Paper composite for billboards and banners

Abstract

A paper composite for use on billboards, including at least one water-resistant paper outer layer impregnated with a polymeric resin, and having one or more pigmented or clear coatings suitable for high quality printing on the surface of the paper, the composite optionally also including a reinforcing lightweight polymeric fabric.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a coated paper with a reinforcing fabric in one embodiment of the invention.

FIG. 2 illustrates a cross section of the embodiment of FIG. 1.

FIG. 3 illustrates a second embodiment of a coated paper with a reinforcing fabric according to the invention.

FIG. 4 illustrates a cross section of the embodiment of FIG. 3.

Claims

1. A paper composite comprising: a first paper sheet having a first side and a second side, said paper sheet impregnated with a first synthetic polymeric resin in an amount sufficient to render the sheet water-resistant; anda coating layer on said first side of said paper sheet, said coating layer comprising a second polymeric resin;

2. The paper composite of claim 1, wherein the first synthetic polymeric resin is present at a level of at least 0.07 lb of resin per pound of paper.

3. The paper composite of claim 1, wherein the first synthetic polymeric resin does not comprise olefinic or aromatic unsaturation.

4. The paper composite of claim 1, wherein the first synthetic polymeric resin is an elastomer.

5. The paper composite of claim 1, wherein the first synthetic polymeric resin is selected from the group consisting of acrylic resins, epoxy resins, polyurethane resins, and copolymers of any of these.

6. The paper composite of claim 1, wherein the second polymeric resin is an acrylic resin or an aliphatic polyurethane resin.

7. The paper composite of claim 1, wherein the second polymeric resin has a glass transition temperature in a range from about 6° C. to about 70° C.

8. The paper composite of claim 1, wherein the paper composite further comprises a layer of a polymeric fabric having a first side and a second side and having a basis weight of from 0.2 to 2.0 ounces/yd2, wherein the first side of the polymeric fabric is adhered to the second side of the paper sheet.

9. The paper composite of claim 8, wherein the polymeric fabric is a nonwoven fabric.

10. The paper composite of claim 8, wherein the polymeric fabric comprises oriented polyethylene.

11. The paper composite of claim 8, wherein the polymeric fabric comprises a cross-laminated polyethylene open mesh nonwoven fabric.

12. The paper composite of claim 8, wherein the first polymeric resin is an elastomer that does not comprise olefinic or aromatic unsaturation, and the second polymeric resin is an acrylic resin or an aliphatic polyurethane resin having a glass transition temperature in a range from about 6° C. to about 70° C.

13. The paper composite of claim 1, further comprising a second layer of paper adhered to said second side of said polymeric fabric.

14. The paper composite of claim 1, further comprising a visible pictorial or textual image thereon, said paper composite having a rectangular shape and dimensions of at least 30 inches on each side.

15. A method of applying a visible textual or pictorial image to a billboard, comprising the steps of: 1) providing a billboard comprising a flat side; and2) attaching a substantially coextensive paper composite onto the flat side, the paper composite comprising: a first paper sheet having a first side and a second side, said paper sheet impregnated with a first synthetic polymeric resin in an amount sufficient to render the sheet water-resistant; anda coating layer on said first side of said paper sheet, said coating layer comprising a second polymeric resin;

16. The method of claim 15, wherein the image is an inkjet image or laser-printed image.

17. The method of claim 15, wherein the step of attaching comprises attaching with an adhesive.

18. The method of claim 15, wherein the step of attaching comprises attaching with mechanical fasteners.

19. The method of claim 15, wherein the paper composite further comprises a polymeric fabric having a basis weight of from 0.2 to 2.0 ounces/yd2.

20. A method of forming a paper composite, comprising the steps of: adhering together a polymeric fabric having a basis weight of from 0.2 to 2.0 ounces/yd2 and a paper sheet having a basis weight in a range from 10 to 60 lbs/1300 ft2; andeither before or after the adhering step, impregnating the paper sheet with a first synthetic polymeric resin in an amount sufficient to render the sheet water-resistant and thereafter applying a coating layer onto the paper sheet, said coating layer comprising a second polymeric resin;

21. The method claim 20, wherein the adhering step comprises applying a liquid adhesive.

22. The method of claim 20, wherein the adhering step comprises thermally laminating.