AU613336B2 - Cb carbonless copy paper - Google Patents

Abstract

Record material comprising a paper sheet having on its front a printable pigment coating and on its back isolated droplets of colour former solution each confined within a pressure rupturable barrier, wherein the pigment coating comprises a binder for the pigment together with a synthetic reactive sizing agent or a coating structure agent or both the sizing agent and the coating structure agent.

Description

PCT

AU-AI-10507/88 WORLD INTELLECTUAL PROPERTY ORGANIZATION International Bureau

S

INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (51) International Patent Classification 4 :(11 Internation ub ion ember: WO 88/ 04614 B41M 5/22, 5/12, 1/36 B41L 1/002 (43 Intern io I u ic ion e: 30 June 1988 (30.06.88) (21) International Application Number: PCT/GB87/00910 (74) Agent: PHILLIPS LEIGH; 7 Staple Inn, Holborn, London WC1V 7QF (GB).

(22) International Filing Date: 17 December 1987 (17.12.87) (81) Designated States: AT, AU, CH, DE, FI, GB, JP, NL, (31) Priority Application Numbers: 8630231 SE, US.

8723732 (32) Priority Dates: 18 December 1986 (18.12.86) Published 9 October 1987 (09.10.87) With international search report.

Before the expiration of the time limit for amending the (33) Priority Country: GB claims and to be republished in the event of the receipt of amendments.

(71) Applicant (for all designated States except US): THE WIGGINS TEAPE GROUP LIMITED [GB/GB]; Gateway House, Basing View, Basingstoke, Hamp- 8 AUG 1 shire RG21 2EE 1 8 AUG 1988 (72) Inventors; and

AUSTRALIAN

Inventors/Applicants (for US only) COOPER, John,AU Brian [GB/GB]; 3 Kings Row, Stokenchurch, Buck- 15 JUL 1988 inghamshire CLAY, Kevin, James [GB/GB]; 36 1 JL Dawlish Avenue, Perivale, Greenford, Middlesex UB6 8AF PATENT OFFICE (54) Title: PRESSURE SENSITIVE RECORD MATERIAL (57) Abstract Record material comprising a paper sheet having onr its front a printable pigment coating and on its back isolated droplets of colour former solution each confined within a pressure rupturable barrier, wherein the pigment coating comprises a binder for the pigment together with a synthetic reactive sizing agent or a coating structure agent or both the sizing agent and the coating structure agent.

1 z~,ui~I i~vn~; WO 88/04614 PCT/GB87/00910 PRESSURE SENSITIVE RECORD MATERIAL The invention relates to paper for carbonless copy paper sets and to copy paper sets made up using it.

BACKGROUND

Carbonless copy paper sets consist of a top sheet known as the CB (coated back) sheet, a back sheet known as the CF (coated front) sheet, and optionally one or more intermediate sheets known as CFB (coated front and back) sheets. The coatings of the back of the CB sheet, of the front and back of the CFB sheets if any, and of the front of the CF sheet contain materials that when brought into association with each other develop a coloured image.

When the front of the CB sheet is typed on or otherwise pressure imaged material is transferred between the back of one sheet and the front of the next through the set to give rise to the copies required. Usually, a solution of a dye precursor or "colour former" carried on the sheet as isolated droplets each confined within a pressure rupturable barrier is transferred from the back of one sheet to the front of the next after rupture of the barrier by the applied pressure, and interacts with a "colour develooer" present there to give the image.

All of this is very well known and requires no detailed descriotion.

PIGMENT IN CB-SHEET FRONT COATINGS The present invention has arisen from a requirement, in it PCT/GB 87/ 009 1 06 Oq 4 September 1988 the highest grade products, for a pigment-containing coating on the front face of CB sheets, improving them in appearance and in printability.

THE INVENTION The invention provides record material comprising a paper sheet having on its front a printable pigment coating and on its back isolated droplets of colour former solution each confined within a pressure rupturable barrier, wherein the pigment coating comprises a binder for the pigment together with a synthetic reactive sizing agent or a coating structure agent or both. The sizing agent is for example an alkyl ketene dimer, alkenyl succinic anhydride, or other neutral reactive size. Another example is a polyurethane size. The coating structure agent is for example a carboxy methyl cellulose, a soya or other protein, an alginate, or other hydrophilic polymer. The relative amounts of components in the coating are desirably by weight 95 parts pigment, 10 30 parts binder, 0.5 10 parts size where present and 0.5 5 parts coating structure agent where present. Binder may however be lower, for example down to 5 parts. In options within these ranges, pigment, binder and size are respectively 60 95 parts, 16 22 parts and 0.5 10 parts or pigment, binder and coating structure agent are respectively 75 85 parts, 12 22 parts and 0.5 to 5 parts, with in the latter case optionally 1 5 parts size being present also. Where the coating 0 structure agent is present without size, specific ranges are SUBSTITUTE SHEET u ~d Kirgdcm Patnt Office SUBTT ITUTE SHE I A- PC"TI/uti 87/009 1 S- -9 September 1988 2a 82 parts pigment, and 15 22 parts binder.

