Articles comprising a substrate and a foamed or a foamable composition, a kit of foamable inks and a method of making an article

Abstract

An article is described comprising a (e.g. paper) substrate having a first major surface and opposing major surface. At least a portion of the first major surface comprises a foamed composition that defines a decorative design. Typically the foamed composition a) forms a discontinuous pattern comprising an array of discrete elements of the decorative design and the discrete elements or portion thereof comprises the foamed composition and / or b) forms a continuous pattern surrounding an array of discrete elements of the decorative design and the discrete elements or portion thereof lack the foamed composition. Also describes are kits and methods.

Description

[0001] ARTICLES COMPRISING A SUBSTRATE AND FOAMED COMPOSITION BACKGROUND WO2022 / 165304 describes foamed compositions, foam padded materials, and packaging articles. SUMMARY In one embodiment, an article is described comprising a substrate having a first major surface and opposing major surface, wherein at least a portion of the first major surface comprises a foamed composition that defines a decorative design. Typically the foamed composition a) forms a discontinuous pattern comprising an array of discrete elements of the decorative design and the discrete elements or portion thereof comprises the foamed composition; b) forms a continuous pattern surrounding an array of discrete elements of the decorative design and the discrete elements or portion thereof lack the foamed composition; or a combination of a) and b). The foamed composition may comprise a colorant, such as a different color than the substrate. In some embodiments, the decorative design and / or foamed composition comprises at least two colors. In some embodiments, the discrete elements comprise one or more geometric shapes, non-geometric shapes, alphanumerical characters, or braille. In typical embodiments, the substrate comprises paper. Representative articles include for example gift wrap, greeting card, postcard, notes including stack of notes, ribbon, streamer, coaster, table runner, tablecloth, placemat, sign, wallpaper, tape, label, decal, bag, or envelope. In some embodiments, the article further comprises a release coating disposed on the foamed composition of the first major surface. In some embodiments, the article further comprises an adhesive disposed on opposing major surface of the substrate. The adhesive may be a removable adhesive having a 90 degree peel to stainless steel of no greater than 500 g / inch (2.54 cm). The article is preferably repulpable. In another embodiment, an article is described comprising a substrate having a first major surface and opposing major surface, wherein at least a portion of the first major surface comprises a foamable composition that defines a decorative design. The substrate is subsequentially heated (e.g. by a customer or consumer) such that the foamable composition is converted into a foamed composition. In another embodiment, a kit of foamable inks comprising a foaming agent (e.g. expanded microspheres) and a water soluble or water dispersible polymer are described. The kit typically comprises multiple (e.g. at least two) colors. In other embodiments, a method of making an article is described comprising providing a substrate having a first and second major surface, printing a decorative design onto a major surface of the substrate, wherein at least a portion of the decorative design is defined by a foamable composition comprising a water soluble or water dispersible polymer, and heating the foamable composition to dry the foamable composition and expand the composition. BRIEF DESCRIPTION OF THE DRAWINGS FIG.1-5 are plan views of a substate comprising a foamed decorative design; FIG. 6A-6D are plan views of portions of a decorative design including the dimension between vertical parallel lines; FIG.7 is a schematic cross-sectional view of an illustrative article comprising a release coating disposed on the first major surface comprising the foamed decorative design; FIG. 8 is a schematic cross-sectional view of an illustrative article comprising a release coating and a pressure sensitive adhesive; FIG.9 is a schematic of an illustrative gift bag article with a foamed decorative design; FIG.10-12 are perspective views of envelopes. DETAILED DESCRIPTION With reference to FIG.1, presently described are articles comprising a substrate 10 having a first (e.g., exterior viewing) major surface 12 and an opposing major surface 14. The first (e.g., exterior viewing) major surface comprises a foamed composition that at least in part defines a decorative design 15. The substrate is typically a sheet or roll-good, such as paper. Thus, the first major surface is parallel to the opposing major surface. The thickness of the (e.g. paper) substrate, foamed composition, and article is in a direction orthogonal to the first and opposing major surfaces. Although substrate 10 is illustrated as white, the substrate may be any color such as brown, (i.e. the color of unbleached repulpable paper). Although the decorative design is illustrated as black, it may also be any color, such as white. In some embodiments, the entire decorative design, depicted in black, comprises a foamed composition. In other embodiments, a portion of the decorative design comprises the foamed composition. For example, all the decorative design 15, depicted is black, is a printed (e.g., white) color and only portions 15A comprise a foamed (e.g., white) composition. Illustrative articles include sheet and roll-good articles stationary articles and party supplies including gift wrap, greeting cards, postcards, notes (including a stack of notes adhesively bonded along one edge such as Post-It® notes), book and note book covers, file folders, ribbons, streamers, coasters, table runners, tablecloths, placemats, signs and banners; wallpaper, tape, labels, decals, etc. In some embodiments, the article comprises one or more sheets that are bonded at the edges to form an enclosure such as in the case of (e.g., shopping and gift) bags and envelopes. The substrate 10 is typically a sheet or roll-good. The substrate is preferably recyclable. Although the substrate can be other materials, such as a polymeric film (e.g., polyester PET), in typical embodiments, the substrate comprises “paper” comprised of (naturally or artificially derived) cellulose, derived from the pulp of plant sources such as wood, corn, grass, rice, and the like. Paper includes products made from both traditional and non-traditional paper making processes, as well as materials of the type described above that have other types of fibers embedded in the sheet, for example, reinforcement fibers. The reinforcement fibers may be woven or nonwoven. The paper and / or fibers may further comprise coatings. Exemplary paper substrates include Kraft liner paper, fibreboard, chipboard, corrugated boards, paper medium, corrugated medium, solid bleached board (SBB), solid bleached sulphite board (SBS), solid unbleached board (SLB), white lined chipboard (WLC), kraft paper, kraft board, coated paper, internally sized paper, binder board, or mixtures thereof. Examples of non-traditional products that are “paper” within the context of this disclosure include the material available under the trade designation TRINGA from PAPTIC (Espoo, Finland), and sheet forms of the material available under the trade designation SULAPAC. In some embodiments, the paper substrate can comprises 100% virgin (unrecycled) fiber. In other embodiments, the paper comprises recycled fiber in an amount of at least 30, 40, 50, 60, 70, 80, 90, or 100%. The (e.g. paper) substrate has a suitable basis weight depending on the use. For example, gift wrap may have a lower basis weight than the (e.g. paper) substrate of a gift bag or envelope intended to contain a heavy object. Wallpaper may also have a higher basis weight to minimize tearing during removal. Typically, the basis weight (in units of grams per square meter (g / m2or gsm)) will be at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, or at least 70 gsm. The basis weight (in units of g / m2(gsm)) is typically no greater than 200, 150, 140, 130, 120, 110, 100, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, or 25 gsm. Kraft paper typically has a basis weight of 35-65 lbs (51.8 – 96.2 grams / square meter (gsm); whereas note paper typically has a basis weight of greater than 65 lbs, such as at least 70 (103.6 gsm) or 75 lbs (111 gsm). Although any form of paper can be utilized, it is preferred that the paper and article is repulpable (i.e., capable of being turned into pulp). Papers (or cellulosic fibers) are by nature pulpable but once the papers are treated, their recyclability depends on the amount of fibers separated during the repulping process. For example, in the USA, the FBA Volunteer Standard specifies a minimum fiber recovery of 80-85%. This standard was created by a joint committee of the Fibre Box Association and the American Forest & Paper Association (AF&PA). Not only is the paper substrate repulpable, but the article comprising the paper substrate and foamed composition is also repulpable. When the article further comprises a release coating and / or pressure sensitive adhesive, such coatings and / or adhesive is selected such that the article comprising such is also repulpable. The (e.g. paper) substrate may have any color, such as a brown or white color. In some embodiments, the foamed composition comprises a colorant. In some embodiments, the foamed composition is color matched to the (e.g. paper) substrate. In this embodiment, the foamed composition of the decorative design provides a three-dimensional, rather than flat appearance. The foam composition can also provide a different feel or in other words tactile quality to the surface of the article. The height of the foam, the softness or hardness of the foam, physical dimensions, and surface area of the (e.g. paper) substrate covered with the foamed composition contribute to tactile quality. In this embodiment, the foamed composition may be present on the surfaces that are ordinarily touched. For example, a (e.g. packaging) envelope may have a (e.g. plaid) decorative design comprising the foamed composition near the edges of the article of the first and / or second major surfaces forming a frame of discontinuous foam. In other embodiments, the foamed composition of the decorative design is not color matched to the (e.g. paper) substrate. Thus, when the paper is brown, the foamed composition is not also brown. In this embodiment, the colorant of the foamed composition is a different color than the substrate. In typical embodiments, the different color is a complementary contrasting color. FIGs. 1-6 depict illustrative decorative designs. In some embodiments, the (e.g. paper) substrate is depicted as white and the different color of the decorative design is depicted as black. In the absence of colored drawings, other colors cannot be depicted. However, various colors of (e.g. paper) substrates