CA1107955A - Manifold carbonless form and process for the continuous production thereof - Google Patents

Abstract

Abstract of the Invention This invention relates to a process for the production of a manifold carbonless form having one or more surfaces coated with capsular chromogenic material.
The process comprises providing a plurality of continuous webs, at least one web of the plurality of continuous webs being marked with a pattern and at least one non-aqueous, solvent-free coating of the capsular, chromogenic material being applied to at least a portion of at least one conti-nuous web of the plurality of continuous webs. The non-aqueous, solvent-free coating is then set followed by collating of the plurality of continuous webs. The colla-ted, continuous webs are placed in contiguous relationship to one another to create a manifold form. After the con-tinuous webs are placed in collated, contiguous relation-ship they can be finished by any combination of the steps of combining, partitioning, stacking, packaging and the like. This invention also relates to a process for con-tinuously producing a manifold carbonless form. This invention also relates to the manifold form which is the product of the process of this invention.

Description

'7~5 ~ 3L_und of the Invention Field of the Invention This invention relates to pressure sensitive copying systems, and more particularly to a process for the production of a manifold carbonless form and to the carbonless form itself.
Prior Art Manifold forms for commercial and private use have been in common use for several years. Historically, the standard business form has taken a variety of shapes.
The most common is a multiple part form with sheets of carbon paper being insertable between the various sheets.
This concept is very cumbersome as the carbon paper had to be both inserted, removed and disposed of in addition to the deficiences commonly noted in the use of carbon paper such as smudging. In response to the obvious prob-lems a form was developed having the carbon paper already inserted between the various sheets making up the form and being available for easy removal and disposal. This re-moval and disposal was made even more convenient by theattachment of the carbon paper together at one edge, generally the bottom, so that by merely ripping out the bottommost edge of the form all of the carbon paper would be removed. This system has been and still is being used by many retail department stores. All of these systems have historically suffered from one common deficiency, namely the use of carbon paper. Carbon paper, while adequate for some image transfer purposes is not a prefer-red product as it is very cumbersome to work with, it is very messy and in general does not form the quality image which is desired. In addition, as is commonly encountered with the use of carbon paper the more sheets of carbon paper that are used the fainter the image on the last sheets

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of the form. This is especially true where more than three to four sheets per form are used. Examples of patents relating generally to the use and manufacture of carbon paper and other image transfer systems containing dyes and pigments are:
U.S. Patent 2,299,694 (1942) to Green U.S. Patent 2,374,862 (1945) to Green U.S. Patent 3,016,308 (1962) to Macauley U.S. Patent 3,020,170 (1962) to Macauley U.S. Patent 3,079,351 (I963) to Staneslow et al In recognition of the deficiencies of carbon paper as an image transfer media a variety of new products have been introduced into the marketplace. One such pro-duct is commonly referred to as carbonless paper. Carbon-less paper, briefly stated, is a standard type of paper --wherein during manufacture the backside of the paper sub-strate is coated with what is referred to as a CB coating, the CB coating containing one or more colour precursors generally in capsular form. At the same time the front side of the paper substrate is coated during manufacture with what is referred to as a CF coating, which contains one or more colour developers. Both ~he colour precursor and the colour developer remain in the coating composi-tions on the respective back and front surfaces of the paper in colourless form. This istrue until the CB and CF coatings are brought into abutting relationship and sufficient pressure, as by a typewriter, is applied to rupture the CB coating to release the colour precursor.
At this time the colour precursor contacts the CF coating and reacts with the colour developer therein to form an image. Thus the image from the top sheet is transferred to the next sheet without the use of carbon paper. Car-bonless paper has proved to be an exceptionally valuable

-3-image transfer media for a variety of reasons only one of which is the fact that until a CB coating is placed next to a CF coatiny both the CB and the CF substrates are in an inactive state as the co-reactive elements are not in contact with one another. Patents relating to carbonless paper products are:
U.S~ Patent 2,712,507 (1955) to Green U.S. Patent 2,730,456 (1956~ to Green et al A third generation product which is in an advan-ced stage of development and commercialization at this timeand which is available in some business sectors is referred to as self-contained paper. Very generally stated self-contained paper refers to an image transfer system wherein only one side of the paper needs to be coated and ~he one coating contains both the colour precursor, generally in - encapsulated form, and the colour developer. Thus when pressure is applied, again as by a typewriter or other writing instrument, the colour precursor capsule is ruptu-red and reacts with the surrounding colour developer to form an image. Both the carbonless paper image transfer system and the self-contained transfer system have been the subject of a great deal of patent activity. A typical autogeneous record material system, earlier sometimes referred to as "self-contained" because all elements for making a mark are in a single sheet, is disclosed in U.S.
Patent 2,730,457 (1956) to Green.
In an especially preferred embodiment of this invention the manifold paper product is produced continu-ously without requiring roll storage or the like. As can be appreciated from the above the continuous production of a manifold paper product would require simultaneous coating, simultaneous drying, simultaneous printing, and simultaneous collating and finishing of a plurality of paper substrates.

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Because of the complexities of the drying step this has not been commercially possible to date. More particularly, the drying step involving solvent evaporation and/or water evaporation and the input of heat does not permit the simul-taneous or continuous manufacture of manifold forms.
A disadvantage of coated paper products such as carbonless and self-contained stems from the necessity of applying a liquid coating composi~ion containing the colour forming ingredients during the manufacturing process. In the application of such coatings volatile solvents are sometimes used which then in turn requires evaporation of excess solvent to dry the coating thus producing volatile solvent vapours. An alternate method of coating involves the application of the colour forming ingredients in an aque-ous slurry, againrequiringrémoval of excess waterby drying.
Both methods suffer from serious disadvantages. In parti-cular the solvent coating method necessarily involves the production of generally volatile solvent vapours creating both a health and a fire hazard in the surrounding environ-ment. In addition, when using an aqueous solvent systemthe water must be evaporated which involves the expenditure of significant amounts of energy. Further, the necessity of a drying step requires the use of complex and expensive apparatus to continuously dry a substrate which has been coated with an aqueous coating cQmpound. A separate but related problem involves the disposal of polluted water.
The application of heat not only is expensive, making the total paper manufacturing operation less cost effective, but also is potentially damaging to the colour forming ingredients which are generally coated onto the paper sub-strate during manufacture. High degrees of temperature in the drying step require specific formulation of wall-forming compounds which permit the use of excess heat. The lL~ 5 problems encountered in the actual coating step are gene-rally attributable to the necessity for a heated drying step following the coating operation.
The drying step involving solvent evaporation and/or water evaporation and the input of heat does not permit the most economic and efficient manufacture of mani-fold forms. In addition to the drying step which hinders manifold form production the necessity for the application of heat for solvent evaporation is a serious disadvantage since aqueous and other liquid coatings require that spe-cial grades of generally more expensive paper be employed and even these often result in buckling, distortion or warping of the paper since water and other liquids tend to strike through or penetrate the paper substrate~ Addi-tionally, aqueous coatings and some solvent coatings are generally not suitable for spot application or application to limited areas of one side of a sheet of paper. They are generally suitable only for application to the entire surface area of a sheet to produce a continuous coating.
Patents considered relevant to this concept are:
Canadian Patent 945,443 (1974) to Busch U.S. Patent 3,914,511 (1975) to Vassiliades Another problem which has been commonly encoun-tered in attempts to continuously manufacture manifold forms has been the fact that a paper manufacturer must design paper from a strength and durability standpoint to be adequate for use in a large variety of printing and finishing machines. This requires a paper manufacturer to evaluate the coating apparatus of the forms manufacturers he supplies in order that the paper can be designed to accommodate the apparatus and process designed exhibiting the most demanding conditions. Because of this, a higher long wood fiber to short wood fiber ratio must be used by j~r;,, ~L~ 7~
the paper manufacturer than is necessary for most coating, printing or finishing machines in order to achieve a pro-per high level of strength in his finished paper product.
This makes the final sheet product more expensive as the long fiber is generally more e~pensive than a short fiber.
In essence, the separation of paper manufacturer from forms manufacturer, which is now common, requires that the paper manufacturer overdesign his final product for a variety of machines, instead of specifically desiyning the paper product for known machine conditions.
By combining the manufacturing, printing and finishing operations into a single manufacturing facility a number of advantages are achieved. First, the paper can be made using ground wood and a lower long fiber to short fiber ratio as was developed supra. This is a cost and potentially a quality improvement in the final paper ;~ product. A second advantage which can be derived from a combination of manufacturing, printing and finishing is that waste or recycled paper hereinafter sometimes refer-red to as "broke" can be used in the manufacture of the paper since the quality of the paper is not of an over-designed high standard. Third and most importantly, several steps in the normal process of the manufacture of forms can be completely eliminated. Specifically drying steps can be eliminated by using a non-aqueous, solvent-free coating system and in addition several warehousing and shipping steps can be avoided thus resulting in a more cost efficient product.
Additionally, by using appropriate coating me-thods, namely non-aqueous, solvent-free coating composi-tions and methods, and by combining the necessary manufac-turing and printing steps, spot printing and spot coating can be realized. Both of these represent a significant X

