The present invention relates to a hydrous kaolin product having improved optical properties, for example, when used in the production of paper products. The present invention comprises an improved barrier coating for paper and a method of making the coated paper. The present invention also comprises an improved method from making filled and coated paper products. The present invention uses a composition comprising kaolin having a shape factor of at least about 70:1, such as at least about 80:1 or at least about 100:1.

Hyperplaty clays and their use in paper coating and filling, methods for making same, and paper products having improved brightness

A coating system on a fibrous substrate, such as a fibrous ceiling panel, having a first surface and a second surface. A first coating is disposed on the first surface of the substrate and includes a first binder and a first filler material. A second coating may be disposed on the second surface of the substrate. The second coating includes a second binder and a second filler material. The first coating and the second coating expand at different rates in the presence of humidity in order to help prevent sagging of the substrate in presence of humidity. The first coating is preferably a hydrophobic coating having a large particle size, high elastic modulus filler material. The second coating is preferably a hydrophilic coating having a lower concentration of high elastic modulus material and a polymer having a hydrophilic moiety.

Coating system for sag resistant formaldehyde-free fibrous panels

The invention relates to an imaging member comprising at least one image layer and a base, said base comprising a cellulose paper that has its surfaces impregnated with water dispersible ester-based condensation polymer wherein the surface of said base has a roughness of less than 2.03 μm Ra and a hydrophobicity as measured by 40/20 Acid Valley test in excess of 500 seconds.

Water-borne polyester coated imaging member

A method is provided for producing a wide range of high quality coated recyclable paper or paperboard for use in a variety of applications. In accordance with the process, paper or paperboard is coated with a polymer emulsion in one or more coating stations which are off-line from a paper or paperboard machine. The process provides coated paper or paperboard products with enhanced barrier properties.

Coated recyclable paper or paperboard and methods for their production

A cellulosic product such as paper coating composition is disclosed comprising aqueous-based semi-crystalline vinyl acetate-ethylene polymer emulsions, containing crystalline ethylene segments, which are useful for imparting oil, grease, solvent, water, and moisture vapor resistance. The polymer emulsions are prepared via the direct aqueous-based free radical emulsion polymerization of ethylene with various other comonomers. The semi-crystalline aqueous-based polymer emulsions of this invention have a crystalline melting point and a crystalline heat of fusion ranging from 5 to 100 J/g. The semi-crystalline aqueous-based emulsion polymers of this invention can be used directly as a paper or paperboard coating for imparting oil, grease, solvent, water, and moisture vapor resistance. Further, the present invention provides a repulpable paper and paperboard.

Polymer emulsion coatings for cellulosic substrates with improved barrier properties

The present invention provides a repulpable moisture vapor barrier. The moisture vapor barrier comprises a resin latex and a hydrophobic component having a crystalline platelet structure. Suitable resin latexes include polystyrene, styrene-acrylonitrile, styrene-acrylonitrile-butadiene, styrene acrylates, styrene-butadiene, carboxylated styrene butadiene, polyvinyl chloride, polyvinyl acetate, waterborne polyurethanes, alkyl acrylates, polyvinylidene chloride, ethyl vinyl chloride, and copolymers and terpolymers thereof. Preferably the hydrophobic component is suspended in means for suspending the component such as fully hydrolyzed polyvinyl alcohol.

David E. Stark

Papers

Repulpable moisture vapor barrier