are known including yellow, red, orange, blue, violet, etc. Further, the foamed composition of the decorative design may comprise any color. In some embodiments, the foamed composition forms a discontinuous pattern comprising an array of discrete elements. For example, Figure 1 depicts an array of discrete (e.g., spot) elements printed on the substrate. With reference to FIGs. 6A-6D, an illustrative test design, the discrete elements can be in the form of a wide variety of alphanumerical characters (e.g. numbers of a list, months and days of a calendar), braille (as depicted in FIG. 5) parallel lines, grids, and various geometric shapes, such as squares, rectangles, triangles, diamonds, hexagons, spirals, circles, ovals, and the like. In some embodiments, as illustrated by FIGs. 1-4 the discrete elements often have a non-geometric shape, meaning a shape that cannot be (readily) mathematically defined such as shapes that appear in nature and decorative designs created by artists. It has been found that discrete elements of the foamed composition can be produced having high resolution. For example, the foamed composition may comprise legible alphanumerical characters having a height of 1.5 - 5 mm (e.g.1.5, 2, 2.5, 3.3.5, 4, 4.5 or 5 mm) and greater. In other embodiments, the foamed composition forms a continuous pattern surrounding an array of discrete elements of the decorative design. For example, Figure 2 depicts a continuous (e.g., black) decorative design surrounding an array of white colored pine and berry discrete elements. In this embodiments, the discrete element of the decorative design is the paper that lacks the foamed composition. However, the foamed composition surrounding the discrete elements defines the decorative design. In an alternative embodiment, FIG. 2 may depict an array of pine and berry discrete elements (represented by white) printed on a (e.g. paper) substrate (represented as black). In some embodiments, the decorative design has a repeating pattern such as in the case of gift wrap, wallpaper, decorative tapes, etc. In some embodiments, the foamed composition of the decorative design comprises a single (e.g. different) color such as white spots on a brown background, as previously described with respect to FIG. 1. In other embodiments, the foamed composition of the decorative design comprises at least two different colors. For example, in the alternative embodiment of FIG. 2 that depicts an array of pine and berry discrete elements (represented by white) printed on the substrate (represented as black); the first (e.g. pine) discrete elements may be a first color (e.g. green) and the second (e.g. berry) discrete elements may be a second color (e.g. red). Both first (e.g. pine) and second (e.g. berry) discrete elements comprise different colors of foamed composition. Alternatively, the first (e.g. pine) discrete elements may be printed (e.g. green), yet not comprise a foamed composition; whereas the second (e.g. berry) discrete elements may comprise a (e.g. red) foamed composition. In other embodiments, articles such as a gift card or gift bag may comprise a single (non-repeating) decorative design. In some embodiments, the substrate comprise a foamed composition having the same height, (+ / - 10% of the average height). In other embodiments, the foamed composition comprises first portions with a first height and second portions with a greater height to enhance a three-dimensional effect. For example with reference to FIG.4, the first row of trees 45A may comprise a foam composition having a greater height than the foamed composition of the second row of trees 45B. In some embodiments, the discrete elements (e.g. first row of trees 45A) may comprise a continuous layer of the foamed composition. In other embodiments, the discrete elements may comprise parallel lines of the foamed composition such as depicted by the second row of trees 45B and third row of trees 45C. In this embodiment, the background may comprise the paper or printed paper (e.g. blue sky) that lacks the foamed composition. Foamed Composition The foamed composition is an organic polymeric foam, i.e., a composite of a polymer matrix (i.e., polymeric component) and a gas dispersed therein, typically in bubbles or cells. During foam volumetric expansion, a gas phase is initially dispersed into a continuous polymeric phase. A polymeric foam can be prepared mechanically (e.g., by air dispersion), physically (e.g., by gas injection, bead foaming, expandable microspheres), or chemically (e.g., by using a foaming agent that generates effective gases through thermal decomposition). Such foamed compositions typically include closed cell foams although open cell foams are also possible. In certain embodiments, the foams include closed cells, optionally with open cells and / or ruptured cells. The foamable / foamed composition comprises at least one water soluble and / or water dispersible polymer. The foamed composition is preferably sufficiently water soluble and / or water dispersible such that the substrate comprising the foamed composition is repulpable as previously described. In typical embodiments, at least 50% 60%, 70%, 80%, 85%, 90%, or 95% of the foamed composition dissolves and / or readily disperses in 130°F (54°C) water. Such foamed compositions include water-soluble components such as one or more polymers, and one or more optional water-soluble additives, as described in greater detail below. The foamed composition is typically formed from a foamable water-based composition that includes a solids content of at least 20, 30, 40 or 50 wt.%, based on the total weight of the foamable composition prior to foaming. The foamable composition typically comprises a solids content of no greater than 70, 60, or 50 wt.%. The solids includes of the foamable composition include the water soluble / dispersible polymer(s), any solid foaming agents (or solid residues remaining after foaming) such as unexpanded microspheres, colorant, and (non-volatile) additives, such as defoamer. The amount of water soluble / dispersible polymer is typically at least 60, 65, 70, 75, 80, 85, 90, or 95 wt.%, based on the total wt.% solids of the foamable composition (i.e., the final (dried) foam conditioned at 72°F and 50% relative humidity for 24 hours). The wt.% solids of the foamable composition is nominally the same as the wt.% solids of the foamed composition. In some embodiments, the foamable / foamed composition comprises at least 91, 92, 93, 94, 95, or 96 wt.% of water soluble and / or water dispersible polymer. Various water soluble / dispersible polymers are known, including for example polyvinyl alcohol, polyethylene glycol, polyacrylic acid, polyacrylamide, polyvinylpyrrolidone, polyvinyl acetate polymers including homopolymers, copolymers (e.g. vinyl acetate / ethylene copolymer, vinyl alcohol / vinyl acetate / ethylene copolymer), and stabilized polymers (e.g. dextrin or polyvinyl alcohol stabilized polyvinyl acetate). Suitable water soluble / dispersible polymers for making the foamed composition are typically obtained from a supplier as a water-based dispersion or emulsion. Such water-based dispersion or emulsions may optionally comprise organic cosolvent. In one embodiment, the water soluble / dispersible polymer is a (e.g. polyvinyl alcohol) stabilized vinyl acetate ethylene (VAE) emulsion, such as commercially available polymer is that available under the tradename Dur-O-Set (Celanese, Florence, KY USA), Other illustrative commercially available water soluble / dispersible polymers include those available under the trade designation Nichigo G-Polymer (Nippon Gohsei Synthetic Chemical Industry, Osaka, Japan), a highly amorphous polyvinyl alcohol, that is believed to have divalent monomer units of hydroxyethylene, 3,4- dihydroxybutan-l,2-diyl, and optionally acetoxyethylene. Nippon Gohsei also refers to Nichigo G-Polymer by the chemical name butenediol vinyl alcohol (BVOH). Exemplary materials include Nichigo G-Polymer grades AZF8035W, OKS-1024, OKS-8041, OKS-8089, OKS-8118, OKS- 6026, OKS-1011, OKS-8049, OKS-8074P, OKS-1028, OKS-1027, OKS-1109, OKS-1081, and OKS- 1083. An exemplary G-Polymer is available under the tradename OKS-8074P from Soarus LLC, Arlington Heights, IL, USA. These hydroxy-ethylene-butylene copolymers are believed to have a saponification degree of 80 to 97.9 mole percent, and further contain an alkylene oxide adduct of a polyvalent alcohol containing 5 to 9 moles of an alkylene oxide per mole of the polyvalent alcohol. In typical embodiments, the foamable composition comprises expandable microspheres. In some embodiments, the expandable microspheres are heat expandable polymeric microspheres. That is, the expandable microspheres are capable of expanding in size in the presence of heat and / or radiation energy (including, for example, microwave, infrared, radiofrequency, and / or ultrasonic energy). Expandable microspheres typically comprise a thermoplastic barrier shell encapsulating a fluid (e.g., liquid isobutane or isobutene). The thermoplastic shell of the microsphere, having a spherical shape, maintains the encapsulated fluid. When the thermoplastic shell is heated above its glass transition temperature (i.e., the onset temperature of the microsphere), the shell softens and the encapsulated fluid changes from a liquid to a gaseous state, thus dramatically expanding the volume of the microsphere. Although other mechanism of foaming can be used, especially for articles that comprise only one (e.g. contrasting) color of a foamed composition, the use of heat expandable microspheres is particularly advantageous for sequentially printing a first and at least one second foamable composition having different colors and then concurrently expanding (in other words “puffing”) all the differently colored foamable compositions after all foamable colors have been printed onto the substrate. The expansion of the expandable microspheres occurs at a temperature range including an onset temperature range of the expandable microspheres. The expandable microspheres typically have a minimum onset temperature of at least 80°C, 90°C, 100°C, 110°C, 120°C, 130°C, 140°C or 150°C. In some embodiments, the minimum onset temperature of the expandable microspheres is no greater than 200°C, 190°C, 180°C, 170°C, 160°C, or 150°C. The maximum onset temperature of the range is typically 5-10 degrees greater than the minimum onset temperature. The expandable microspheres also have a maximum temperature range, having a minimum temperature that is 20-30 degrees greater than the maximum onset temperature. Before the composition is fully dried, these microspheres are able to move within the composition and are able to expand. Once the composition is fully dry, however, the microspheres are substantially locked in place. The expanded composition typically has a greater than 2000%, preferably greater than 2500%, total volume expansion from a wet or partially dry composition. In some embodiments, the expandable microspheres have a polymeric (e.g., polyacrylonitrile) shell and a hydrocarbon core. Suitable microspheres include, for example, heat expandable polymeric microspheres, including those having a hydrocarbon core and a polyacrylonitrile shell (such as those sold under the trade name DUALITE) and other similar microspheres (such as those sold under the trade name EXPANCEL, such as EXPANCEL 043 DU 80). The expandable microspheres typically have an unexpanded (e.g. average) particle size of at least 5 or 10 microns. In some embodiments, the expandable microspheres have an unexpanded (e.g. average) particle size of no greater than 40, 35, 30, 25, 20, 15, or 10 microns in diameter. In some embodiments, mixtures of different sizes of microspheres may be utilized. In the presence of heat, the expandable microspheres are capable of increasing in diameter by 3 times to 10 times. Upon expansion of the microspheres in the composition, the composition becomes a foamed material. Alternatively, the expandable microspheres can be pre-expanded before combining with the polymer component and fully expanded without a need to undergo further expansion. In typical embodiments, the foamed composition of the decorative design comprises a plurality of microspheres stacked on top of each other to obtain the desired foam height. The expandable microspheres are typically present in an amount of at least 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9 or 10 wt.