The coating mixes themselves, besides their use, are new and an aspect of the invention as, specifically, are:- A. Multiple form sets each comprising a CB sheet, a CF sheet and optionally one or more CFB sheets, and carrying an edge padding adhesive to join the sheets within the sets and the sets to each other, wherein the CB sheet is of the record material a s a b o v e the sizing agent being present to enable the sets to be fanned apart without separation of the sheets within the sets.

B. A method of making a record material comprising a paper sheet having on its front a printable pigment ;coating and on its back isolated droplets of colour former solution each confined within a pressure rupturable barrier, wherein the- paper sheet is coated with a mix containing a binder for the pigment together with a synthetic reactive sizing agent or a coating structure agent, or both the sizing agent and the coating structure agent, in an aqueous medium at 25 advantageously 50 65% solids by weight of the mix; is dried to give a coated sheet of Bendtsen porosity 25 to 30 ml/min or more; and is coated on the back at 400 to 450 m/min or more with a colour former ;4 -6 0 coating formulation to give said record material.

United Kingdom Patent Office SUBSTITUTE SHEET PCT Intornationrl Application PCT/G3 87/0091 06 cq 91 September 1988 2b C. A method of making multiple form sets each comprising a CB sheet, a CF sheet and optionally one or more CFB sheets and carrying an edge padding adhesive to join the sheets within the sets and the sets to each other, said sets being as a block or fanned apart, wherein a record material as above or produced by the method above is assembled as the CB sheet in association with said CF sheet, and if present said CFB sheet(s) between the CB and CF sheets, repeatedly in a stack, and the edge padding adhesive is applied down one side of the stack and dried, the sizing agent being present in said record material to enable the sets to be fanned, apart without separation of the sheets within the sets.

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W'O 88/04614 PCT/GB87/00910 3 fqs hembFor AF;r2 -^i '-hebinder is present to hold the pigment in a nondusting, printable coating, and to enable enough binder to be used for that purpose it must be a material that when tested at 40 weight in water gives a fluid preparation mixable with pigment to give a coatable dispersion.

Normally it will be a latex binder but for example hydroxyalkyl ether derivatives of starches are suitable.

Auxiliary binder materials may also be included.

The size, as discussed further below, is used to hold off latex-based or other edge-padding adhesives to allow form sets to be fanned.

fs k ere-'Kn^e-qcc(- A&e.(=neA fVe lThe coating structure agent, as also discussed further below, is a hydrophilic polymer that provides a Bendtsen porosity of the finished i.e. CB coated sheet of not less than 25 ml/min, preferably more. Such porosities reflect porosities before CB coating of around 30 ml/min or more allowing economic application of the CB coating. Suitable materials are believed to act by gelling the pigment coating in the course of drying, preventing it from compacting into an impermeable layer, and all are materials that when tested in water at 25 weight or more give a gel-like preparation not mixable with pigment to give a coatable dispersion.

It will be understood that as the intention is to improve appearance as well as printability, the pigment coating should not have any significant colour developing properties. Such properties would give rise to edge .,staining after slitting or sheeting, and possibly other WO 88/04614 PCT/GB87/00910 4 marking arising from capsule rupture and release of colour former solution.

EDGE PADDING A well known use of copy paper sets is in the production of multiple sets or "form sets". In these, repeats of the sequence of sheets, CB, optionally one or more CFB and CF, that constitute an individual set are made up as a stack. An adhesive, known as an edge padding adhesive, is applied down one side of the stack, its characteristic being that it is attracted to the coating of the back of the CB (and any CFB) sheets, or to the coating of the front of the CF (and any CFB) sheets, or to both, to a greater extent than to what are, conventionally, uncoated faces of the sheets in the stack, which are the fronts of the CB sheets and the backs of the CF sheets. Thus there is only a weak bond between CB sheets and adjacent CF sheets above them and individual sets can be seDarated from each other by "fanning" without the sheets within the sets coming apart from each other.

However a CB front face pigment coating would be thought of as incompatible with edge padding, the coatinc attracting the edge padding adhesive in the same way as the coatings within the sets. The invention, in the asoect in which a size is present, overcomes such problems. While of course the use of sizes in paper generally is known, and so is pigment coating and the use of binders to retain the pigment on the paper, there has been no reason to size a Wb 88/04614 PCT/GB87/00910 pigment coating as such. Indeed a pigment would normally be thought of as incompatible with size, using a lot of it to no purpose, and the success of the combination is surprising.

USE OF HIGH PIGMENT COAT WEIGHTS Separate from questions of edge padding is a desirability of high pigment coat weights for the best properties of printability and appearance.

The requirement however conflicts with ready application of CB coatings. These, containing colour former in relatively fragile (usually encapsulated) form, must in practice be applied after the coating of the front of the sheet. Application involves use of driving rolls run at high speed with the paper tensioned over them and if air is not to be entrained between paper and roll-the paper must have enough permeability for the air to escape. Without it the paper is liable to "hover" on a layer of air over the roll with loss of control of the process and variation in the product. Running the coater at a lower speed to avoid the problem is unacceptable for production efficiency.