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cost savincJs but nevertheless one which is not generally availabl~ when aqueous or solvent coatings are used or where the manufacture, printing and finishing of paper are performed at ~eographically separated manufacturing facilities. An additional advantage of the use of solvent-free, non-aqueous coating compositions and the combination of paper manufacturer, printer and finisher is that when the option of printing followed by coating is available significant cost advantages occur. More particularly, by printing prior to coating from about 10% to about 30% fewer capsulated colour forming ingredients need to be used to achieve the same satisfactory levels of image transferabi-lity. This advantage is realized because when the paper is transferred to a forms manufacturer in coated form the paper of necessity will lose some of its capsulated colour formers when printed because of the pressure rupturability of the material. This disadvantage is eliminated when the paper is printed first followed by coating.
Many of the particular advantages of the process and product of this invention are derived from the fact that a non-aqueous, solvent-free coating composition is used to coat the paper substrate. This is in contrast to the coatings used by the prior art which have generally required an aqueous or solvent coating. For purposes of this application the term "100~ solids coating" will some-times be used to describe the coating operation and should be understood to refer to the fact that a non-aqueous, solvent-free coating composition is used and therefore the normal drying step normally present in the manufacture of paper and in coating has been eliminated.
The present invention provides a process for the production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:

~;-r 7 ~ 5 (a) providing a continuous web said continuousweb having a first and second surface;
tb) marking said second surface of said conti-nuous web with a pattern;
(c) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of said continuous web said first non-aqueous, solvent-free coating comprising said : firs chromogenic material dispersed in a hot melt suspen-ding medium, said coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composi-tion to said first surface;
(d) setting said first coating by means of temperature decrease to form a marked, coated continuous web;
~- (e) combining said printed, coated continuous web with at least one additional continuous web to form a , plurality of continous webs, (i) each of said additional continuous webs having a first and second surfacel (ii) each of said additional continuous webs ~ being characterized by having at least a portion of the - second surface thereof coated with a second chromogenic material, said second chromogenic material being coreactive with said first chromogenic material to form a colour, (iii) all except one of said additional con-tinous webs being further characterized by at least a por-tion of the first surface thereof being coated with at least one non-aqueous, solvent-free coating of said first chromogenic material, said non-aqueous, solvent-free coating on said first surface of all except one of said additional continuous webs comprising said first X

chromogenic material dispersed in a hot melt suspending medium, (iv) said coating on said first surface of all except one of said additional continuous webs being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application thereof, (f) setting said coating on said first surface on all except one of said additional continuous webs by means of temperature decrease;
(g) collating said plurality of printed coated continuous webs such that coreactive chromogenic materials are in facing relationship; and (h) placing said collated continuous webs in contiguous relationship to one another to create a mani-fold carbonless form.
Detailed Description of the Preferred Embodiment . .
The process of this invention is directed to the complete production of manifold carbonless forms at a single processing or manufacturing facility. The term "carbonless"
as used herein shall be understood to be a generic term to ; encompass any t~pe of image transfer paper or paper system not requiring the use of carbon paper. The carbonless paper will be described herein as having a topmost and bottommost surface corresponding to those surfaces as they would appear to a person using the paper. One, both or none of the surfaces of the carbonless paper can be coated with a chromogenic material in the form of microcapsules, droplets or other vehicle dispersed in a binder. Prefer-ably the capsular material is microencapsulated. Included in the chromogenic materials are colour precursors, colour developers, colour inhibitors and like materials and oom-binations thereof.

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The manifold carbonless forms of this invention will usually comprise from about 2 to about 10 individual sheets and preferably from about 2 to about 4 individual sheets per form. The actual number of sheets or layers making up the particular carbonless form is not limiting to the practice of the process of this invention, but rather can be manufactured to the convenience of the indi-vidual customer.
The apparatus which can be used in the process of this invention includes apparatus which is traditionall~
used in paper manufacturing and forms printing. During the collating and/or finishing steps as the various continuous webs are advanced towards their final finishing or packing - station they must be advanced at substantially the same speed and other process variables must be specifically controlled. For example, if the individual paper webs are various colours indicating second or third copies the col-lating must be coordinated so that the colours of the forms are properly arranged. Additionally, it is preferred al-though not essential that the size of the individual con-tinuous webs be substantially equal. It is necessary in the manufacture of carbonless paper forms that the CB/CF
coatings be adjacent to one another; and finally it is necessary that the distinction be made between carbonless and self-contained so that two sides coated with a self-contained coating composition are not adjacent to each other. For purposes of this application the arranging of the various sheets in the proper order shall be sometimes referred to as collating the sheets, webs or substrates.
A particular advantage enjoyed by the process of this invention is the fact that the printing or marking step can be completed prior to the coating step. In this fashion it can be seen that fewer encapsulated materials ~L~37~3~5 need be coated on the paper as from about 10% to about 30%
of the encapsulated material which is normally ruptured or otherwise destroyed during the printing operation is not necessary as the web has already been printed during the coating operation.
The continuous webs, sometimes referred to here-in as substrates, are any of those commonly used in the manufacture of carbonless papers. Included in the prefer-red continuous web materials are paper and plastic although other substrates can be substituted. The continuous webs can be supplied in any of a variety of shapes, sizes and configurations. The preferred and most common shape is in a roll form. While the particular dimensions of the roll ; are not critical a standard roll would be sized at approxi-mately a width of from about 3 inches to about 72 inches and a total length of approximately from about 500 feet to about 10,000 yards. This particular size has been found suitable to fit more printing and coating apparatus~ In this fashion a substrate is printed and coated and then stored for future use in combination with other compatible printed and coated substrates to make a finished manifold carbonless form. After the individual treated substrates have been stored they are placed in collating and finishing apparatus to complete the manufacturing process. In an alternative embodiment the continuous web can be supplied as an on-line substrate forming process. In this parti-cular embodiment the manifold carbonless form ~lanufacturing process is the final stage in the paper making process.
The preferred continuous web material is paper and as developed supra the overall quality of the paper can be somewhat lower than was previously considered accep-table and as a result the paper can generally be made using ~`
some ground woods and additionally the paper has a lower 3'~C3~