% based on the total wt.% solids of the foamable composition. The amount of expandable microspheres is typically no greater than 20, 15, or 10 wt.%. In some embodiments, the amount of expandable microspheres is no greater than 9, 8, 7, 6, 5, 4, 3, 2, or 1 wt.%. With reference to Table 4 of the forthcoming examples, there is a linear relationship between the amount of expandable microspheres and height of the foamed composition of the substrate. In one embodiment, the linear relationship can be defined by y=1.251x-0.4861 and R2= 0.967. The slope and y- intercept may vary depending on the foamable composition (e.g., polymer thereof). Thus, the desired foam height can be controlled by the concentration of expandable microspheres. The desired concentration of expandable microspheres can be applied to the (e.g. paper) substrate with a single coating of foamable composition having the concentration that will provide the desired foam height. Alternatively, two or more coatings with a lower concentration of expandable microspheres can be applied to the same location to provide the desired total concentration of expandable microspheres and desired foam height. Further, different amounts of expandable microspheres can be applied to portions of a decorative design to form decorative designs that have a greater foam height in some portions of the decorative design as compared to other portions. While expandable microspheres are preferred, other mechanisms of foaming can be used. For example, a polymeric foam can be prepared mechanically (e.g., by air dispersion), physically (e.g., by gas injection, bead foaming, expandable microspheres), or chemically (e.g., by using a foaming agent that generates effective gases through thermal decomposition). Foaming agents other than expandable microspheres can be used including, for example, physical blowing agents or chemical blowing agents. When one or more foaming agents are present, the amount is typically at least 0.5 wt.% and typically no greater 20 or 15 wt.%, based on the total weight of the foamable composition. Physical blowing agents include a wide variety of naturally occurring atmospheric materials that are vapors at the temperature and pressure at which the foam is formed. A physical blowing agent may be introduced into the polymeric component as a gas, liquid, or supercritical fluid, preferably as a liquid. A physical blowing agent is usually in a supercritical state at the conditions existing during the foaming process. If a physical blowing agent is used, it is preferable that it is soluble in the polymeric component being used. The physical blowing agents used will depend on the properties sought in the resulting foam articles. Other factors considered in choosing a blowing agent are its toxicity, vapor pressure profile, and ease of handling. Flammable blowing agents such as pentane, butane and other organic materials, such as hydrofluorocarbons (HFC) and hydrochlorofluorocarbons (HCFC) may be used, but non-flammable, non- toxic, non-ozone depleting blowing agents are preferred because they are easier to use, e.g., fewer environmental and safety concerns. Suitable physical blowing agents include, for example, carbon dioxide, nitrogen, SF6, nitrous oxide, perfluorinated fluids, such as C2F6, argon, helium, noble gases, such as xenon, air (nitrogen and oxygen blend), and blends of these materials, hydrofluorocarbons (HFC) and hydrochlorofluorocarbons (HCFC). Suitable chemical blowing agents include, for example, sodium bicarbonate and citric acid blend, dinitrosopentamethylenetetramine, p-toluenesulfonyl hydrazide, 4-4'-oxybis (benzenesulfonyl hydrazide, azodicarbonamide (1,1’-azobisformamide), meta-modified azodicarbonides, p-toluenesulfonyl semicarbazide, 5phenyltetrazole, 5-phenyltetrazole analogues, diisopropylhydrazodicarboxylate, 5-phenyl- 4-oxadiazin-2-one, and sodium borohydride. Another exemplary chemical blowing agent includes that available from Avient, Avon Lake, OH, under the trade name HYDROCEROL 40 CB. The colored foamable / foamed composition comprise a colorant. The colorant may be a pigment, dye or combination thereof. It is appreciated that any color can be formed by combining different concentrations of yellow, red, and blue. Further, the darkness and lightness can be adjusted with white and / or black pigments. The amount of colorant is typically at least 0.1, 0.2, 0.3, 0.4 or 0.4 wt.% solids of the foamable / foamed composition. In some embodiments, the amount of colorant is no greater than 10, 9, 8, 7, 6, or 5 wt.%. The foamable / foamed composition may also include one or more additional optional additives. Examples of suitable optional additives include tackifiers (e.g., rosin esters, terpenes, phenols, and aliphatic, aromatic, or mixtures of aliphatic and aromatic synthetic hydrocarbon resins), plasticizers (other than physical blowing agents), nucleating agents (e.g., talc, silicon, or TiO2), colorants (e.g., pigments, dyes), reinforcing agents, solid fillers (e.g., pearl starch, physically modified starch, chemically modified starch, glass microspheres, clay, cork, saw dust, sand, inorganic particles (e.g., ceramic or metal), organic particles (e.g., carbon black particles, wood pulp, nanocrystal cellulose, crosslinked polymeric particles that are insoluble in water such as polystyrene-divinylbenzene)), rheology modifiers, toughening agents, thickening agents (e.g., water-soluble cellulose ethers, fumed silica, thermoplastic starch, synthetic polymers or oligomers that can be linear, branched, hyperbranched, dendritic, or star in structure), flame retardants, preservatives (e.g., biocide, 1,2-benzisothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one), antioxidants, defoamers, crosslinkers (to increase the structural integrity of the composition after the microspheres are expanded), waxes (e.g., paraffin wax, beeswax, synthetic polyethylene wax), stabilizers (e.g., UV stabilizers), humectants, accelerators, anti-static agents, slip agents, glitter, fragrance (e.g. suitable for scratch and sniff), and combinations thereof. In some embodiments, the foamable / foamed composition comprises little or no tackifer (less than 10, 5 or 1 wt.% solids) to reduce the tendency of the foamed composition adhering to the opposing surface of the (e.g. paper) substrate of a roll-good. The optional additives may be used in various combinations and in amounts sufficient to obtain the desired properties for the foam being produced. Typically, one or more such additives (e.g. defoamer) is present in an amount of at least 0.05 wt.%, based on the total wt.% solids of the foamable water-based composition. In some embodiments, one or more optional additives are present in an amount up to 5, 10, or 15 wt.%. The foamable composition has a suitable viscosity which permits high speed printing / coating / spraying / spreading / overlaying or similar process to deposit onto a substrate. Useful ranges of viscosities include 300 to 100,000 cPs at 25°C, and desirably 1000 cPs to 70,000 cPs at 25°C, as measured with a rheometer at a shear rate of 0.1 to 11 / sec (Hz) according to the Brookfield Viscosity Test in the Examples Section. For foamed compositions having a low basis weight, the viscosity is typically no greater than 10,000, 5,000 or 1,000 cps. When the foamed composition is applied with gravure or flexography, the foamable composition typically has a viscosity of at least 50 cPs and no greater than 500 or 250 cPs. Various methods of printing, coating, spraying, spreading, overlaying, or otherwise applying a foamable water-based composition to a substrate may be used to form a foamed composition of the present disclosure. In particular, screen printing, rotogravure printing, flexographic printing, and random element printing methods may be used. The printing process typically utilize a printing plate or more commonly a printing sleeve provided on a roll. In the case of gravure coating the cavities of the printing plate / sleeve correspond to the decorative design or portion thereof that will have the foamed composition. In the case of flexographic printing, the raised portions of the printing plate / sleeve correspond to the decorative design or portion thereof that will have the foamed composition. An anilox roll, a hard metal cylinder whose surface is engraved with millions of very fine dimples, known as anilox cells is coated with the foamable ink in a precise layer that is then transferred to the printing plate / sleeve. The number, size, and geometry of the anilox cells vary and will determine the amount of ink that the anilox roll delivers to the plate. For discrete elements such as thicker lines of the foamed composition, the anilox roller may comprise about 36 bcm (billons of cubic mirons) of anilox cells. For alphanumerical characters of the foamed composition, the anilox roller may comprise about 24b cm of anilox cells that provides a wet film thickness of about 8-12 microns. Printing plates and sleeves are prepared by various techniques know in the art. For example, the decorative design may be engraved onto a metal roll for gravure coating or onto a polymeric sleeve for flexographic printing. Flexographic printing sleeves are also prepared by various other techniques known in the art, such as 3D printing. The substrate surface area may be 100% covered, but typically is less than 100% covered, by the foamed composition (i.e., foam). In some embodiments, the foamed composition covers less than 10, 9, 8, 7, 5, or 5% of the surface area of the substrate. In typical embodiments, the foamed composition covers at least 10%, 20%, 30%, 40% or 50% of the surface area of the substrate. In some embodiments, the foamed composition covers no greater than 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, or 10% of the surface area