Increasing the tension to exclude the air is possible in theory but risks damage to the product, e.g. by more frequent breaks and/or curling or inferior aspect.

In conventional pigment coated printing paper, the pigment coating is typically highly consolidated to give a smooth surface. The use of these highly .consolidated coatings means that the sheet porosity of the paper is very WO 88/04614 PCT/GB87/00910 fi low. We have however surprisingly found both good binding and permeability, even though the invention uses a high content of binder such as would in itself be expected to give an entirely impermeable coating. The adverse effects of this high content of binder are overcome by the presence in the coating mix of the coating structure agent, sufficient permeability for successful subsequent application of CB coatings being obtained.

The inclusion of the coating structure agent in the coating mix promotes the generation of a relatively porous coating. We believe that this arises because as the coating mix dries, the coating structure agent helps the mix to set ot gel before all the water is removed, and that the set or gelled structure is, at least in part, preserved through drying to give a relatively bulky and thus porous coating.

That this effect generates a porous coating even at the high binder levels typically used in this invention is very surprising as such binder levels would ordinarily be Sexpected to "blind" the coating.

The reason for the success of the invention appears, though such theory is not to be taken as a limitation of the invention itself, to lie in a microporositv arisina from early setting or gelling of the coatina as referred to above, without excessive loss of binder into the paper, followed by drying out of the water content cf the coating without loss of the structure. It does not appear to arise by a multiple micro-cracking of the coating such as is seen WO 88/04614 PCT/G B87/00910 7 in the colour-developer clay coatings used in CF sheets or the CF face of CFB sheets.

PIGMENTS

The pigments are, generally, conventional paper coating pigments, in particular inorganic or mineral-derived particulate materials. Calcium carbonate especially is economic and suitable, giving good whiteness and purity and having good printing characteristics. It may be supplemented with coating clays such as china clay (kaolin), although with large amounts of clay care will be necessary in formul.ation to achieve satisfactory rheology and stability for successful coating, as will be appreciated by those skilled in the art.

Other suitable pigments besides china clay include calcined clays, titanium dioxide, finely divided silica and talc.

A mixture of calcium carbonate and china clay, particularly calcined china clay, is preferred. Calcium carbonate contributes good whiteness and brightness, and high print definition, but on its own tends to give dusting on the surface and may not give good ink receptivity. Clay or talc contribute to a good surface finish and give good ink receptivity without dusting but give a less white appearance. Ground calcite as the calcium carbonate has high purity (to give whiteness etc. as compared with ground limestone or chalk) without the very high surface of precipitated carbonates, which can be used but are not WO 88/04614 PCT/GB87/00910 8 preferred because of high binder demand arising from small particle size.

It will be understood that the pigment in the coatings is not such as to have colour developing properties. To this end the inclusion as pigments of specific colour developer materials, such as the clays that are used as the active constituents of many CF coatings, will be avoided.

Kaolin has been mentioned in the literature as a colour developer but in unmodified form is not so used or suitable, and papercoating grades are essentially non-colour developing. The use of high levels of binder reduces even further or eliminates any minor residual colour developing activity of the raw material.

The particle size of the pigment is important. The finer the particles are the more effective the pigment is in terms of brightness but, equally, the more the coating is consolidated (thus reducing porosity) and also the more difficult any required sizing is. Particularly in a sizing context, a balance is desirable and the range of 1 to microns, advantageously 2 to 5 microns, is preferred.

Such particle sizes are as measured by a laser particle sizer such as the standard Malvern 3600 E Type. For particles of broadly the same dimensions in any direction, such as those of calcium carbonate, such sizes approximate actual sizes; for flat or elongated particles such as those of coating clays the particle sizes as measured are nominal.

The laser instrument assesses particle size by measuring the I WO -8804614 PCT/G!187/00910 9 interference pattern arising from diffraction of the laser light illuminating a sample suspension e.g. in water, of the particles. The pattern is manipulated by a computer to give results as particle size by volume, e.g. the volume itself or the diameter of spheres of equal volume.

Amounts of pigment are given earlier, but a particularly convenient range when size is not being used is 76 80 wt.% of which preferably:- 88% CaCO 3 12 25% China clay, native or calcined, or talc Small quantities say up to 10% of specialist pigments, for example TiO 2 whitener, can conveniently be included.

BINDERS

Within the constraints above, the binder may be selected from among those conventional in themselves in paper coating technology. In particular it may be a synthetic rubber latex such as styrene butadiene latex (normally a carboxylated grade to give good dispersibility and stability in water) or styrene acrylic latex. It is also however possible for it to be example an ether derivative of starch, as already mentioned, and these are not conventional in the sense of being in wide use.

SIZING AGENTS The size will typically be a neu-ral reactive size such as an alkyl ketene dimer or alkenyl succinic anhydride with the alkyl or alkenyl groups from Cg upwards, generally from

C

1 2 upwards, with C 1 5

-C

18 typical and the upper limit WO 88/04614 PCT/GB87/00910 .determined, for example C 2 4 by mix workability and suitability of the final coating for printing. Such sizes, in which "neutral" connotes effectiveness as sizes at neutral coating mix pH, are effective in small quantities and readily provide acceptable rheology in the coating process, for example blade, roll or slot (extrusion) coating as known per se. Other synthetic sizes such as polyurethane sizes may however be used. Amounts within the ranges given earlier are typically 1 to 5% dry weight of the coating but more usually 1 to 2% will be used.

