Paper substrates useful in wallboard tape applications

Abstract

A paper substrate, particularly useful in wallboard tape applications containing PVOH on and/or in at least one surface of the paper, as well as methods of making and using the same. The use of the tape of the invention is used in conjunction with a joint compound that may contain no or, reduced amounts of bonding agent.

What is claimed is: 
     
         1 . A paper substrate, comprising
 a web of cellulose fibers; and   polyvinyl alcohol.   
     
     
         2 . The paper substrate according to  claim 1 , comprising polyvinyl alcohol on and/or within the web of cellulose fibers. 
     
     
         3 . The paper substrate according to  claim 1 , wherein said substrate is wallboard tape. 
     
     
         4 . The paper substrate according to  claim 1 , wherein said paper substrate is neutral, acidic or alkaline. 
     
     
         5 . The paper substrate according to  claim 1 , wherein a surface of the substrate is abraded. 
     
     
         6 . The paper substrate according to  claim 1 , comprising from 0.05 to 20 wt % polyvinyl alcohol based on the total weight of the substrate. 
     
     
         7 . The paper substrate according to  claim 1 , further comprising starch. 
     
     
         8 . The paper substrate according to  claim 1 , further comprising from 0.05 to 20 wt % starch based on the total weight of the substrate. 
     
     
         9 . The paper substrate according to  claim 1 , wherein said polyvinyl alcohol is from 75 to 100% hydrolyzed. 
     
     
         10 . The paper substrate according to  claim 1 , wherein said substrate has a basis weight of from 50 to 120 lbs/3000 sq. ft. 
     
     
         11 . The paper substrate according to  claim 1 , wherein the substrate has a CD tensile of from 5 to 60 lbf/inch width as measured by TAPPI method  494 . 
     
     
         12 . The paper substrate according to  claim 1 , wherein the substrate has a MD tensile of from 25 to 100 lbf/inch width as measured by TAPPI method  494 . 
     
     
         13 . A method of making the paper substrate according to  claim 1 , comprising contacting the polyvinyl alcohol with the cellulose fibers. 
     
     
         14 . The method according to  claim 13 , wherein said contacting occurs during at least one point in the paper-making process, said point selected from at least one member selected from the group consisting of the head box, size press, water box and coater. 
     
     
         15 . The method according to  claim 13 , wherein said contacting occurs at the size press. 
     
     
         16 . The method according to  claim 13 , further comprising contacting the fibers with starch. 
     
     
         17 . The method according to  claim 16 , comprising contacting the fibers with starch and polyvinyl alcohol at the same time. 
     
     
         18 . The method according to  claim 16 , comprising contacting the fibers with starch and polyvinyl alcohol at the same time so that the ratio of starch/polyvinyl alcohol is from 99 wt % starch/1 wt % polyvinyl alcohol to 5 wt % starch/95 wt % polyvinyl alcohol, wherein the wt % is based upon the total weight of the starch and polyvinyl alcohol. 
     
     
         19 . The method according to  claim 13 , wherein the fibers are contacted with polyvinyl alcohol at the size press at a wt % solids from 1 to 10 wt % in aqueous solution based upon the total weight of the solution. 
     
     
         20 . The method according to  claim 13 , further comprising abrading at least one surface of the substrate.