of the (e.g. paper) substrate. When only a portion of the surface area comprises a foamed composition, the article may have a low absorption energy loss, e.g. less than 100, 90, 80, 70, 60, or 50 KJ according to the Compression Strength and Energy Absorption and Loss Test described in WO2022 / 165304. Further, the compression stress at 50% compression strain may be less than 8, 7, 6, or 5 Kpa. When only a portion of the surface area comprises a foamed composition, the article may have a low absorption energy loss, e.g. less than 100, 90, 80, 70, 60, or 50 KJ according to the Compression Strength and Energy Absorption and Loss Test described in WO2022 / 165304 The foamed composition is disposed on the surface of the (e.g. paper) substrate in an amount (i.e., coating weight) of at least 1, 2, 3, 4, or 5 grams per square meter (gsm). Typically, the amount of foamed composition is no greater than 15 or 10 gsm. In some embodiments, the foamed composition is disposed on the surface of the substrate (e.g., sheet material) in an amount no greater than 120, 110, 100, 90, 80, 70, 60, 50, or 40 gsm. For example, portions of a decorative design may comprise higher concentrations of foamed composition to provide a greater difference in foam height, thereby enhancing the three- dimensional visual and tactile effect. Following application of a foamable water-based composition to a substrate, the coated substrate is subjected to conditions to remove the water and optional cosolvent or in other words dry the foamable composition and foam the composition (such as by expansion of the expandable microspheres). This typically includes exposing the coated substrate to an elevated temperature for a period of time effective to dry the composition and form a foam. In typical embodiments, the temperature is at or above the melting temperature of the polymeric component of the foamable composition. When the composition comprises expandable microspheres, the drying temperature is below the previously described expansion temperature of the expandable microspheres. The foaming (i.e. puffing) temperature is within and typically above the expansion temperatures (onset and maximum) of the expandable microspheres. In some embodiments, a foamable composition is dried and foamed (i.e. puffed) in a single step at the foaming (i.e. puffing) temperature. In other embodiments, a two-step drying process is used where the foamable composition is dried at a lower temperature and foamed (i.e. puffed) at a higher temperature. The two-step process is particularly useful for applying more than one foamable composition, at least partially drying each foamable composition prior to applying a second foamable composition, and concurrently foaming (i.e. puffing) after all the foamable compositions have been applied. In some embodiments, the second foamable composition may be the same composition selectively applied to only portions of the decorative design to provide a greater foam height. In other embodiments, the second foamable composition may comprises a different (e.g. greater) amount of expandable microspheres. In yet another embodiment, the second foamable composition may comprises a different color of foamable composition. The foamed composition typically has an average height less than 0.25, 0.20, 0.15, 0.10, 0.05, or 0.01 mm. Portions of the foamed composition may have a greater height, such as at least 0.25, 0.5, 1.0, 2, 5, or even 10 mm. In some embodiments, all the foamed composition of the decorative design have about the same foam height varying by no more than + / - 10% of the average height. In other embodiment, foamed composition of article has a heigh that varies by greater than + / - 10, 20, 30, 40, or 50% of the average height. The tactile property of the foamed composition can be characterized in terms of coefficient of friction (COF). The higher the coefficient of friction, the more rubbery the foamed surface area feels to the touch. In some embodiments, the static COF of the foamed composition is typically at least 0.5, 1, 1.5, 2, 2.5, 3, 3.5, or 4. In some embodiments, the static COF of the foamed composition is no greater than 4, 3.5, 2.5, 2, 1.5 or 1. The static COF of the foamed composition can be range having a minimum and maximum value as just described. The COF of the surface of the article, i.e. the paper and the foamed composition is typically lower depending the surface area coverage of the foamed composition. For example, copy paper is reported to have a COF of about 0.3. Thus, if the surface area of the article comprises 50% of a foamed composition having a COF of 1.0, the COF of the article is an average of these values (i.e.0.65). As yet another example, if the surface area of the article comprises 10% of a foamed composition having a COF of 1.0, the COF of the article is (0.1 X 1.0)+(0.9 X 0.3) = 0.27. Various other COFs of the surface of the article can be calculated using this same methodology. The foamed compositions typically have a density of at least 0.01 gram per cubic centimeter (g / cc), and up to 0.5 g / cc, measured according to ASTM D3575-14 (“Standard Test Methods for Flexible Cellular Materials Made from Olefin Polymers” using a pycnometer (DELTARANGE Model AG204 from Mettler- Toledo, LLC, Columbus, OH) and density calculated using Archimedes” Principal). Articles In some embodiments, such as gift wrap or postcards, the article comprises a sheet or roll-good of a (e.g. paper) substrate having a foamed composition that at least in part defines a decorative design. In other embodiments, such as greeting cards the article comprises a folded sheet of (e.g. paper) substrate having a foamed composition that at least in part defines a decorative design. In some embodiments, the article having a foamed composition that at least in part defines a decorative design further comprises a release coating (also known as low adhesion backsize), a (e.g. pressure sensitive) adhesive, or a combination thereof. The presence of the release coating and / or pressure sensitive adhesive preferably does not interfere with the repulpability. This is achieved by utilizing a repulpable adhesive and / or repulpable pressure sensitive adhesive and / or by use of low coating weights, such that the presence thereof does not affect the repulpability. Repulpable release coatings and pressure sensitive adhesives are typically water-based. In some embodiments, the adhesive and / or pressure sensitive adhesive is a discontinuous (e.g., gravure) coating. In some embodiments, the (e.g. paper) substrate) comprises release coating and / or adhesive in an amount (i.e., coating weight solids) of at least 1, 2, 3, 4, or 5 grams per square meter (gsm). In some embodiments, the release coating and / or adhesive in an amount no greater than 15, 10 or 5 gsm. The release coating may be disposed on either major surface of the substrate. In some embodiments, the release coating is disposed at a location lacking the foamed composition. With reference to FIG.7, in one embodiment, the article comprises substrate 710, a foamed composition 715A that at least in part defines a decorative design, and release coating 750 disposed on the foamed decorative design 715A. In another embodiment, the release coating may be disposed on the opposing surface of the substrate. The release coating prevents the foamed composition from sticking to the opposing surface of the (e.g. paper) substrate. A variety of release coatings are known in the art. Release coatings generally include silicone release coatings, fluorinated release coatings, release coatings comprising waxy substances, typically comprising C12-C30 hydrocarbon (e.g. alkyl) groups, and release coating with combinations of such components. Release coating can be water-based, organic solvent-based, as well as (e.g., thermoplastic) 100% solids compositions. In some embodiments, the release coating does not contain fluorinated components. Water- based release coating are typically preferred. In some embodiments, the release coating composition may comprise a (A) polyorganosiloxane having alkenyl groups, (B) a crosslinking agent having organohydrogensiloxane groups, a catalyst for the hydrosilylation reaction between (A) and (B), such as described in US20100255205; incorporated by reference. The polyorganosiloxane may have the general formula: YX2SiO(X2SiO)x(XZSiO)ySiX2Y wherein each X denotes independently a phenyl group or an alkyl or cycloalkyl group having from 1 to 10 carbon atoms, for example, methyl, ethyl, propyl, butyl or cyclohexyl; each Y and Z denotes an alkenyl group; and X and Y are such that (A) has a viscosity at 25° C. is in the range from 50 to 5000 mm2 / s, most preferably 200 to 500 mm2 / s. Typically 90%- 100% of all the X substituents of (A) are methyl groups.Typically, no more than 4% of all units of (A) organopolysiloxane are units with an alkenyl group. A smallamounts (preferably less than 2% of all the substituents present) may be other substituents, such as hydroxyl groups. In some embodiments, the release coating can be combined with the foamable composition rather than being applied to the foamable / foamed composition. In some embodiments, the article comprises a pressure sensitives adhesive. The pressure sensitive adhesive may be disposed on either major surface, but is typically disposed at a location lacking the foamed composition. In some embodiments, the pressure sensitive adhesive is disposed on the opposing major surface of the (e.g. paper) substrate, such as in the case of tape or wallpaper. With reference to FIG.8, in some embodiments, the article comprises substrate 710, a foamed composition 715A that at least in part defines a decorative design, release coating 750 is disposed on the foamed decorative design, and pressure sensitive adhesive 775 disposed on the opposing surface of substrate 710. A variety of pressure sensitives adhesives are known in the art such as natural or synthetic rubber-based pressure sensitive adhesives, acrylic pressure sensitive adhesives, vinyl alkyl ether pressure sensitive adhesives, silicone pressure sensitive adhesives, polyester pressure sensitive adhesives, polyamide pressure sensitive adhesives, urethane pressure sensitive adhesives, and styrenic block copolymer based pressure sensitive adhesives. Pressure sensitive adhesives generally have a storage modulus (E’) as can be measured by Dynamic Mechanical Analysis at room temperature (25oC) of less than 3 x 106dynes / cm at a frequency of 1 Hz. Pressure sensitives adhesives can be water-based, organic solvent-based, as well as (e.g., thermoplastic) 100% solids compositions. Water-based pressure sensitive adhesives are typically preferred. Acrylic pressure sensitive adhesive comprise polymerized units of one or more low Tg (meth)acrylate monomers, i.e. a (meth)acrylate monomer when reacted to form a homopolymer has a Tg no greater than 0oC. In some embodiments, the low Tg monomer has a Tgno greater than -5oC, or no greater than -10oC. The Tg of these homopolymers is often greater than or equal to -80oC, greater than or equal to -70oC, greater than or equal to -60oC, or greater than or equal to -50oC. The low Tg monomer may have the formula H2C=CR1C(O)OR8wherein R1is H or methyl and R8is an alkyl with 1 to 22 carbons or a heteroalkyl with 2 to 20 carbons and 1 to 6 heteroatoms selected from oxygen or sulfur. The alkyl or heteroalkyl group can be linear, branched, cyclic, or a combination thereof. Exemplary low Tg monomers include for example ethyl acrylate, n-propyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, n-pentyl acrylate, isoamyl acrylate, n-hexyl acrylate, 2- methylbutyl acrylate, 2-ethylhexyl acrylate, 4-methyl-2-pentyl acrylate, n-octyl acrylate, 2-octyl acrylate, isooctyl acrylate, isononyl acrylate, decyl acrylate, isodecyl acrylate, lauryl acrylate, isotridecyl acrylate, octadecyl acrylate, and dodecyl acrylate. Low Tg heteroalkyl acrylate monomers include, but are not limited to, 2-methoxyethyl acrylate and 2-ethoxyethyl acrylate. In typical embodiments, the acrylic pressure sensitive adhesive comprises polymerized units of at least one low Tg monomer(s) having an alkyl group with at least 4, 5, 6, 7, or 8 carbon atoms. Exemplary monomers include, but are not limited to, 2-ethylhexyl (meth)acrylate, isooctyl (meth)acrylate, n-octyl (meth)acrylate, isodecyl (meth)acrylate, lauryl (meth)acrylate, as well as esters of (meth)acrylic acid with an alcohol derived from a renewable source, such as 2-octyl (meth)acrylate. The acrylic pressure sensitive adhesive typically comprises at least 50, 55, 60, 65, 70, 75, 80, 85, 90 wt.