long fibre to short fibre ratio. This cost saving advan-tage of lower overall paper quality is realized because the paper can be manufactured specifically for use in combina-tion with known coating and printing apparatus.
A particular advantage enjoyed by the process of this invention is the fact that the printing or marking operation can be completed prior to the coating step. In this fashion it can be seen that fewer encapsulated materi-als need be coated on the paper as from about 10~ to about 30% of the encapsulated material which is normally ruptured or otherwise destroyed during the printing operation is not necessary as the web has already been printed during the coating operation. This is in contrast to what was previ-ously possible due to the fact that formerly after any coating step a drying step was of necessity required, the drying step generally requiring the application of substan-tial heat and the expenditure of a significant amount of energy. This represents a substantial cost and convenience advantage over any methods shown or disclosed by the prior ;~ 20 art.
As described above in the preferred process of this invention the individual substrates are subjected to a printing or marking step prior to the coating step. While this is preferred it is not critical. For purposes of this application the term "marking" shall be used and shall be understood to be generic to printing, writing, lining or any other marking of a continuous web whether the marking is visible or not. In the preferred process of this inven-tion the topmost surface of each individual web of the plurality of continuous webs is marked with a printing ink to provide the printed information and blanks usually found in a business form. However, it is sometimes the case that only one surface, normally the topmost surface, of the X

~ t~c~ 5 topmost continuous web will be so marked. The actual con-tent of the marking and the number of webs which are marked are dependent on the particular form being manufactured and may be conveniently adjusted during the manufacturing opera-tion.
In the preferred embodiment of this invention the marking step is performed by the application of a marking fluid, preferably a printing ink, by suitable printing appa-ratus to one or more surfaces of the continuous webs. The preferred printing method is offset although any of the other well known printing methods are equally applicable.
The actual printing method is merely an apparatus limitation and depends on the printer capabilities of the particular manufacturer. The inks which can be used in this printing step are any of the inks commonly used in the printing in-dustry today. The ink must only be selected from a group ;~ or type which are compatible with the coating process and composition.
For the production of manifold carbonless forms according to the process of this invention it is necessary that at least one coating composition be applied to at least one surface of at least one continuous web prior to colla-ting into a manifold form. In the preferred embodiment of this invention each continuous web of the plurality of con-tinuous webs, except the topmost web, will have a CF coating containing a colour developer on the topmost surface and a CB coating containing an encapsulated colour precursor on the bottommost surface. As another preferred embodiment a self-contained image transfer system can be used wherein both the colour developer and colour precursor are coated on a single surface, preferably the topmost surface, of each continuous web again with the exception of the topmost web which does not require any coating material regardless -X

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of what particular form o~ carbonless transfer system is used.
Depending on the particular coating method and composition the coating of a self-contained composition on-to the continuous web can require either one or two separate coating steps. While the coating step can be performed by a variety of known methods the preferred coating methods and coating compositions are hot melt suspension media and radiation curable resins. One of the particularly signifi-cant advantages found in both of these preferred coatingmethods is that no coating drying step is necessary. Rather, a curing or setting step is substituted for the drying step and no heat, elapsed time or elevated temperatures are necessary. Thus the coating compositions for use ih the process of this invention are best described as solvent~free, non-aqueous coating compositions or expressed differently "100% solids coatings'l.

HOT MELT SYSTEM
The preferred coating method of this invention involves the use of a hot melt suspension medium, preferably waxes, resins or the like in combination with microcapsules, -~ the microcapsules containing a colour precursor or colour precursor combination. The most preferred hot melt suspen-ding media comprise the low molecular weight polar waxes.
The hot melt suspending medium procedure described herein -will be hereinafter sometimes referred to as the hot melt ; activation system. The hot melt activation system has been found most suitable for use as the CB coatin~ for car-bonless paper although to a somewhat lesser extent it can also function as the CF coating containing the colour deve-loper or colour developer combination. This preferred pro-cedure involves microencapsulating a colour precursor using any of a variety of well-known microencapsulation techniques 7~

most of which re~uire the use of a cross-linking agent with a wall forming compound to initiate an interfacial reaction resulting in the formation of microcapsules having charac-teristics determined by the particular wall forming compound.
The chromogenic coating composition for use in the hot melt embodiment of this invention is essentially a dispersion of a chromogenic material in a hot melt system.
The chromogenic material can be either soluble or insoluble in the hot melt system and the colour precursors are prefe-rably in microencapsulated or dispersed form. Fillermaterials can also be added to the hot melt to modify the properties of the final coated substrate. The use of sol-vents, which require heat to remove them during the setting of the coated film, is avoided.
The chromogenic colour precursors most useful in the practise of the hot melt embodiment of this invention are the electron-donors and include the lactone phthalides, such as crystal violet lactone, and 3,3-bis~ ethyl-2-methylindol-3'-yl) phthalide, the lactone fluorans, such as 2-dibenzylamino-6-diethylaminofluoran and 6-diethylamino-1,3-dimethylfluorans, the lactone xanthenes, the leucoaura-mines, the 2-(omega substituted vinylene)-3,3-disubstituted- -~
3-H indoles and 1,3,3-trialkylindolinospirans. Mixtures of these colour precursors can be used if desired. In the pre-ferred hot melt process of this invention microencapsulated oil solutions o~ colour precursors are used. The colour precursors are preferably present in such oil solutions in an amount of from about 0.5~ to about 20.0% based on the weight of the oil solution, and the most preferred range is from about 2~ to about 7%.