'Suitability-o--fsiz es-w ill 1h tTrm nf water repellency of the coating in an edge paddin context. The water repellency of the coating is define in terms of the contact angle taken up by a water dropl on the surface of the coated paper, measured within the drop, which for a size to be suitable is above 700 and ad antageously above 900 or 1000.

A convenient method of determining the contact angle depends on measurement of he observed height and contact width of a droplet of kn wn volume applied to the paper, in particular in a Lo entzen Wettre No. 28 surface wettability tester. The method is as follows:i) A drop of water (initial diameter 4 mm volume ca.

3.3' microlitres) is placed on a test strip of y U A/ I 10a As hereinafter defined, the expression "synthetic reactive sizing agent" means that the sizing agent as a whole is synthetic in the sense that it is typically made up with other materials such as dispersants etc. in addition to the size itself and is reactive in the sense that the sizing agent as a whole interacts with other components in the coating, but does not necessarily undergo any chemical reaction. It does not mean that each component or even the major component in the sizing agent is necessarily itself synthetic or chemically reactive.

.oSuitability of sizes will be in terms of water repellency of the coating in an edge padding context. The e" water repellency of the coating is defined in terms of the contact angle taken up by a water droplet on the surface of the coated paper, measured within the drop, which for a size to be suitable is above 700 and advantageously above 900 or 1000.

A convenient method of determining the contact angle depends on measurement of the observed height and contact S* width of a droplet of known volume applied to the paper, moo• in particular in the Lorentzen Wettre No. 28 surface 5* wettability tester. The method is as follows:- 1. A drop of water (initial diameter 4mm volume ca.

3.35 microlitres) is placed on a test strip of paper me WO 88/04614 PCT/GB87/00910 11 ii) The drop height and width of contact of the drop on the paper are measured on a projected image of the drop using a graticule iii) The contact angle is calculated as 2 tan 1 (2h/w) Since the paper will absorb the water slowly the contact angle is taken as that measured 2 seconds after the drop is placed on the paper.

COATING STRUCTURE AGENTS The coating structure agents that are suitable include in particular carboxy methyl cellulose such as is used in coating technology as a dewatering control. Other suitable materials are proteins, such as soya protein, and alginates such as sodium alginate, their essential characteristic being to provide the desired porous coating structure at the low amounts specified. The amounts used, within the overall range, depend on the nature of the material, enough to be effective but not so much as to increase viscosity or modify the rheology to make the mix uncoatable.

Amounts are typically, weight on coating:- Carboxy methyl cellulose high mol.wt. 0.5 medium mol.wt. 1 2 low mol.wt. 2 3 Sodium alginare 0.7 Soya protein 1.5 4

I

WO 88/04614 PCT/GB87/00910 12 OTHER COMPONENTS Other agents, known in themselves may also be present in the mix, for example sodium hydroxide or other alkalis such as potassium hydroxide or ammonia for pH adjustment, and further components of the final coating such as optical brightening agents, dispersants for the pigments, lubricants calcium stearate) or antifoams.

COAT WEIGHTS Coat weights may conveniently be 2 to 20 g/m 2 advantageously 3 to 15 g/m 2 Papers of reduced substance compared to normal, in terms of fibre weight per square metre, may be used compensating in part for the extra cost of the coatings.

POROSITY

For high speed, high quality (good curl good aspect) CB coatina the Bendtsen oorositv of the final product is not less than 25 ml/min and preferably not less than ml/min with (for this product) a typical range of 35 ml/min. "High speed" is ca.500 m/min or above and a preferred lower limit 400/450 m/min. A typical range is ca.

600 900 m/min and higher speeds e.g. up to 1500 m/min are possible.

WO 88/04614 PCT/GB87/00910 13 SOLIDS OF TOPCOAT MIX Widest convenient range 25 75% solids, more usual 70%, advantageously 50 65%. Lower solids give a wetter mix and greater drying requirement which restricts machine speed; higher solids may give mix viscosity/rheology problems.

DETAILED PREFERENCES The invention is described broadly above, but in the edge padding context most desirably provides a CB sheet with a printable front coat at 2 20g/m comprising an inorganic or mineral derived pigment and a latex-derived binder together with a sizing agent, the sizing agent being an alkyl ketene dimer or alkenyl succinic anhydride or other reactive neutral size giving a contact angle of 90 0 or more.

Preferred proportions of components by weight are pigment 95 parts, binder 5 30 advantageously 16 22 and size 10 parts.

In the context wherein edge padding is not an essential, the invention most desirably provides a CB sheet for carbonless copy paper sets carrying in addition to a CB coatinc a front coating at 3 15 g/m 2 comprising pigment 82 parts, latex-derived binder 15 22 parts, and coating structure agent 0.5 5 parts, all by weight, such that the finished sheet has a Bendtsen porosity of 25 ml/min or more.

