes, mold and/or fungus. The paper substrate is characterized by its excellent physical properties including cross direction (CD) tensile, machine (MD) tensile, internal bond, wet tensile, hygroexpansivity, curl, bonding properties, bonding of joint tape to joint compound, etc. The paper product of the invention contains a sizing agent and an antimicrobial compound as well as other optional components including without limitation a binder. The paper product of the invention may be produced by contacting the plurality of cellulose fibers with each of the sizing agent, antimicrobial compound, and optional components at any point in the papermaking process, converting process, and/or post-converting process. Finally, the invention relates to methods of using the paper substrate.

What is claimed is: 
     
         1 . A wallboard joint tape, comprising
 a web of cellulosic fibers;   at least one antimicrobial compound;   at least one sizing agent; and   optionally at least one binder.   
     
     
         2 . The tape according to  claim 1 , wherein
 the antimicrobial compound is present at an amount ranging from about 10 ppm to about 5,000 ppm;   the sizing agent is present at an amount ranging from about 0.05 to about 1.5 wt %; and   the binder is present at an amount ranging from 0.0% to not more than about 5%.   
     
     
         3 . The tape according to  claim 1 , further comprising at least one surface that is abraded. 
     
     
         4 . The tape according to  claim 1 , said tape having:
 a basis weight ranging from 50 to 120 lb per 3,000 sq. ft.;   a cross-direction Tensile ranging from 5 to 50 lbf/inch width as measured by Tappi Test Method T 494 om-06; and   a thickness ranging from 0.006 to 0.012 inch thickness as measured by Tappi Test Method T 411 om-05.   
     
     
         5 . The tape according to  claim 1 , wherein said sizing agent is present within the web and the antimicrobial agent is present at the surface of the web. 
     
     
         6 . The tape according to  claim 5 , wherein said surface of the web has a naphthereon. 
     
     
         5 . A method of making the tape according to  claim 1 , comprising
 contacting said web to said binder, sizing agent, and antimicrobial compound.   
     
     
         6 . The method according to  claim 1 , wherein said web is contacted with said binder, sizing agent, and antimicrobial compound simultaneously or consecutively. 
     
     
         7 . The method according to  claim 6 , wherein said contacting occurs at a size press, water box, a coater. 
     
     
         8 . The method according to  claim 6 , wherein said contacting occurs by spraying the said binder, sizing agent, and/or antimicrobial compound directly onto at least one surface of a moving web. 
     
     
         9 . A method of making the tape according to  claim 1 , comprising
 contacting a paper substrate comprising a web of cellulosic fibers and a sizing agent with a composition comprising said antimicrobial agent.   
     
     
         10 . The method according to  claim 9 , further comprising
 abrading or sanding a surface of said web.   
     
     
         11 . The method according to  claim 9 , further comprising
 abrading or sanding a surface of said web prior to said contacting.   
     
     
         12 . The method according to  claim 11 , wherein said contacting is performed such that the composition comprising said antimicrobial agent is contacted with said surface of said web. 
     
     
         13 . The method according to  claim 12 , wherein said contacting said web with said composition comprising said antimicrobial agent is performed using a size press, a coater, or a sprayer. 
     
     
         14 . The method according to  claim 9 , wherein said contacting said web with said composition comprising said antimicrobial agent is performed using a size press, a coater, or a sprayer. 
     
     
         15 . A method of reducing, inhibiting, preventing, stalling, and/or retarding the growth of mold or fungus on a wallboard joint tape and/or wallboard, comprising
 abrading or sanding a surface of a paper substrate comprising a web of cellulosic fibers and a sizing agent;   then contacting said surface with a composition comprising said antimicrobial agent.   
     
     
         16 . The method according to  claim 15 , further comprising
 abrading or sanding a surface of said web.   
     
     
         17 . The method according to  claim 15 , further comprising
 abrading or sanding a surface of said web prior to said contacting.   
     
     
         18 . The method according to  claim 17 , wherein said contacting is performed such that the composition comprising said antimicrobial agent is contacted with said surface of said web. 
     
     
         19 . The method according to  claim 18 , wherein said contacting said web with said composition comprising said antimicrobial agent is performed using a size press, a coater, or a sprayer. 
     
     
         20 . The method according to  claim 15 , wherein said contacting said web with said composition comprising said antimicrobial agent is performed using a size press, a coater, or a sprayer. 
     
     
         21 . A composition comprising,
 wallboard or gypsum board;   joint compound; and   wallboard joint tape comprising
 a web of cellulosic fibers; 
 at least one antimicrobial compound; 
 at least one sizing agent; and 
 optionally at least one binder.