% or greater of polymerized units of monofunctional alkyl (meth)acrylate monomer having a Tg of less than 0°C, based on the total weight of the polymerized units (i.e. excluding inorganic filler or other additives). The acrylic pressure sensitive adhesive may further comprise polymerized units of polar monomers. Representative polar monomers include for example acid-functional monomers (e.g. acrylic acid), hydroxyl functional (meth)acrylate) monomers, nitrogen-containing monomers (e.g. acrylamides), and combinations thereof. In some embodiments, the acrylic pressure sensitive adhesive comprises at least 0.5, 1, 2 or 3 wt-% and typically no greater than 10 wt-% of polymerized units of polar monomers, such as acrylamide. The pressure sensitive adhesive may further include one or more additives such as crosslinking agents (e.g. multifunctional (meth)acrylate crosslinkers, epoxy crosslinking agents, isocyanate crosslinking agents, melamine crosslinking agents, aziridine crosslinking agents, etc.), tackifiers (e.g., phenol modified terpenes and rosin esters such as glycerol esters of rosin and pentaerythritol esters of rosin, as well as C5 and C9 hydrocarbon tackifiers), thickeners, plasticizers, fillers, antioxidants, ultraviolet absorbers, antistatic agents, surfactants, leveling agents, colorants, flame retardants, and silane coupling agents. In some embodiments, the adhesive composition comprises a (e.g. water-based) adhesive comprising polymer microspheres such as described in WO2021198754; incorporated herein by reference. The polymer microspheres may typically have an average particle size of at least 20 µm and no greater than 300 µm. The polymer microspheres may comprise polymerized units of (e.g. at least one, two or three structural isomers) of a secondary (meth)acrylate of Formula (1): (I) linear alkyl group, the sum of the 7to 18 H orThe acrylic adhesives including the polymer microspheres may optionally comprise polymerized units of at least one high Tg monomer. Examples of high Tg monomers having a single (meth)acryloyl group include, for example. methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, tert-butyl (meth)acrylate, cyclohexyl methacrylate, isobomyl (meth)acrylate, stearyl (meth)acrylate, phenyl acrylate, benzyl methacrylate, 3,3,5 trimethylcyclohexyl (meth)acrylate, 2-phenoxyethyl methacrylate, and mixtures thereof. Suitable high Tg monomers for use in monomer compositions of the present disclosure generally have a homopolymer Tg of at least 25, 30, 35, 4045 or 50°C. The peel adhesion of the pressure sensitive adhesive can be characterized according to the test method described in the examples. In some embodiments, the PSA has a 90 degree peel adhesion to stainless steel of at least 10, 25, 50, 100, 150, 200, or 250 g / inch (2.54 cm). In some embodiments, the PSA has a 90 degree peel adhesion to stainless steel of no greater than 1000, 900, 800, 700, 600.500, 400, 300, 200, 150, 100, 75, 50, or 25 g / inch (2.54 cm). The peel adhesion to paper and polyester can also fall within a range of values just described. The PSA is preferably stable, as indicated by a change in peel adhesion of no greater than the absolute value of 25% of the average peel value after 3 days ageing at 120°F. In some embodiments, the change is peel adhesion is no greater than 20, 15, or 10% of the average peel value after 3 days ageing at 120°F. In some embodiments, the pressure sensitive adhesive may be characterized as removable or repositionable. In some embodiments, the article comprises multiple sheets or a folded sheet of (e.g. paper) substrate wherein the edges of the (e.g. paper) substrate are bonded. Illustrative articles include bags and envelopes. The outside of these articles is the exterior viewing surface that comprises a foamed composition that at least in part defines a decorative design. FIG.9 is a perspective view of an illustrative gift 300 where edges 311, 312 are in the form of gussets that attach first and second walls 330, 340 while leaving opening 350 where the first and second walls 330, 840 are not attached. The bottom (not show) is typically a rectangular sheet bonded along the edge to the first and second walls and the gussets. The exterior viewing surface of least one wall comprises a foamed composition that at least in part defines a decorative design. FIG. 10 is a perspective view of an illustrative envelope 500 with adhesive portion 501 disposed along the perimeter near the top of opening 550 to close the opening 550. FIG.11 is a perspective view of another illustrative envelope 600 with adhesive portions 601 and 602 disposed on flap 660 to close opening 650. FIGs. 10-11 depicted the back of the envelope. The exterior viewing surface of the front of the envelope (not shown) comprises a foamed composition that at least in part defines a decorative design. One or more release liners can be disposed over any or all the one or more PSA portions. While it is advantageous that the release liners be compostable and / or recyclable, this is not required because the release liners can be disposed of separately from the packaging article after use and do not have to be placed with the packaging article in a composting and / or recycling environment. Thus, if the packaging articles as described herein have one or more release liners, the packaging articles can be compostable and / or recyclable even if the release liners are not. The edges of (e.g. paper) substrate that are bonded to form a gift bag or envelope may be bonded with any suitable means. In typical embodiments, the edges are coated with a heat sealable or hot melt adhesive. Most commonly the heat sealable adhesive is one that can be sealed at a moderate or low heat by use of an impulse sealer, or heat sealer, for example, a handheld heat sealer. Many handheld heat sealers are commercially available both for home and commercial use, for example the Mini Bag Sealer from EEX Co., Ltd., and the iTouchless Handheld Heat Bag Sealer (available from Amazon, USA). Examples of heat sealable adhesives that can be used include poly(butylene succinate), poly (butylene succinate adipate), silicone, fluorinated polymer, acrylics, acrylates, poly(ethylene succinate), poly(tetramethylene adipate-co- terephthalate), castor wax, or thermoplastic starch, particularly at least one of poly(butylene succinate), poly (butylene succinate adipate), poly(ethylene succinate), castor wax, or poly(tetramethylene adipate-co- terephthalate), more particularly poly(butylene succinate), castor wax, or both poly(butylene succinate) and castor wax. Most particularly, poly(butylene succinate) (sometimes known as PBS) is employed. In some embodiments, the articles may be characterized as packaging articles (e.g. mailers and packaging wraps. With reference to FIG.12, such packaging articles may further comprise a (e.g., thicker) foamed composition on the opposing (interior, non-viewing) surface as a padded or cushioning layer, such as described in WO2022 / 165304; incorporated herein by reference. For example, the foam height of the padded / cushioning layer may be at least 0.25 mm. at least 0.5 mm, at least 1 mm, at least 2 mm, and often up to 10 mm or even up to 50 mm. The terms “polymer” and “polymeric material” include, but are not limited to, organic homopolymers, copolymers, such as for example, block, graft, random, and copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetries. The term “copolymer” refers to polymers containing two or more different monomeric units or segments, including terpolymers, tetrapolymers, etc. The term “compostable” refers to materials, compositions, or articles that meet the standard ASTM D6400 or ASTM D6868. It should be noted that those two standards are applicable to different types of materials, so the material, composition, or article need only meet one of them, usually whichever is most applicable, to be “compostable” as defined herein. In certain embodiments, the term “compostable” preferably refers to materials, compositions, or articles that meet the standard ASTM D6400. Particularly, compostable materials, compositions, or articles will also meet the ASTM D5338 standard. Particularly, compostable materials, compositions, or articles will also meet one or more of the EN 13432, AS 4736, AS 5810, or ISO 17088 standards. More particularly, compostable materials, compositions, or articles will also meet the ISO 14855 standard. It should be noted that the term “compostable” as used herein is not interchangeable with the term “biodegradable.” Something that is “compostable” must degrade within the time specified by the above standard or standards into materials having a toxicity, particularly plant toxicity, that conform with the above standard or standards. The term “biodegradable” does not specify the time in which a material must degrade nor does it specify that the compounds into which it degrades pass any standard for toxicity or lack of harm to the environment. For example, materials that meet the ASTM D6400 standard must pass the test specified in ISO 17088, which addresses “the presence of high levels of regulated metals and other harmful components,” whereas a material that is “biodegradable” may have any level of harmful components. The term “recyclable” refers to materials, compositions, or articles that meet at least one of the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard as promulgated by the Fibre Box Association (FBA) part 1 (repulpability), Voluntary Standard for Repulping and Recycling Corrugated Fiberboard as promulgated by the Fibre Box Association (FBA) part 2 (recyclability), and ISO 18601 standards. Particular recyclable items meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard part 1 (repulpability). Particular recyclable items meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard part 2 (recyclability). More particular recyclable items meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard part 1 (repulpability) and part 2 (recyclability). Still more particularly, recyclable items meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard part 1 (repulpability) and part 2 (recyclability) standards, as well as the ISO 18601 standard. Even more particularly, recyclable items additionally meet the ISO 18604:2013 standard. All references to the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard standard, whether to part 1, part 2, or both, refer to the 2013 version of the standard. It should be noted that a recyclable material may include materials, such as adhesives, that do not meet one or more of the above standards. This is because materials, particularly adhesives, are commonly removed from paper products during the recycling process. Such materials, especially adhesives, that are not themselves recyclable but are readily removed from a product during the recycling process are referred to herein as “recycle- compatible.” A “recyclable” article thus may contain components that are recyclable as well as components that are recycle-compatible. Also herein, the recitations of numerical ranges by endpoints include all numbers subsumed within that range as well as the endpoints (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.). Table 1. Materials Material / Description Supplier Tradename Dur-O-SetTM E-200Celanese, Florence, KY A polyvinyl alcohol stabilized vinyl acetate USA ethylene (VAE) copolymer emulsion. Solids 54.5%, Brookfield viscosity at 77°F 1800- 2700 cps, Tg = 0°C, Heat Seal Temp 130- 140°F Expancel 043 DU 80 Expandable thermoplastic microsphere Nouryon Pulp and having an average particle size of 16-24 Performance Chemicals micron before expansion, an onset LLC, Marietta, GA USA expansion temperature of 94-114°C and a maximum expansion temperature of 144- 164°C. BYK-028 VOC-free silicone-containing defoamer "BYK USA Inc.524 South Cherry Street Wallingford CT 06492 Pigment Dispersions - AurasperseTMW-4123 Phthalo Blue BASF Corporation, 11501 AurasperseTMII W-1241 Azo Yw, AurasperseTMII W-7014 Bk Steele Creek Road, AurasperseTMII Rd 2030, PureOptions™ J Violet Charlotte, NC 28273, USA Pigment Dispersions - 36R872 RED CONC.36B828 BLACK Penn Color CONC, 36Y870 YELLOW CONC, 36S808 BLUE CONC.36W101 2801 Richmond Rd. WHITE CONC Hatfield, PA 19440 Acrylic microsphereas described in WO2021198754adhesive Acronal 3760 Aqueous acrylate copolymer dispersion BASF Corporation, 11501 Pressures sensitive Solids content 55%, Viscosity 80 mPas at Steele Creek Road, adhesive for 20°C 1001 / s, Tg = -55°C Charlotte, NC 28273, USA removable paper and primed film labels Low adhesion (Meth)Acrylate Grafted Silicone 3M backside Copolymers as described in US Patent No.5,032,460 TEST METHODS Repulpability: Samples were subjected to water dissolution tests to quantify the percentage of recoverable content. The samples were cut into two specimens each approximately 5.1-cm by 5.1-cm (2- in by 2-in) and the weight of each specimen was measured and recorded. Then, the specimens for each sample were placed in a lidded glass jar with 500 g of deionized (DI) water and subjected to heat and agitation in a heated shaker water bath (Aqua Pro Linear Shaker Bath, available from Grant Instruments, Beaver Falls, PA, USA) operating at 55.5°C (130°F) and at 100 strokes / minute. The samples were monitored for up to 6 hours to record the amount of time elapsed when the printed features visually detached from the paper substrate. After the heated soak, the glass jars were removed from the shaker and the paper substrates were removed with a tweezer and allowed to air dry. The contents of the glass jars were drained and filtered through a stainless-steel wire cloth having 0.5-mm (0.02-in) openings and 57% open area (McMaster-Carr, Elmhurst, IL, USA) to remove excess water, and then dried in a 70°C oven for 30 minutes (min). Then the dried remaining contents were weighed, and the % recoverable content from water dissolution was calculated as: ^^^^^^ ^^^^^^^^ℎ^^ ^^^^ ^^^^^^^^^^^^^^ ^^^^^^^^ ^^^^ ^^^^^^^^^^^^ %^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^ ൌ 1 െ^^^^^^^^ℎ^^ ^^^^ ^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^ The samples was repulpable when at least 80% of the paper fiber was recovered. Coefficient of Friction Test: The static and dynamic coefficient of friction of the discrete foamed bubbles coated on paper were determined using the procedures outlined in ASTM D1894-14 “Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting”. The test setup followed setup C (moving sled -fixed plane) as described in ASTM 1894-14 using an Instron coefficient of friction test apparatus part #2810-005 (available from Instron, Norwood MA, USA) and were tested on an Instron Universal Testing Load Frame 5564 (available from Instron, Norwood MA, USA) using a 100N load cell. Specimens were tested against steel planes with either a mirror or matte finish. The steel planes were wiped with 70 / 30 Isopropyl alcohol / water prior to testing. Samples were conditioned overnight in a controlled temperature and humidity room at 22.8 ± 1.1°C (73.1 ± 2°F) and 50 ± 2% relative humidity prior to testing. Test specimens were cut to size and adhered to the movable sled as outlined in the ASTM. The sled weight was 200g + / - 5g with the attached specimen. A crosshead speed of 6” / min was used to test the specimen. Samples were tested in triplicate. The static coefficients of friction were recorded, and the average value is reported. Thickness Measurement: Thickness of the substrates and coating was measure using a digital micrometer, TMI Model 49-60-01 or 49-70-01 micrometers. taking multiple readings on the same sample in different areas and average the results. For coating thickness, the substrate (e.g. backing) thickness was subtracted from the total thickness. Adhesion Peel Test: To test peel adhesion, 1 inch wide samples were adhered to stainless steel, the paper substrate, or PET film and peeled at a 90-degree angle using an Instron with a crosshead speed of 12 in / min according to ASTM D3330 (at 72°F and 50% relative humidity). The average peel force was determined. Foam Basis Weight Test: The weight of the foam was measured using TAPPI T 410 OM-19, “Grammage of Paper and Paperboard (Weight per Unit Area).” A 10-centimeter (10-cm) by 10-cm (4-inches (4-in) by 4-in) square was cut from each foamed sample and was weighed and the total basis weight in gsm (grams per square meter) was calculated. To determine the coating weight of the foam only, the basis weight of the substrate was subtracted from the total basis weight. Method of Making Foamable Ink DurOSet E200, Defoamer and Expancel 043 DU80 were mixed with overhead stirrer at ~2000 rpm for 30 min to generate the base solution. DI water was post-added to adjust the viscosity for printing and pumping within a viscosity range of about 1000 cp to 5000 cp. Additives, which include the deformer and pigments, were added at the percentage described in the forthcoming tables. The following colored compositions A-H, uncolored compositions I-O, and Comparative Example 1 were prepared: Table 2A - Foamable Ink Compositions A-H – wt.% solids Materials A B C D E F G HDUR-O- SET E-200 95.9 % 92.7 % 91.1 % 94.5 % 92.7 % 94.5 % 94.5 % 91.8 % Expancel 043 DU80 3.5 % 3.4 % 6.9 % 3.4 % 3.4 % 3.4 % 3.4 % 3.3 % BYK-028 0.1 % 0.1 % 0.1 % 0.1 % 0.1 % 0.1 % 0.1 % 0.1% 3M proprietary 4.8 % LAB Pergopak M3 2.0 % Aurasperse W-4123 Pathalo 3.8 % Blue Aurasperse II W-1241 1.2 % Azo Yellow Aurasperse II 2030 Red 0.8 % Pure Options J 0.5 % Violet 36R872 RED 3.7 % 0.2 % CONC 36Y870 YELLOW 1.3 % CONC 36S808 BLUE 0.2 % 0.4 % CONC 36W101 WHITE 2.0 % CONC Table 2B - Foamable Ink Compositions I-O – wt.% solids Materials Comparative Example 1 I J K L M N O DUR-O- SET E- 100 % 99 % 96.5 % 95 % 93 % 90 % 85 % 80 % 200 Expancel 043 0 % 1 % 3.5 % 5 % 7 % 10 % 15 % 20 % DU80 Method of Applying Foamable Ink Samples were prepared by applying foamable ink composition to an anilox roll that transfers the foamable ink to a flexographic plate (as depicted in FIG.6A-D) to create prints on a paper substrate. The printed paper substrate is conveyed through an oven at 280-300°F (138-149°C) to dry the foamable composition and expand the microspheres. The foamable ink compositions were applied to several paper substrates including virgin Kraft paper having a basis weight ranging from 67 to 81 gsm and paper having a basis weight of 72-75 gsm and a caliper of 3.85-4.25 mils having various colors (e.g. white, yellow, green and aqua). Some colors of the 72-75 gsm basis weight paper comprised 30% or 100% recycled fiber content. Other colors of the 72-75 gsm basis weight paper comprised 100% virgin fibers. The foam height and foam basis weight were measured as reported in Table 3. Table 3. Foam Height and Foam Basis Weight Ex. Ink Pattern of Foam basis composition FIG.6 Foam height (mm) weight (gsm) 1AOval (6C) 0.1310.652 C Line / dot 0.53 (6B) 0.01 3CWavy (6C) 0.174.784 E Diamond 2.34 (6C) 0.13 Foamable Compositions was coated onto paper using Mayer rods. Samples of coated paper were dried in an oven at 280°F. In the 1-step process, the foamable ink was dried and the microspheres expanded (puffed) in a single step. Samples of coated paper were also subjected to a 2-step process where the coated paper was dried at 180°F, cooled to room temperature, and then expanded (puffed) at 280°F. Table 4. Comparison of 1-step and 2-step drying processes of Foamable Composition A Average Wet Drying Drying Puffing Puffing Process thickness tem time time height p temp paper + (mm) (min) (min) foam (mm) Bare paper 0.10 Ex.5 0.03 N / A N / A 280 2 0.171 step dry only 0.03 180 2 N / A N / A 0.11 (not puffed) Ex.6 2 steps (dry 0.03 180 2 280 2 0.15 – puff) Ex.7 2 steps (dry 0.03 180 2 280 4 0.15 – puff) Ex.8 0.04 N / A N / A 280 2 0.22 1 step dry only 0.04 180 2 N / A N / A 0.12 (not puffed) Ex.9 2 steps (dry 0.04 180 2 280 2 0.20 – puff) Ex.10 2 steps (dry 0.04 180 2 280 4 0.22 – puff) Ex.11 1 step 0.10 N / A N / A 280 2 0.39 dry only (not puffed) 0.10 180 2 N / A N / A 0.15 Ex.12 2 steps (dry 0.10 180 2 280 2 0.39 – puff) Ex.13 2 steps (dry 0.10 180 2 280 4 0.40 – puff) Compositions I-O with different amounts of expandable microspheres were coated with a Mayer rod bar at a wet thickness of 1.6 mil (0.04 mm). The foam height and coefficient of friction results are reported in Tables 5 and 6. Table 5. Foam Height Expandable Foam Basis Microsphere Average foam Formulation he Weight (gsm)ight – mils Amount (mm) wt.% Comparative 18.770 0.767 (0.0195) Example 1 Ex.14 - 17.371 1.993 (0.0506) Composition I Ex.15 22.063.5 3.341 (0.0849) Composition J Ex.16 22.455 6.077 (0.1544) Composition K Ex.17 22.207 6.973 (0.1771) Composition L Ex.18 10.141 22.6410 Composition M (0.2576) Ex.19 16.634 25.7715 Composition N (0.4225) Ex.20 27.121 30.2520 Composition O (0.6880)