The hot melt suspending media generally useful in the practise of this invention include waxes and resins.
The preferred group of compounds useful as hot melt suspending media include: deresinatecl, oxidized mineral waxes such as the montan waxes, amide waxes such as bis-stearamide wa~, stearamide wax, behenamide wax, fatty acid waxes, hy-droxylated fatty acid waxes, hydroxy stearate waxes, oxa-zoline waxes, amine waxes and mixtures thereof. The hot melt suspending medium is characterized by having a pene-tration hardness of less than or equal to from about 0.1 to about 20.0, a melting point of from about 60C to about 140C, a narrow melting range, a low viscosity when molten, a certain amount of polarity and a light colour. Any wax or wax mixture with the foregoing properties can be used successfully as suspending media in the practise of this invention. These waxes are all suitable to act as a dis-persing medium for the chromogenic material and other in-gredients of the coating composition and at the same time ; are compatible with the chromogenic properties of the chro-mogenic material. These materials are settable to a solid when cooled.
Included in the preferred group of hot melt sus-pending media are the following waxes: 2-n-heptadecyl-4,4-bis-hydroxy-methyl-2-oxazoline, N,N'-ethylenebisstearamide, N- (2-hydroxyethyl)-12-hydroxystearamide, glyceryl mono-hydroxystearate and ethylene glycol monohydroxystearate.
Other waxes of this type which have generally proved to be effective are generically described as modi-fied mineral type, synthetic waxes or those of vegetable origin or combinations thereof. These waxes must be characterized by a high melting point and a great hardness which eliminates wax transfer to the developing sheet, thus improving image clarity, increasing blocking tempera-ture and diminishing packing problems. One of the most preferred waxes for use in the process and product of this invention are the deresinated crude montan waxes. These -7~5~
waxes are produced from a raw material of bitumen-rich lig-nite which is extracted with organic solvents to form a crude montan wax. The montan wax is deresinated by extrac-tion with organic solvents followed by oxidation with chro-mic acid to yield acid waxes.
Another type of preferred hot melt suspending media is a non-polar hydrocarbon wax, such as Be Square*
170/175 (m.p. range 170-175F) from Bareco Division of Petrolite Corporation which includes a small amount of dispersing agent. The dispersing agent may, for instance, be Turkey Red Oil.
The preferred waxes of this invention have a penetration hardness of from about 0.1 to about 20 measured by the needle penetration test given a ASTM designation of D1321-61T. The range of 0.1 to 20.0 represents a practical penetration hardness range. A more preferred ranged is from about 0.1 to about 3 and the most preferred range is from about 0.1 to about 1 on the same needle penetration index. The needle penetration index covers a test proce-dure for the empirical estimation of the consistency of ~; waxes derived from petroleum by measurement of the extent of penetration of a standard needle. This method is appli-cable to waxes having penetration of not greater than 250.
The penetration of petroleum wax is the depth, in tenths of a millimeter, to which a standard needle penetrates into the particular wax under defined conditions. The defined conditions generally are that the sample is melted, heated to 30F above its melting point, poured into a container, and then air cooled under controlled conditions. The sample is then conditioned at test temperature in a water bath. Penetration is measured with a penetrometer, which applies a standard needle to the sample for 5 seconds under a load of 100 grams.

* Trade Mark ~"3'~35~i A second characteristic of the desired hot melt suspending media of this invention is a melting point of from about 60C to about 140C. A more preferred melting point for the waxes or resins of this invention is from about 70C to about 100C. Also relative to the melting point, it is necessary for the coating composition of this invention to set rapidly after application to the particu-lar substrate. More particularly, a practical melting range limitation, or in other words range of temperature in which the li~uid hot melt composition sets into a solid composition, is from about 1.0C to about 15C. The pre-ferred setting time is from about 0.5 seconds to about 5 seconds while the most preferred setting time is from ; about 0.5 seconds to about 2 seconds. While melting ranges of more than 15C can be used the time necessary for such a coating composition to set requires special apparatus and handling and makes use of these hot melt compounds commercially unattractive.
The hot melt waxes and resins of this invention must also have a low ~iscosity when in a molten state in order to facilitate ease of spreading on the substrate.
In general, it is desirable that the hot melt suspending media have a viscosity of less than about 120 centiposes at a temperature of approximately 5 above the melting point of a particular hot melt suspending medium. In addi-tion, it is preferred that the hot melt wax or hot melt suspending media of this invention havea light colour in order to be compatible with the final paper or plastic product being produced~ This means that it is preferred for the hot melt to be white or transparent after applica-tion to the particular substrate being coated.

The preferred waxes, resins and other hot melt suspending media of this invention preferably are polar.

5~i By polar it is meant that a certain amount of polarity is characteristic of the preferred waxes, the polar composi-tions being characterized by the presence of functional groups selected from the group consisting of: carboxyl, carbonyl, hydroxyl, ester, amide, amine, heterocyclic groups and combination thereof. An alternative but less preferred embodiment of this invention includes the use of non-polar hydrocarbon waxes which must be used in conjunc-tion with a dispersing agent.
The additives which may be included in the hot melt CB coating composition are typically an opacifying agent such as titanium dioxide or clay, a stilting agent such as Arrowroot starch and wax modifying agents such as polycinyl acetate, isophthalic polyester, or any other resin materials soluble or dispersible in the main wax and which improves wax quality.
The method of dispersing the microcapsules in the hot melt suspending media is also important since it is, likewise, necessary to use a process which prevents significant agglomeration of the microcapsules. In the preferred process the microcapsules are formed into an aqueous slurry containing approximately 40% solids and are then spray dried to form a free-flowing powder. The free-flowing microcapsules are stirred into a molten phase of a suspension medium, such as a wax, a mixture of waxes, a ; resin or mixture thereof to form a smooth dispersion of microcapsules in the continuous molten phase. This hot melt can then be coated or printed, by gravure, blade coa-ting, flexography or other means onto the continuous web.
The hot melt system sets substantially immediately after application to the web and forms an excellent marking sheet.
In the most preferred embodiment of this invention .~.4~3~5 a dispersing agent is added to the microcapsules prior to combining the microcapsules with the hot melt suspending mediu~. A preferred group of dispersing agents are the an-ionic dispersing agents, many of which are commercially available. A preferred group of anionic dispersing agents includes the sodium salts of condensed naphthalene sulfonic acids, the sodium salt of polymeric carboxylic acids, the free acids of complex organic phosphate ester, sulfated castor oil, poly-(methylvinyl ether/maleic and hydride) and combinations thereof. The most preferred dispersing agent is sulfated castor oil. The dispersing agent is added to the microcapsules in an amount of from about 0.1 to about 10% based on the dry weight of the microcapsules.
A preferred range of addition is from about 0.5% to about 5.0~ based on the dry weight of the microcapsules while a most preferred range is from about 1.0% to about 3.0% based on the dry weight of the microcapsules.
In the most preferred embodiment of this inven-tion a dispersing agent is added to the microcapsules prior to combining the microcapsules with the hot melt suspending ; medium. In some instances the dispersing agent and the wall forming material are one in the same and the wall for-ming material not actually used in the microcapsule wall formation is present in hot melt coating dispersion as a dispersing agent. Although as described above many of the well-known, commercially available dispersing agents can be used in the process and product of this invention a group of secondary dispersing agents that may be present as excess wall forming material includes: hydroxypropyl-cellulose, gum arabic, gelatin, polyvinyl alcohol, carboxy-methylcellulose, and mixtures of the above.
While the dispersing agent can be added at any point in the process of this invention prior to the setting 7s`~

of the coating composition, to achieve the most desirable results the dispersing agent should be added to the micro-capsules prior to combining the microcapsules with the hot melt suspending medium. The particular amount of disper-sing agent used is dependent on several variables inclu-ding the particular type of microcapsule used, the particu-lar type of hot melt suspending medium, the concentration of the aqueous microcapsular slurry, the viscosity of the hot melt suspending medium and the desired final coated product. For purposes of this application a practical range of addition based on the weight of the microcapsules is from about 0.1 part by weight to about 10.0 parts by weight. A preferred range of addition would be from about 0.5 to about 5.0 parts by weight while the most preferred range of addition would be from about l.0 to about 3.0 parts by weight.
The chromogenic coating composition can be applied to a substrate, such as paper or a plastic film by any of the common paper coating processes as developed above such as roll, blade coating or by any of the common printing processes, such as gravure, or flexographic printing. The rheological properties, particularly the viscosity of the coating composition, can be adjusted for each type of application by proper selection of the type and relative amounts of hot melt suspending media. While the actual amount of the hot melt coating dispersion applied to the substrate can vary depending on the particular final pro-duct desired for purposes of coating paper substrates CB
coat weight of from about 1 pound to about 8 pounds per 3300 square feet of substrate have been found practical.
The preferred range of CB coat weight application is from about 2.5 pounds to about 5.0 pounds per 3300;square feet of substrate, while the most preferred range is from about X ,.