WO 88/04614 PCT/G B87/00910 14

EXAMPLES

The invention is illustrated in the following examples, of which Examples 1 and 2 show the use of a coating structure agent in the absence of size.

Example 1 A coating material was prepared from the following components 48.2% solids in water, final pH Material Parts by wt.

Coating structure agent 0.8 Sodium hydroxide (first batch) 0.2 Calcium carbonate pigment 60.1 China clay pigment 20.0 Latex binder 16.0 Optical brightener 0.8 Sodium hydroxide (remainder) 0.1 Mix Procedure Place water in a high speed mixing vessel Add the dry coating structure agent and stir for minutes at high speed Add first batch of NaOH (40% solids) Add calcium carbonate and china clay and stir for minutes at hich speed Check DH and adjust to approximately 10.0 with some of the remaining NaOH Reduce the stirring speed tc slow, add the binder and stir for 10 minutes Add the optical brightener Bring final pH to 9.5 with NaOH.

it -i li WO 88/04614 PCT/GB87/00910 Materials i) The coating structure agent is a medium molecular weight carboxymethyl cellulose.

ii) The calcium carbonate pigment is a ground calcite, desirable as high-white material economic in cost.

Its median particle size is 2.8 microns.

iii) The china clay is a fine, white, commercially available coating clay, median particle size 3.3 microns.

It acts as a white pigment accordingly, while preserving the advantages of clay coatings generally in terms of coat adhesion and printing characteristics. It gives no unacceptable reduction in the brightness of coating given by the calcium carbonate.

iv) The binder is a conventional carboxylated styrenebutadiene synthetic latex giving the coating the necessary adhesion as a whole.

-L.

WO 88/04614 PCT/GB87/00910 16 The coating mix so prepared was applied using trailing blade metering to standard base paper of 48 g/m 2 substance for 'Idem' (Trade Mark) CB sheet to give coat weights of 3 Sg/m 2 to 7 g/m The coated paper was then calendered and its porosity checked and found to be at a suitable figure. It was CB coated at 800 rn/min using a 3 roll coater head, solids of the coating mix ca. 24%, constitution of solids:- 70% capsules conventional gelatin-based capsules, black-copy colour former formulation in solvent, formed by coacervation encapsulation 20% stilt cellulose floc, ungelatinised starch particles or mixture.

10% binder maize starch and dried to give ca 4.5 g/m coat weight (dry). A steam shower was used to remove/reduce curl otherwise present from paper wetting during coating.

The resulting CB sheets had excellent printing characteristics and improved visual appeal and feel in terms of formation and roughness.

-MV-1 I: ii ii ii:i- 'i I :I-Llsr~uu_.l-- .WO 88/04614 PCT/GB87/00910 17 Example 2 Similarly to Example 1, a coating material was prepared from the following components, made up to 3308 Kg with water Component Dry weight Approx.% of dry (Kg) weight 'Dispex' N 40 (40% in water) 3.6 0.2 dispersing agent 'Hydrocarb' 70 calcium 1275 64.5 carbonate pigment Sodium hydroxide 2.4 0.12 in water) 'Alphatex' calcined kaolin 300 15.2 (china clay) pigment Carboxymethyl cellulose 24 1.2 coating structure agent 'Revinex' 98 F10 latex 360 18.2 solids in water) 'Nopcote' C 104 (50% in 10 water) calcium stearate Revinex 98 F10 latex is a carboxylated SBR latex ex Doverstrand Limited. 'Dispex', 'Hydrocarb', 'Alphatex', 'Revinex' and 'Nopcote' are trade marks.

This coating was applied to a conventional CB base paper containing 'Leucophor' (Trade Mark) LN optical brightener which after checking porosity was given a CB coating as before. A CB paper of excellent printability was given without pronlems in the CB coating process.

WO 88/04614 PCT/GB87/00910 18 Examples 3 and 4 Examples 1 and 2 were repeated with respectively 2 parts by weignt and 24 Kg of 'Aquapel' (Trade Mark) 360 X 3 neutral C 16 alkyl ketene dimer size (the level used being such as to give a final coating contact angle of 1100 Papers of excellent printability and, further, edge paddable with 100% fanning were obtained.

Examoles 5 and 6 These are further Examples with coating structure agent and size together, mixes as below, with water to total 3630 parts, i.e. solids of mix .WO 88/04614 r

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Vy I -Irlrrr;l~~;-~ PCT/GB87/00910 Example 5 Example 6 Component Wet Dry Parts Parts Wet Dry Parts Parts calcium carbonate 'Alphatex' calcined kaolin 'Dispex' N40 dispersing agent CMC (med mol.wt.) coating structure agen 'Aquapel' 360 X 3 size 'Revinex' 98F10 latex binder Dow 620 latex binder 'Nopcote' C104 calcium stearate 1275 1275 63.8 300 300 15 9.1 3.6 0.18 24 24 1.2 1259 1259 63.0 300 300 9.1 3.6 0.18 40 40 322.5 24 1.2 322.5 24 1.2 720 360 18 360 18 20 10 0.5 20 10 Procedures for preparation of the coating mix and its application are as in Examples 1 and 2. Measured porosities (Bendtsen) are: Ex. 5 Ex. 6 Before CB coat 40.2 After 35.4 and, generally, similarly successful results to Examples 1 and 2 are obtained.

