Process for the production of pressure sensitive carbonless record sheets using novel hot melt systems and products thereof

A process for producing a pressure-sensitive carbonless record sheet comprising the steps of:

• a. preparing a hot melt coating composition, said hot melt coating composition being non-aqueous and solvent-free, said hot melt coating composition additionally being water insoluble and having a melting point of from about 60.degree. C to about 140.degree. C, said hot melt coating composition including from about 15% to about 100% of a chromogenic material and from about 0% to about 85% of a modifying material, said chromogenic material being a color developer of the acidic electron accepting type selected from the group consisting of the novolaks of p-phenylphenol, p-octylphenol and p-tert-butylphenol, the zinc-modified novolaks of p-phenylphenol, p-octylphenol and p-tert-butylphenol and mixtures thereof, said modifying material being added to improve the coatability of said coating composition;
• b. heating said hot melt coating composition to a temperature above the melting point of said hot melt coating composition
• c. applying said coating composition to a paper substrate, said coating composition being applied at a coat weight of from about 0.2 pounds to about 8.0 pounds per 3300 square feet of paper substrate;
• and
• d. setting said coating composition by cooling said coated paper substrate, said set coating composition being free from any liquid.

A process for the production of a manifold carbonless form having one or more surfaces coated with chromogenic material comprising:

• a. providing a continuous paper substrate;
• b. marking at least one surface of said paper substrate with a pattern;
• c. preparing a hot melt coating composition, said hot melt coating composition being non-aqueous and solvent-free, said hot melt coating composition additionally being water insoluble and having a melting point of from about 60.degree. C to about 140.degree. C, said hot melt coating composition including a chromogenic material, said chromogenic material being a meltable color developer of the acidic electron accepting type;
• d. heating said hot melt coating composition to a temperature above the melting point of said hot melt coating composition to form a liquid chromogenic coating composition;
• e. coating said liquid chromogenic coating composition onto said paper substrate, said coating composition being applied at a coat weight of from about 0.2 pounds to about 8.0 pounds per 3300 square fee of said paper substrate;
• f. setting said coating composition by cooling said coated paper substrate, said set coating composition being free from any liquid;
• g. combining said marked, coated paper substrate with at least one additional paper substrate to form a plurality of paper substrates, each of said additional paper substrates being characterized by having at least a portion of at least one surface coated with at least one non-aqueous, solvent-free coating of said chromogenic material, said coating being set;
• h. collating said plurality of marked, coated paper substrates and;
• i. placing said collated paper substrates in contiquous relationship to one another to create a manifold carbonless form.

A process for the continuous production of a manifold carbonless form having one or more surfaces coated with capsular chromogenic material comprising:

• a. providing a plurality of continuous paper substrates;
• b. advancing each substrate to said plurality of continuous substrates at substantially the same speed, said plurality of continuous substrates being spaced apart and being advanced in a cooperating relationship with one another;
• c. marking at least one substrate of said plurality of continuous substrates with a pattern;
• d. preparing a hot melt coating composition, said hot melt coating composition being non-aqueous and solvent-free, said hot melt coating composition additionally being water insoluble and having a melting point of from about 60.degree. C to about 140.degree. C, said hot melt coating composition including a chromogenic material, said chromogenic material being a meltable color developer of the acidic electron accepting type;
• e. heating said hot melt coating composition to a temperature above the melting point of said hot melt coating composition to form a liquid chromogenic coating composition;
• f. applying said coating composition to one or more of said paper substrates at a coat weight of from about 0.2 pounds to about 8.0 pounds per 3300 square feet of said paper substrate;
• g. setting said coating composition by cooling said coated paper substrate, said set coating composition being free from any liquid;
• h. collating said plurality of continuous webs;
• and
• i. placing said collated continuous webs in contiguous relationship to one another to create a manifold form.