~7~t5-~i 3 pounds to about 4 pounds per 3300 sqaure feet of substrate.
If the CF chromogenic materials and a colour developer (CF) are combined into a single or self-contained chromogenic coating composition practical coat weightsinclude from a-bout 2.0 pounds to about 9.0 pounds per 3300 square feet of substrate, the preferred coat weight is from about 3.0 pounds to about 6.0 pounds per 3300 square feet, and the most preferred range is from about 4.0 pounds to about 5~0 pounds per 3300 square feet of substrate.
These hot melt coating dispersions or hot melt coating compositions, the terms being used interchangeably, can be set by any cooling means. Preferably a chill roll is used on the coating apparatus which cools the hot melt coating immediately after coating, but it is also quite com-mon to simply allow the coating composition to cool natu-rally by atmospheric exposure. As the temperature of the ~ coating composition is substantially higher than room tem-; perature and in light of the fact that the coating thick-ness is generally less than 50 microns it c~n be seen that when spread out over a substrate the hot melt material cools very rapidly. The actual exposure or chill time necessary for setting of the chromogenic coating composition is depen-dent on a number of variables, such as coat weight, the particular hot melt suspending medium used, type of cooling means, temperature of cooling means and others.
The choice of wall-forming material and hot melt suspending media is important since certain microcapsules ;~ having walls of hydroxyethylcellulose when made by certain patented process and certain polyamides tend to agglomerate even in polar waxes. Agglomeration is undesirable since this prevents uniform distribution of the chormogenic ma-terial on the CF sheet. This may adversely affect transfer and uniformity of the intensity of the formed image.

.~L~ 7s,t~S

The particular method of encapsulation or the particular encapsuled chromogenic material are not asser-ted to be an inventive feature herein. Rather, there are described in the patent literature various capsular chro-mogenic materials which may be used. Such chromogens have been encapsulated in gelatin wall-forming materials (see U. S. Patents Nos. 2,730,456 and 2,800,457) including gum arabic, in polyvinyl alcohol, in carboxymethylcellulose, in resorcinol-formaldehyde wall formers (see U. S. Patent No. 3,755,190), isocyanate wall-formers (see U. S. Patent No. 3,914,511) and hydroxypropylcellulose (see U. S. Patent No. 4,025,455) in addition to mixtures of the above. Micro-encapsulation has been accomplished by a variety of known techniques including coacervation, interfacial polymeriza-tion, polymerization of one or more monomers in an oil, various melting, dispersing and cooliny methods, and spray drying methods. Compounds which have been found preferable for use as wall forming compounds in the various microen-- capsulation techniques includes: hydroxypropylcellulose, carboxymethylcellulose, gelatin, melamine-formaldehyde, polyfunctional isocyanates and prepolymers thereof, poly-functional acid chlorides, polyamines, polyols, epoxides and mixtures thereof.
Particularly well suited to use in the present invention are microcapsules of hydroxypropylcelluselose (HPC) materials. This is because such microcapsules are easily dispersed in most hot melt media. If necessary, a small amount of dispersing agent as described above can also be added to improve the disperson. In addition, the HPC capsules have good permeability, strength, and tempe-rature characteristics.

RADIATION CURABLE SYSTEM
The second preferred coating method of this {D7~

invention involves the use of radiation curable resins.
As with the hot melt activation svstem the radiation cu-rable resins can be used as either a CF of a CB coating but preferably are used as the CF coating system. The basic concept of the radiation curable activation system involves dissolving a developing agent such as a novolak resin in a liquid radiation curable material which can be solidified by exposure to radiation such as ultraviolet or electron beam. The liquid mixture containing the deve-loping agent and the liquid radiation curable material isthen applied to a thin film to the continuous web which is exposed to ultraviolet light to cure the coating.
The radiation curable chromogenic coating compo-sition useful in the process of this invesntion is essen-tially a dispersion of a chromogenic material in a liquid radiation curable substance. The chromogenic material can be either soluble or insoluble in the liquid radiation curable substance and the colour developers are preferably in microencapsulated or dispersed form. Insoluble chromo-genic colour developers, for use in preparing carbonlessrecord sheets such as the acid clays, are present in the coating composition as a dispersed particul~te solid. Most organic colour developers are soluble in the radiation cu-rable substance of this invention.
The coating composition can contain additional materials which function as photoinitiators. Addition of these materials depends upon the particular method of cu-ring the chromogenic coating. Filler materials can also be added to modify the properties of the cured film. The use of non-reactive solvents, which require heat to remove them during the drying or curing of the coated film, is avoided.
The chromogenic colour developers most useful in ~1 7~g5~ii the radiation curable emhodiment of this invention are the acidic electron-acceptors and include acid clays such as attapulgus clay, and silton clay, phenolic materials such as 2-ethylhexylgallate, 3,5-di-tert-butyl salicylic acid, phenolic resins of the novolak type and metal modified phenolic materials such as the zinc salt of 3,5-di-tert-butyl salicylic acid and the zinc modified novolak type resins. The most preferred chromogenic colour developers are the novolaks of p-phenylphenol, p-octylphenol and p-tert-butylphenol. Mixtures of these colour developers may be used, if desired. They can be present in the liquid chromogenic composition in an amount of from about 25% to a~out 75~ by weight of the chromogenic composition. The preferred ran~e is from about 35~ to about 65%, and the most preferred range is from about 40% to about 55%.
The radiation curable substances useful in the practise of this invention comprises the free radical polymerizable ethylenically unsaturated organic compounds.
These compounds must contain at least one terminal ethyle-nic group per molecule. They are liquid and act as dis-pers~ng media for the chromogenic material and other in-gredients of the coating composition. They are curable to a solid resin when exposed to ionizing or ultraviolet radi-ation. Curing is by polymerization.
A preferred group of radiation curable compounds are the polyfunctional ethylenically unsaturated organic compounds which have more than one (two or more) terminal ethylenic groups per molecule. Due to the polyfunctional nature of these compounds, they cure under the influence of radiation by polymerization, including crosslinking, to form a hard dry tack-free film.
Included in this preferred group of radiation curable compounds are the polyesters of ethylenically ~' ~1~3~