[0002] Table 6. Static Coefficient of Friction of the Foam (100% coverage of the paper substrate) E200 / DU80 composition Expandable Microsphere Amount wt.% COF Comparative Example 1 0 1.12 Ex.14 1 1.95 Ex.15 3.5 3.03 Ex.16 5 3.41 Ex.17 7 3.44 Ex.18 10 3.45 Ex.19 15 2.95 Ex.20 20 3.22 Table 7. Adhesion of Pressure Sensitive Adhesive The adhesive samples were coated using a B&M slot die coater on the Post-it paper at 25 fpm. The adhesive was delivered using a syringe pump to the slot die. The pump flow rate was adjusted to reach the target thickness. Samples are dried in the oven at 180 F. Adhesive Wet Dry gsm thickness 1 9.7 Acrylic microsphere adhesive221.7439.219.4Acronal 3760221.3439.2Test Adhesive Wet Thickness (mils) Average (ozf / in) c 1 9.08 Acryli (256 g / 2.54 cm) microsphere 2 9.26 adhesive Adhesion to steel Initial 4 9.74 1 1.26 Acronal 3760 2 6.26 4 12.21 1 9.51 Acrylic microsphere 2 12.14 adhesive 4 15.74 Adhesion to steel 120F 3 Day (4456 / 2.54 cm 1 0.94 Acronal (26.6 g / 2.54 cm) 3760 2 5.53 4 13.74 Acrylic 1 8.27 microsphere 2 11.16 Adhesion to paper initial adhesive 4 11.88 1 0.38 (10.7 g / 2.54 cm) Acronal 3760 2 3.90 4 8.00 Acrylic 1 8.54 microsphere 2 11.84 adhesive Adhesion to paper 120F 3 day4 13.18 1 N / A Acronal 3760 2 4.03 4 8.87 Acrylic 1 6.70 microsphere 2 9.16 adhesive 4 11.21 Adhesion to polyester 1 1.23 Acronal 3760 2 6.21 4 9.43 Table 8. Repulpability Adhesive wet thickness Repulpability Bare paper 0 mil Repulpable 1 mil Repulpable Acrylic microsphere 2 mil Repulpable adhesive 4 mil Repulpable 1 mil Repulpable Acronal 3760 2 mil Repulpable 4 mil Repulpable Formulation Expancel content% Repulpability Comparative Example 1 0 Repulpable Ex. 14 1RepulpableEx. 15 3.5RepulpableEx.16 5 Repulpable Ex.17 7 Repulpable Ex. 18 10RepulpableEx.19 15 Repulpable Ex. 20 20Repulpable

