Granted Patent B2

US 7,404,999 · App. 11/092,435 · Granted Jul 29, 2008

Abstract

Claims (53)

1. A composite comprising:

(a) a paper substrate having a first side and a second side, wherein the first side has a hold-out coating thereon and the second side has a print coating thereon;

(b) a barrier layer overlying the hold-out coating; and

(c) an anti-blocking coating overlying the print coating, wherein the anti-blocking coating at least partially defines an outermost surface on the second side of the composite, wherein the anti-blocking coating consists essentially of colloidal silica and, optionally, wax.

2. The composite of claim 1 , wherein the anti-blocking coating consists essentially of colloidal silica in an amount of from about 0.001 lb/ream to about 1 lb/ream of the paper substrate.

3. The composite of claim 1 , wherein the barrier layer has anti-blocking characteristics.

4. The composite of claim 3 , wherein the barrier layer comprises:

polyvinylidene chloride, ethylene vinyl alcohol, or polyvinyl alcohol; and

an anti-blocking agent selected from the group consisting of colloidal silica, a wax, and any combination of colloidal silica and a wax.

5. The composite of claim 1 , further comprising an anti-blocking layer overlying the barrier layer.

6. The composite of claim 5 , wherein the anti-blocking layer overlying the barrier layer comprises a polymeric carrier material and an anti-blocking agent selected from the group consisting of colloidal silica, a wax, and any combination of colloidal silica and a wax.

7. The composite of claim 6 , wherein the polymeric carrier material comprises polyvinylidene chloride.

8. A method of forming a barrier composite comprising:

(a) providing a paper having a first side and a second side;

(b) forming a barrier layer on the first side of the paper; and

(c) applying an anti-blocking coating to the second side of the paper, the anti-blocking coating consisting essentially of colloidal silica and, optionally, a wax.

9. The method of claim 8 , further comprising incorporating an anti-blocking agent into the barrier layer, wherein the anti-blocking agent comprises colloidal silica, a wax, or any combination of colloidal silica and a wax.

10. The method of claim 8 , further comprising forming an anti-blocking layer over the barrier layer, wherein the anti-blocking layer comprises:

a polymeric material; and

colloidal silica, a wax, or any combination of colloidal silica and a wax.

11. The method of claim 8 , further comprising applying a hold-out coating to the first side of the paper prior to forming the barrier layer.

12. The method of claim 8 , further comprising applying a print coating to the second side of the paper prior to applying the anti-blocking coating.

13. The method of claim 8 , further comprising winding the barrier composite into a roll.

14. A composite comprising:

a substrate having a first side and a second side;

a polymer layer overlying the first side of the substrate, the polymer layer comprising a polymer selected from the group consisting of polyvinylidene chloride, ethylene vinyl alcohol, and polyvinyl alcohol; and

an anti-blocking layer overlying the second side of the substrate, the second anti-blocking layer consisting essentially of colloidal silica and, optionally, a wax,

wherein

the composite has a pair of opposite, outermost surfaces, and

each of the outermost surfaces has anti-blocking characteristics.

15. The composite of claim 14 , wherein the polymer layer further comprises an anti-blocking agent selected from the group consisting of colloidal silica, wax, and any combination of colloidal silica and wax.

16. The composite of claim 14 , wherein

the anti-blocking layer is a first anti-blocking layer, and

the composite further comprises a second anti-blocking layer overlying the polymer layer, such that the polymer layer is disposed between the second anti-blocking layer and the substrate.

17. The composite of claim 16 , wherein the second anti-blocking layer comprises

a polymeric material selected from the group consisting of polyvinylidene chloride. ethylene vinyl alcohol, and polyvinyl alcohol, and

an anti-blocking agent selected from the group consisting of colloidal silica, a wax, and any combination thereof.

18. The composite of claim 16 , wherein the first anti-blocking layer and the second anti-blocking layer each at least partially define respective outermost surfaces of the composite.

19. The composite of claim 14 , further comprising

a hold-out coating overlying the first side of the substrate, such that the hold-out coating is disposed between the polymer layer and the substrate; and

a print coating overlying the second side of the substrate, such that the print coating is disposed between the anti-blocking layer and the substrate.

20. A composite comprising:

a paper substrate having a first side and a second side opposite the first side;

a substantially continuous polymer layer overlying the first side of the paper substrate, the polymer layer comprising a polymer selected from the group consisting of polyvinylidene chloride, ethylene vinyl alcohol, and polyvinyl alcohol;

a first anti-blocking layer overlying the substantially continuous polymer layer such that the substantially continuous polymer layer is disposed between the first anti-blocking layer and the paper substrate, wherein

the first anti-blocking layer is an outermost layer on the first side of the composite, and

the first anti-blocking layer comprises

polyvinylidene chloride, and

colloidal silica, wax, or any combination of colloidal silica and wax;

a print coating overlying the second side of the paper, the print coating comprising inorganic particles in a binder; and

a second anti-blocking layer overlying the print coating such that the print coating is disposed between the second anti-blocking layer and the paper substrate, wherein

the second anti-blocking layer is an outermost layer on the second side of the composite, and

the second anti-blocking layer consists essentially of colloidal silica and, optionally, a wax.

Assignments (14)