unsaturated acids such as acrylic acid and methacrylicacids, and a polydydric alcohol. Examples of some of these polyfunctional compounds are the polyacrylates or methacrylates of trimethylolpropane, pentaerythritol, di-pentaerythritol, ethylene glycol, triethylene glycol, pro-pyleneglycol, glycerin, sorbitol, enopentylylycol and 1,6-hexanediol, hydroxy-terminated polyesters, hydroxy-terminated epoxy resins, and hydroxy-terminated polyure-thanes and polyphenols such as bisphenol A. An example of a polyacrylate of a hydroxy-terminated polyurethane found to be useful in this invention is di(2'-acryloxyethyl)-4-methylphenylenediurethane.
Also included in this group are polyall~l and polyvinyl compounds such as diallyl phthalate and tetral-lyloxyethane, and divinyl adipate, butane divinyl ether and divinylbenzene. Mixtures of these polyfunctional com-pounds and their oligomers and prepolymers may be used if desired.
A second group of radiation curable compounds are the monofunctional ethylenically unsatured organic compounds which have one terminal ethylenic group per mole-cule. Examples o~ such monofunctional compounds are the C8 to C16 alcohol esters of acrylic and methacrylic acid, and styrene, substituted styrenes, vinyl acetate, vinyl ethers and allyl ethers and esters. In general, these compounds are liquid and have a lower viscosity than the polyfunctional compounds and thus may be used to reduce the viscosity of the coating composition to facilitate coating by any desired method. These compounds are radi-ation curable and react with the ethylenically unsaturatedpolyfunctional organic compounds during radiation curing to give a hard drying flexible film. Compounds having only one terminal ethylenic group may be used alone as the 7'3~

radiation curable substance. ~Iowever, the resultant radi-ation cured film may be rather soft and pliable and may be somewhat too tacky for commercial use. The preferred radi-ation curable substance is a mixture containing one or more polyfunctional compounds and one or more monofunctio-nal compounds. By proper selection of these compounds a chromogenic coating composition having the desired coating characteristics for any type of coating application can be made, and a hard, flexible, tack-free radiation cured film can be obtained. In general, the most desired films are obtained by using a radiation curable substance comprising from about 33~ to about 61~ of the polyfunctional compounds to about 33~ to about 67% of the monofunctional compounds.
A photoinitiator is preferably added to the coating compositions if the composition is to be cured by ultraviolet radiation. A wide variety of photoinitiators are available which serve well in the system described in this invention. The preferred photoinitiators are the benZoin alkyl ethers, such as, Vicure* 30 (a mixture of alkyl~enzoin ethers manufactured and sold by Stauffer Chemical Co., Westport, Connecticut), benzoin butyl ether (Vicure* 10, Stauf~er), benzoin methyl ether, and a,a-diethoxyacetophenone. Other photoinitiators which have been used are ~enzophenone,4,4'-bis-(dimethylamino)benzo-phenone, ferrocene, xanthone, thioxanthane, a,a-azobisiso-butylnitrile, decabromodiphenyl oxide, pentabromomonchlo-rocyclohexane, pentachlorobenzene, polychlorinated biphenyls such as the Arochlor* 1200 series (manufactured and sold by Monsanto Chemical Co., St. Louis, Missouri), benzoin ethyl ether,2-ethyl-anthroquinone,l-(chloroethyl)naphtha-lene, desyl chloride, chlorendic anhydride, naphthalene sulfonyl chloride and 2-bromoethyl ethyl ether zinc oxide * Trade Marks 7~S

combined with a small quantity of water also serves as a good substitute photoinitiation system. The amount of photoinitiator added can be from about 0.2% to about 10 by weight of the coating composition, with a preferred range being from about 3~ to about 8~ by weight.
Photoinitiation synergists can also be added to the ultraviolet curing coating compositions. Photoiniti-ation synergists serve to enhance the initiation ef~iciency of the photoinitiators. The preferred synergists are chain transfer agents, such as the tertiary alcoholamines and substituted morpholines, such as triethanolamine, N-methyl-diethanolamine, N,N-dimethylethanolamine and N-methylmorpho-line. The amount of photoinitiation synergist added can be from about 0.2% to about 10~ by weight of the coating com-position, with a preferred range being from about 3~ to about 8~ by weight.
Filler materials can be added as flattening agents, particularly to colour developing coating composi-tions, to reduce the glossy appearance of the cured resin films and preserve the appearance of the substrate prior to coating. Thus a bond paper which has been coated with the coating composition of this invention and which is then cured to a solid film gives the impression of being an un-coated bond paper.
The preferred filler materials are of the colloi-dally precipitated or fumed silicas. Typical of the silicas which can he used are the ones trade namedLoVel* 27 (a pre-cipitated silica manufactured and sold by PPG Industries, Inc., Pittsburgh, Pennsylvania), Syloid* 72 (a hydrogel silica manufactured and sold by W.R. Grace & Co., Davisan Chemical Division, Baltimore, Maryland) and Cab-o-sil* (a fumed silica manufactured and sold by Cabot Corporation, * Trade Marks 1~.37~3S~
Boston, Massachusetts). All of these silicas are known to gi~e an initial bluish colour with colour precursors such as crystal violet lactone. However, this colour fades quickly on aging. Using the record sheet produced by the process of this invention, the developed colour does not fade easily. It is theorized that the filler material through its large surface area provides for increase poro-sity of the cured resin film, thereby promoting more rapid and more complete transfer of an oily solution of colour precursors from a transfer sheet to the record sheet sur-face. The amount of filler materials can be up to about 15% by weight of the coating composition and the preferred range is from about 10~ to about 15~ by weight.
Mixing of the ingredients of the coating composi-tion is not critical. Ingredients can be added one at a time or they can be added all at once and stirred until they are uniformly mixed. Good results are obtained when the ingredients making up the radiation curable substance and the chromogenic material are heated with stirring to facilitate blending of these ingredients. If used, the photoinitiator, photoinitiation synergist and filler are best added when the coating composition is at or slightly above room temperature. It is also preferable to add micro-capsules at room temperature.
The chromogenic compositions can be applied to a substrate, such as paper or a plastic film by any of the common paper coating processes such as roll, air knife, or blade coating, or by any of the common printing processes, such as offset, gravure, or flexographic printing. The rheological properties, particularly the viscosity, of the coating composition, can be adjusted for each type of appli-cation by proper selection of the type and relative amounts of liquid radiation curable compounds. While the actual 11~37~5S
amount of chromogenic coating composition applied to the substrate can vary depending on the particular final pro-duct desired, for purposes of coating paper substrates the practical range of coat weights for the CF chromogenic coating compositions of this invention are from about 0.2 pounds to about 8 pounds per 3300 square feet of substrate, thepreferred rangebeing fromaboutO.5 pounds toabout4pounds per 3300 square feet of substrate and the most preferred range from about 1.0 pounds to about 3.0 pounds per 3300 1~ square feet of substrate. If the CF and CB chromogenic materials are combined into a single or self-contained chromogenic coating compositions practical coat weights include from about 2.0 to about 9.0 pounds per 3300 square feet of substrate, the preferred coat weight is from about 3.0 pounds to about 6.0 pounds per 3300 square feet, and the most preferred range is from about 4.0 pounds to about 5.0 pounds per 3300 square feet of substrate.
These coating compositions can be cured by any free radical initiated chain propagated addition polymeri-~ 20 zation reaction of the terminal ethylenic groups of the -~ radiation curable compounds. These free radicals can be produced by several different chemical processes including the thermal or ultraviolet induced degradation of a molecu-lar species and any form of ionizing radiation utilizing alpha-particles, beta-rays (high-energy electrons), gamma-rays,-x-rays and neutrons. The actual exposure time neces-sary for curing of the chromogenic coating composition is dependent on a number of variables such as coat weight, coat thickness, the particular radiation curable substance, type of radiation, source of radiation, radiation intensity and distance between the radiation source and the coated substrate. In most instances curing is virtually instan-taneous with actual curing times ranging from about 1 X