Claims

What is claimed is:

1. An article comprising a substrate having a first major surface and opposing major surface, wherein at least a portion of the first major surface comprises a foamed composition that defines a decorative design.

2. The article of claim 1 wherein the foamed composition a) forms a discontinuous pattern comprising an array of discrete elements of the decorative design and the discrete elements or portion thereof comprises the foamed composition; b) forms a continuous pattern surrounding an array of discrete elements of the decorative design and the discrete elements or portion thereof lack the foamed composition; or a combination of a) and b).

3. The article of claims 1-2 wherein the foamed composition comprises a colorant.

4. The article of claim 3 wherein the colorant is a different color than the substrate.

5. The article of claims 1-4 wherein the decorative design and / or foamed composition comprises at least two colors.

6. The article of claims 2-5 wherein the discrete elements comprise one or more geometric shapes, non- geometric shapes, alphanumerical characters, or braille.

7. The article of claim 6 wherein an alphanumerical character have a height of 1.5 – 5 mm is legible.

8. The article claims 1-7 wherein the foamed composition covers 10-90% of the surface area of the substrate.

9. The article of claims 1-8 wherein the substrate comprises paper.

10. The article of claims 1-9 wherein the article comprises a sheet or roll-good and the first major surface is a viewing surface of the article.

11. The article of claims 1-10 wherein the article is selected from the group consisting of gift wrap, greeting card, postcard, note including stack of notes, ribbon, streamer, coaster, table runner, tablecloth, placemat, sign, wallpaper, tape, label, decal, bag, or envelope.

12. The article of claims 1-11 wherein the foamed composition is present in an amount no greater than 15 grams / square / meter.

13. The article of claims 1-12 wherein the article has a height in a direction orthogonal to the major surfaces of the substrate and the foamed composition has an average height of less than 0.20 mm, 0.15 mm, or 0.10 mm.

14. The article of claims 1-13 wherein the foamed composition of the article has a height that is substantially the same, varying by no more than + / - 10% of the average height.

15. The article of claims 1-14 wherein foamed composition of article has a height that varies by greater than + / - 10, 20, 30, 40, or 50% of the average height.

16. The article of claims 1-15 wherein the foamed composition has a static coefficient of friction of 0.5 to 4.

17. The article of claims 1-16 wherein the foamed composition comprises expanded microspheres and a water soluble or water dispersible polymer.

18. The article of claims 1-17 wherein the article further comprises a release coating disposed on the foamed composition of the first major surface.

19. The article of claims 1-18 wherein the article further comprises an adhesive disposed on opposing major surface of the substrate.

20. The article of claim 19 wherein the adhesive is a removable adhesive having a 90 degree peel to stainless steel of no greater than 500 g / inch (2.54 cm).

21. The article of claims 1-20 wherein the article is repulpable.

22. An article comprising a substrate having a first major surface and opposing major surface, wherein at least a portion of the first major surface comprises a foamable composition that defines a decorative design.

23. The article of claim 22 further characterized by claims 1-21.

24. A kit of foamable inks comprising expanded microspheres and a water soluble or water dispersible polymer wherein the kit comprises at least two colors.

25. The kit of claim 24 wherein the foamable inks are suitable for making a foamed composition that defines a decorative design according to claims 1-21.

26. A method of making an article comprising: providing a substrate having a first and second major surface, printing a decorative design onto a major surface of the substrate, wherein at least a portion of the decorative design is defined by a foamable composition comprising expandable microspheres and a water soluble or water dispersible polymer, heating the foamable composition to dry the foamed composition and expand the foamed composition.

27. The method of claim 26 wherein the step of printing the decorative design comprises sequentially printing the first and at least one second foamable composition.

28. The method of claims 26-27 wherein the first and at least one second foamable composition comprise the same or different colors.

29. The method of claims 26-28 wherein the first and at least one second foamable composition comprise the same or different amounts of expandable microspheres.

30. The method of claims 26-29 wherein the at least one second foamable composition is printed at the same location of the major surface as the first foamable composition.

31. The method of claims 26-30 wherein the at least one second foamable composition is printed at a different location as the first foamable composition.

32. The method of claims 26-31 wherein the first foamable composition is at least partially dried prior to printing the at least one second foamable composition.

33. The method of claims 26-32 wherein the first and at least one second foamed compositions are concurrently foamed after all the foamable compositions have been applied.

34. The method of claims 26-33 wherein the printing comprises flexographic or gravure printing.

35. The method of claim 34 wherein a different printing plate or printing sleeve is used for each color.

36. The method of claims 26-35 wherein the method is further characterized by claims 2-21.

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