WO 88/04614 PCT/GB87/00910 Example 7 The following is again of the use of a coating structure agent and size together, and is in effect six examples in one (three mixes each coated at two levels).

The formulations were made and coated as in Example 1, the calcium carbonate being of 4 microns median particle size, at 3 and 6 g/m 2 ,on the rougher side of 'Idem' base paper as used in Example 1.

Material Dry parts Mix 1 Calcium carbonate 100 Binder 22 Total Coating structure agent 1 55% solids Size 2.5 pH Optical brightener 1 Mix 2 Calcium carbonate China clay Binder Coating structure agent Size Optical brightener Mix 3 Calcium carbonate China clay Binder Coating structure agent Size Optical brightener 25 20 1 1 50 20 3.7 1 Total 50% solids pH Total 47% solids pH WO 88/04614 PCT/GB87/00910 21 The pairs of samples, all of which showed satisfactory porosities, were subjected to physical testing, in comparison to the uncoated base itself, on a number of criteria significant to CB sheet performance.

a) Roughness Lower values of rate of passage of air) indicate improved smoothness Base 220 ml/min 3 g/m 2 samples 170 ml/min 6 g/m 2 samples 140 ml/min b) Contact Angle Base 1180 Mix 1, both samples 1170 Mix 2, both samples 1160 Mix 3, both samples 1110 These are all very good values of above 1100 and, it may be noted, do not vary with the coating weight.

c) Cobb Lower Cobb values (of water uptake) represent improvement.

Base 19.0 g/r 2 /mi'n Other samples 15.5 17.0 2 "I i WO 88/04614 PCT/GB87100910 d) Whiteness/Brightness A. Elrepho Values calculated using filters 9, 10, 11, the brightness being given by the filter 11 value.

Brightness Lightness a b Base 87.3 96.96 15.85 -8.81 Coatings 88.5 to 89.1 96.24 16.16 to 16.42 -9.29 to a redder b yellower a greener b bluer.

B. Macbeth IC System.

Results were taken with the U.V. in. Significant improvement was seen in reflectance at 440 nm.

Sample Coat 440 nm L a b weight g/m Reflectance D65 D65 -9.83 Base Run 1 Run '2 Run 3 Run 4 Run 5 Run 6 88.95 3 91.19 6 92.64 3 91.43 6 92.14 3 91.03 6 91.30 95.54 95.19 95.60 95.31 95.61 95.85 95.78 -0.05 0.24 0.39 0.19 0.32 0.20 0.29 0.32 -0.67 -0.74 -0.65 -0.52 0.27 0.11 WO 88/04614 PCT/GB87/00910 23 e) I G T Pick Using Spring A (35 Kgf) and medium oil, Mix 1 and Mix 2 show improvements on the base and Mix 3 approximately equal values to the base, all satisfactory.

In a printing trial, mix 1, 2 and 3 papers, which had been CB coated with production black copy formulation with control samples from normal production CB, were printed on a Muller-Martini webb offset printing machine using 'Irlam T11392' (Trade Mark) black ink and a speed of 670 rpm (250 m/min). The Mix 1, 2 and 3 papers all showed low dust, with good ink density/intensity, very little set off, and IGT pick very low or not visible.

In an edge padding trial, form sets were made up using a latex-based adhesive with CB, 2 x CFB, and CF sheets, the CFB and CF sheets being standard 'Idem' production and the CB sheets being either standard 'Idem' production base, for comparison, or the Mix 1, 2 and 3 papers above. All sets r fanned apart 100%. Bonding strengths within sets, on a subjective 1 to 5 scale (too weak, slightly weak, optimum, slightly strong, too strong) were acceptable throughout, the CB-CF bond in particular, though a little less stronc with the Mix 1, 2 and 3 papers than with the base, givinc no problem through the presence of the front coating.

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pCT/GB87/00910 WO 88/04614 Example 8 In a further multi-part example the formulation below was made up as before, first as shown (Example 8-C) then with the following changes, substitutions being weight for weight:- Example 8-2 Mistron Vapour 3 P (Trade Mark) talc as pigment replacing the kaolin clay Example 8-5 Solfa ex A 55 (Trade Mark) starch hydroxyalkyl ether as binder replacing latex Example 8-7 Cyclopal A (Trade Mark anionic modified polyurethane as size replacing the 'Aquapel' Example 8-10 CMC coating structure agent omitted Example 8-11 Procote 400 (Trade Mark) soy protein as coating structure agent replacing the CMC WO 88/04614 PCT/GB87/00910 Formulation Example 8-C Components are given in the order, pigment, binder, other components, not the order of addition used in mix preparation.