7~5 millisecond to about 2.0 seconds. The preferred curing time is from about 0.1 seconds to about 1.0 seconds, while the most preferred curing time is from about 0.3 seconds to about 0.6 seconds.
The preferred curing process is by exposure of the coating composition to ultraviolet radiation having a wavelength of about 2000A to about 4000A. For ultra-violet curing to occur the composition must contain sui-table ultraviolet absorbing photoinitiators which will pro-duce polymerization initiating free radicals upon exposureto the radiation source. A typical ultraviolet source suitable for this type of curing process is a Hanovia 200 watt medium pressure mercury lamp. Curing efficiencies of the coating composition are dependent on such parameters as the nature of the radiation curable substance, atmos-phere in contact with the coating, quantum efficiency of -'he radiation absorbed, thickness of coating and inhibi-tory effects of the various materials in the composition.
In the ionizing radiation inducedilcuring of these coaiing compositions a specific radiation absorbing material (photoinitiator) is not necessary. Exposure of the coating composition to a source of high energy electrons results in the spontaneous curing of the composition to a hard, tack-free coating. Any of a number of commercially avail-able high energy ele~tron beam or linear cathode type high energy electron sources are suitable for curing these com-positions. Parameters such as the atmospheric environment and inhibitory effects of the various materials in the com-position play an important role in the determination of `
the curing efficiency of these compositions.

A particular advantage of the coating step ofthe process of this invention is that it permits the use of spot coating. Spot coating refers to the fact that less ~llf37~5 than 100~ of the surface area of the individual sheet whether it is a CF, CB, self-contained or other sheet need be coated. For instance, the area of the paper normally associated with the margin on either side of the printed side portion need not be coated. This, of course, repre-sents a significant cost advantage in the savings of encap-sulated material. The encapsulated material is one of the most costly materials which goes into the forms manufac-ture. Therefore by eliminating certain sections of the web surface that need to be coated a significant cost sa-vings can be appreciated. The use of spot printing can vary from simply omitting coating of the margin portion of the paper to the making of a form wherein only a single line is actually coated. At the same time, forms such as computer printouts can be made wherein only every other line is coated. Thus it can be seen that from about 10% to about 95% of the surface area of the paper need not be -~ coated. In most instances it would be most convenient to simply not print the marginal areas of the paper which would save from about 10% to about 30~ of the total encap-sulated material cost.
Upon completion of the coating operation and the appropriate setting or curing operation the web or sub-strate is wound onto a mandrel and placed in storage. The individual roll is held in storage and then combined with a predetermined number of additional coated or uncoated webs during the collating operation. For purposes of this application the term collating shall refer to a step in the process of this invention whereby a plurality of individual coated or uncoated webs are arranged in order, i.e. CB coating next to a C~' coating, e~c. The term colla-ting means shall be understood to refer to apparatus or other means for accomplishing the desired arrangement of X' s the plurality of individual webs.
An adhesive step is completed prior to, duringor after the collating operation. The adhesive material is applied or the adhesive means are used generally only after a plurality of the individual webs have been removed from storage and are being processed, i.e. collated. The adhesive is applied to one or more edges of the plurality of individual webs or in the alternative an adhesive can be applied over all or a portion of the surface of one or more of the individual webs. Any of the well known glues or adhesives normally used in the paper industry are usable in the adhesion means of this invention. Alternate adhesion methods include bonding members such as adhesive strips, staples, V-shaped slits and other less commonly encountered methods. While the adhesion step has been described as generally occurring after the coating step or steps and before the collating and finishing steps it can be completed at any convenient point during the process of this inven-tion. More particularly, in the most preferred embodiment of the process of this investion a liquid adhesive is ap-plied by adhesion means prior to the collating step and the individual webs are combined during the finishing step.
Thus in the most preferred embodiment an adhesive is applied prior to collating but the webs themselves are not actually -placed in combination with one another until the finishing step. In anothex embodiment of this invention the adhe-sion means may be omitted altogether and the individual webs are not necessarily joined to one another but may be merely arranged in the appropriate sequence with one another.
In still another embodiment of this i~vention the adhesion means may be located after the collating means in the ope-rating sequence. In a further embodiment the collated and finished sheets may be bound or adhered to one another after S

the finishing step. The p~rticular sequence and apparatusused in the adhesion means, collating means and finishing means is a matter of individual choice and is dependent upon the final product desired. No special significance is attached to the particular order or occurrence of these steps.
After, during or prior to the adhesive operation the continuous substrates are advanced to collating means.
The collating means arrange the various individual webs into the proper relationship with one another. This can involve the arrangement of colours if the customer copy or if the original is white the customer copy is green and the file copy is red or in the alternative this can involve the arrangement of particular sheets so that the CB and CF
coated sheets will be in contact when the final form is made. If self-contained type carbonless paper is used the coated surface of the paper is the topmost surface of each sheet. All of this is done by pre-arranged programming of the collating apparatus.
After collating the forms are finished by any of a variety of steps. The finishing operation can involve the steps of attaching the sheets to one another, parti-tioning the sheets into suitable sizes, stacking the sheets into appropriate stacks and/or packaging the sheets in addition to other steps which may be desired.

Claims (39)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A process for the production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a continuous web said continuous web having a first and second surface;
(b) marking said second surface of said continuous web with a pattern;
(c) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of said continuous web said first non-aqueous, solvent-free coating comprising said first chromogenic material dispersed in a hot melt suspending medium, said coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said first surface;
(d) setting said first coating by means of temperature decrease to form a marked, coated continuous web;
(e) combining said printed, coated continuous web with at least one additional continuous web to form a plurality of continuous webs, (i) each of said additional continuous webs having a first and second surface, (ii) each of said additional continuous webs being characterized by having at least a portion of the second surface thereof coated with a second chromogenic material, said second chromogenic material being coreactive with said first chromogenic material to form a color, (iii) all except one of said additional continuous webs being further characterized by at least a portion of the first surface thereof being coated with at least one non-aqueous, solvent-free coating of said first chromogenic material, said non-aqueous, solvent-free coating on said first surface of all except one of said additional continuous webs comprising said first chromogenic material dispersed in a hot melt suspending medium, (iv) said coating on said first surface of all except one of said additional continuous webs being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application thereof, (f) setting said coating on said first surface on all except one of said additional continuous webs by means of temperature decrease;
(g) collating said plurality of printed, coated continuous webs such that coreactive chromogenic materials are in facing relationship; and (h) placing said collated continuous webs in contiguous relationship to one another to create a manifold carbonless form.

2. The process of claim 1 wherein said application of said non-aqueous, solvent-free coating is by means of printing.

3. The process of claim 1 further comprising the step of finishing said collated, contiguous webs, wherein said finishing step includes:
(a) fixably combining said plurality of collated, contiguous webs into a single manifold substrate;
(b) dividing said single manifold substrate into a plurality of sheets, each sheet of said plurality of sheets being dimensioned for use as a manifold carbonless form;
(c) stacking said sheets; and (d) packaging said stacked sheets.