Material Description (w/w) Hydrocarb 70 Calcium carbonate pigment 63.9 Alphatex Calcined kaolin clay pigment 15.0 Dow 620 Styrene butadiene latex binder 18.0 Aquapel 360X Alkyl ketene dimer size 1.2 Finfix 5 Carboxy methyl cellulose coating 1.2 structure agent Nopcote C104' Calcium stearate lubricant Dispex N40 Sodium polyacrylate dispersing agent 0.18 Sodium Hydroxide -0.04 Leucophor LN Optical brightening agent Solids The formulations were coated onto base paper as in Example 1, the machine speed being 400 m/min, and measurements made of important properties. The following table shows the mix viscosity of the coating mix, together with porosity before and after application of the CB coat, contact angle, and Bendtsen roughness.

I

I' WO 88/04614 PCT/GB87/00910 Test Results Example 8 Example Coat Mix Porosity Porosity Contact Roughness Viscosity Before CB After CB Angle (Bendtsen) (cPs) (ml/min) (ml/min) (Degrees after 2 seconds) 8-C 520 31.5 25.0 77.6 119.0 8-2 505 38.3 13.0 79.0 100.0 800 25.2 26.0 108.9 125.0 8-7 525 27.3 26.5 79.1 132.0 8-10 195 55.2 60.4 89.8 150.0 8-11 102 25.0 23.0 95.8 146.0 In addition to the above tests edge padding trials were carried out as before, with bond strengths found normal or slightly low (but still within-specification) CB-CFB and CFB-CF and 100% fan apart. Printing trials, again carried out as before, gave good results, the ink on this occasion being Bonsfield Constat Black 30862 (Trade Mark). Ink density was good (slightly light in the absence of the coating structure agent), piling was absent, dusting acceptable throughout and in the mix with starch ether binder exceptionally low.

W-0 88/04614 PCT/GB87/00910 27 Example 9 In a further example a coat mix was made up as an Example 8-C but with the Aquapel 360X replaced by 3.6 parts by weight of 'Fibran 71' (Trade Mark) from National Starch Chemical Co., which is an alkenyl succinic anhydride size, the other components being in relative parts by weight as shown there, and coated as before. A satisfactory coating was given, the measured contact angle in particular being 1040, well suited to edge padding.

Claims (19)

1. CB carbonless copy paper comprising a paper sheet having on its front a printable pigment coating and on its back isolated droplets of colour former solution each confined within a pressure rupturable barrier, wherein the C- er' beb'oeq A'2?ne pigment coating comprises a binder or the pigment together with a synthetic reactive sizing agent as -S kor%' ole.E-oCe-' dcrf:^>^< hereinbefore defined or a coating structure agent or both the sizing agent and the coating structure agent.

2. CB carbonless copy paper according to claim 1 wherein the sizing agent is an alkyl ketene dimer, alkenyl succinic anhydride or other neutral reactive size.

3. CB carbonless copy paper according to claim 1 wherein the sizing agent is a polyurethane size.

4. CB carbonless copy paper according to any preceding claim, containing the sizing agent, wherein the water repellency of the pigment coating, in terms of the contact angle taken up by a water droplet on the surface of the S* coated paper, is above 90 C and advantageously above 1000C. CB carbonless copy paper according to any preceding claim wherein the coating structure agent is a carboxy methyl cellulose, a soya or other protein, an alginate, or other hydrophilic polymer.

6. CB carbonless copy paper according to any preceding claim wherein the binder is a synthetic rubber latex binder advantageously a styrene butadiene or styrene Sacrylic latex.

7. CB carbonless copy paper according to any one of claims 1 to 5 wherein the binder is a hydroxy alkyl ether starch derivative.

8. CB carbonless copy paper according to any preceding claim wherein the relative amounts of components are by weight 60-95 parts pigment, 10-30 parts binder, 0.5-10 parts size where present and 0.5-5 parts coating structure agent where present.

9. CB carbonless copy paper according to claim 8 wherein 0 the relative amounts of pigment, binder and size are respectively 60-95 parts, 16-22 parts and 0.5-10 parts. I, A -29- CB carbonless copy paper according to claim 8 wherein the relative amounts of pigment, binder and coating structure agent are respectively 75-85 parts, 12-22 parts and 0.5-5 parts.

11. CB carbonless copy paper according to claim 10, parts size being present also.

12. CB carbonless copy paper according to any preceding claim, wherein the coat weight of the front coating is 2 to 20 g/m 2 advantageously 3 to 15 g/m 2

13. CB carbonless copy paper according to any preceding claim, wherein the pigment comprises an inorganic or mineral-derived particulate material, advantageously calcium carbonate.

14. CB carbonless copy paper according to any preceding claim, wherein the particle size of the pigment is in the range of 1 to 10 microns, advantageously 2 to 5 microns.

15. CB carbonless copy paper according to any preceding claim, wherein the size is an alkyl ketene dimer or alkenyl succinic anhydride with the alkyl or alkenyl groups from C 8 upwards, advantageously from C 12 upwards, and with a maximum of C 24

16. Multiple form sets each comprising a CB sheet, a CF sheet and optionally one or more CFB sheets, and carrying an edge padding adhesive to join the sheets within the sets and the sets to each other, wherein the CB sheet is of the record material according to any preceding claim, the sizing agent being present to enable the sets to be fanned apart without separation of the sheets within the *ee sets.

17. A method of making a CB carbonless copy paper comprising a paper sheet having on its front a printable pigment coating and on its back isolated droplets of colour former solution each confined within a pressure rupturable barrier, wherein the paper sheet is coated with a mix containing a binder for the pigment together with a synthetic reactive sizing agent as hereinbefore defined or a coating structure agent, or both the sizing agent and the coating structure agent, in an aqueous medium at r 25-75% 30 advantageously 50-65% solids by weight of the mix; is dried to give the coated sheet a Bendtsen porosity of to 30ml/min or more; and is coated on the back at 400 to 450 m/min or more with a colour former coating formulation to give said CB carbonless copy paper.

18. A method according to claim 17, wherein the components of the pigment coating are such as to give the record material according to any one of claims 2 to

19. A method of making multiple form sets each comprising a CB sheet, a CF sheet and optionally one or more CFB sheets and carrying an edge padding adhesive to join the sheets within the sets and the sets to each other, said sets being as a block or fanned apart, wherein a CB carbonless copy paper as claimed in any one of claims 1 to 15 or produced by the method of claim 17 or 18 is assembled as the CB sheet in association with said CF sheet, and if present said CFB sheet(s) between the CB and CF sheets, repeatedly in a stack, and the edge padding adhesive is applied down one side of the stack and dried, the sizing agent being present in said CB carbonless copy paper to enable the sets to be fanned apart without separation of the sheets within the sets. S* 20. CB carbonless copy paper substantially as described with reference to the description, but not including the prior art includedin examples 7 and 8.

21. A method of making a CB carbonless copy paper substantially as described with reference to the description, but not including the prior art included in examples 7 and 8. DATED this 16th day of April 1991 THE WIGGINS TEAPE GROUP LIMITED Patent Attorneys for the Applicant: F.B. RICE CO. INTERNATIONAL SEARCH REPORT international Application No PCT/GB 87/00910 I. CLASSIFICATION OF SUBJECT MATTER (it several classification symools aoply, indicate all) According to International Patent Classification (IPC) or to both National Classification and IPC IPC B 41 M 5/22; B 41 M 5/12; B 41 M 1/36; B 41 L 1/00 II. FIELDS SEARCHED Minimum Documentation Searched 7 Classification System Classification Symbols C 4 B 41 M 5/00; B 41 M 1/00; B 41 L 1/00; D 21 H 1/00 Documentation Searched other than Minimum Documentation to the Extent that such Documents are Included In the Fields Searched I III. DOCUMENTS CONSIDERED TO BE RELEVANT' Category I Citation of Document, i" with Indication, where aDorooriate, of the relevant passages I Relevant to Claim No. i A EP, A, 0008161 (APPLETON PAPERS INC.) 1-19 February 1980 see page 3, lines 16-19; claims A US,. A, 4397483 (SHIGETOSHI HIRAISHI et al.) 1-19 9 August 1983 see column 5, lines 46-61; claims A GB, A, 1033578 (ETS. L. DELPLANQUE FILS) 1-19 22 June 1966 see the whole document SSpecial categories of cited documents: io later document published after the International filing date document defing the general state of the art which is not r priority date and not in conflict with the aplicaton but considered to be of particular relevance cited to understand the principle or theory underlying the invention earlier document but published on or after the nternational document of particular relevance: the claimed invention filing datcannot be considered novel or cannot be consiaered t, document which may throw doubts on priority claim(s) or Involve an inventive step which is cited to establish th publication dat of another document of particular relevance the claimed nvention citation or other special reaon (as edcannot be considered to involve an inventive step when the document referring to an oral disclosure, use, exhibition or document is combined with one or more other such docu- other means ments, such combination being obvious to a person skilled document published prior to the international filing date but In the art. later than the priority date claimed document member of the same patent famlly IV. CERTIFICATION Date of the Actual Co;i4ttlion of the International Search Date of Mailing of this International Search Report 14th March 19882 7 APR 1988 International Searching Authority 5 i e of Authori i flcer EUROPEAN PATENT OFFICE CD<I T iEN Form PCTISA/210 (second sheet) (January 1985) ANNEX TO THE INTERNATIONAL SEARCH REPORT ON INTERNATIONAL PATENT APPLICATION NO. GB 8700910 SA 19900 This annex lists the patent family members relating to the patent' cunents cited in the abo..e-mcntioned international search report. The members are as contained in the European Patent f-r I Wile on 20/04/88 Thc European P'atent Offie is in no way liable for tiie I x-irs ishicx ar, merely given for the purpose of information. Patent document Publication Patent family Publication cited in search report date member(s) Idate EP-A- 0008161 20-02-80 AU-A- 4907479 JP-A- 55027297 US-A- 4290933 AT-T- 238 AU-B- 523058 CA-A- 1136305 3 1-01-80 2 7-02-30

22-0 9-8 1 15-10-81 03-07-32 2 3-11-32 US-A- 4397433 09-08-33 BE-A- 390736 01-02-32 JP-A- 57069083 27-04-82 JP-A- 57032090 22-05-82 ~JP-A- 57093390 18-06-82 GB-A- 1033578 FR-A- 1353522 M For more details about this annex see Official Journal of the European Patent Office, So. 12/82