4. The process of claim 1 wherein said continuous webs are paper.

5. The process of claim 1 wherein said plurality of continuous webs comprise from about 2 to about 6 continuous webs.

6. The process of claim 1 wherein said marking is by means of printing.

7. The process of claim 1 wherein said marking is by offset printing means.

8. A process for the production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a continuous paper substrate, said continuous paper substrate having a front and back surface;
(b) applying a printing ink to said front surface of said continuous paper substrate, said printing ink being applied in a pattern corresponding to a printed image;
(c) applying a first non-aqueous, solvent-free coating of a capsular first chromogenic material onto said back surface of said continuous paper substrate said first non aqueous, solvent-free coating comprising said encapsulated first chromogenic material dispersed in a hot melt suspending medium, said first coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said back surface;
(d) setting said first coating by means of temperature decrease to form a printed, coated continuous paper substrate;
(e) combining said printed, coated continuous paper substrate with from about 1 to about 5 additional continuous paper substrates to form a plurality of paper substrates, each of said additional continuous paper substrates having a front and a back surface, a second non-aqueous, solvent-free coating of a second chromogenic material being applied to and set on said front surface of at least one of said additional continuous paper substrates, said second non-aqueous, solvent-free coating comprising said second chromogenic material dispersed in a hot melt suspending medium, said second coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said coating composition to said front surface, said second chromogenic material being reactive with said first chromogenic material to form a color;
(f) setting said second non-aqueous, solvent-free coating by means of temperature decrease;
(g) collating said plurality of continuous paper substrates such that said first and second chromogenic materials are in facing relationship to a coreactive chromogenic material;
(h) placing said collated paper substrates in contiguous relationship to one another to create a manifold form; and (i) finishing said manifold form.

9. A process for the production of a manifold carbonless paper form having one or more surfaces coated with chromogenic material comprising:
(a) providing a plurality of paper substrates, said plurality of paper substrates including from about 2 to about 6 paper substrates, each of said paper substrates having a front surface and a back surface;
(b) marking said front surface of each of said paper substrates of said plurality of paper substrates with a printing ink, said printing ink being applied by printing means in a pattern corresponding to a printed image;
(c) applying a first non-aqueous, solvent-free coating of a capsular first chromogenic material to at least a portion of the back surfaces of all except one of said plurality of paper substrates, said first chromogenic material being a color precursor of the electron donating type said first non-aqueous, solvent-free coating comprising said encapsulated first chromogenic material dispersed in a hot melt suspending medium, said first coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said back surface;
(d) applying a second non-aqueous, solvent-free coating of a second chromogenic material to at least a portion of the front surfaces of all except one paper substrate of said plurality of paper substrates, said second chromogenic material being a color developer of the electron accepting type, said color developer being reactive with said color precursor to form an image said second non-aqueous, solvent-free coating comprising said color developer dispersed in a hot melt suspending medium;
(e) setting said first and said second non-aqueous, solvent-free coating by means of a temperature decrease;
(f) collating said plurality of paper substrates into a single manifold form such that coreactive chromogenic materials are in facing relationship, said collating being such that the front surface of the topmost substrate in said manifold substrate has said printing ink applied thereto but does not have any non-aqueous, solvent-free coating, and such that the bottommost back surface of said manifold substrate has not been coated or printed and such that the paper substrates of said plurality of paper substrates between said topmost and said bottommost paper substrates are coated on both said front and back surfaces;
(g) placing said collated paper substrates in contiguous relationship to one another to create a manifold form; and (h) finishing said manifold form, said finishing including the steps of;
(1) fixably combining said plurality of collated continuous paper substrates into a single manifold substrate;
(2) dividing said single manifold substrate into a plurality of sheets, each sheet of said plurality of sheets being dimensioned for use as a manifold carbon-less form;
(3) stacking said sheets; and (4) packaging said stacked sheets.

10. A process for the production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a continuous web said continuous web having a first and second surface;
(b) marking said second surface of said continuous web with a pattern;
(c) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of said continuous web said first non-aqueous, solvent-free coating comprising said first chromogenic material dispersed in a radiation curable material said first coating being applied to said first surface in fluid form;
(d) setting said first coating by means of exposure to radiation to form a marked, coated continuous web;
(e) combining said printed, coated continuous web with at least one additional continuous web to form a plurality of continuous webs, (i) each of said additional continuous webs having a first and second surface, (ii) each of said additional continuous webs being characterized by having at least a portion of the second surface thereof coated with a second chromogenic material, said second chromogenic material being coreactive with said first chromogenic material to form a color, (iii) all except one of said additional continuous webs being further characterized by at least a portion of the first surface thereof being coated with at least one non-aqueous, solvent-free coating of said first chromogenic material, said non-aqueous, solvent-free coating on said first surface of all except one of said additional continuous webs comprising said first chromogenic material dispersed in a radiation curable material, (iv) said coating on said first surface of all except one of said additional continuous webs being applied in fluid form, (f) setting said coating on said first surface on all except one of said additional continuous webs by means of exposure to radiation;
(g) collating said plurality of printed, coated continuous webs such that coreactive chromogenic materials are in facing relationship; and (h) placing said collated continuous webs in contiguous relationship to one another to create a manifold carbonless form.

11. The process of claim 10 further comprising the step of finishing said collated, contiguous webs, wherein said finishing step includes:
(a) fixably combining said plurality of collated, contiguous webs into a single manifold substrate;
(b) dividing said single manifold substrate into a plurality of sheets each sheet of said plurality of sheets being dimensioned for use as a manifold carbonless form;
(c) stacking said sheets; and (d) packaging said stacked sheets.

12. The process of claim 10 wherein said continuous webs are paper.

13. The process of claim 10 wherein said plurality of continuous webs comprise from about 2 to about 6 continuous webs.

14. The process of claim 10 wherein said marking is by means of printing.

15. The process of claim 10 wherein said marking is by offset printing means.

16. The process of claim 10 wherein said application of said non-aqueous, solvent-free coating is by means of printing.

17. A process for the production of a manifold carbonless form having two or more surfaces coating with chromogenic material comprising:
(a) providing a continuous paper substrate, said continuous paper substrate having a front and back surface;
(b) applying a printing ink to said front surface of said continuous paper substrate, said printing ink being applied in a pattern corresponding to a printed image;
(c) applying a first non-aqueous, solvent-free coating of a capsular first chromogenic material onto said back surface of said continuous paper substrate said first non-aqueous, solvent-free coating comprising said encapsulated first chromogenic material dispersed in a radiation curable material, said first coating being applied to said first surface in fluid form;
(d) setting said first coating means by exposure to radiation to form a printed, coated continuous paper substrate;
(e) combining said printed, coated continuous paper substrate with from about 1 to about 5 additional continuous paper substrates to form a plurality of paper substrates, each of said additional continuous paper substrates having a front and a back surface, a second non-aqueous, solvent-free coating of a second chromogenic material being applied to said front surface of at least one of said additional continuous paper substrates, said second, non-aqueous, solvent-free coating comprising said second chromogenic material dispersed in a radiation curable material, said second coating being applied to said front surface in fluid form, said second chromogenic material being reactive with said first chromogenic material to form a color;
(f) setting said second coating by means of exposure to radiation;
(g) collating said plurality of continuous paper substrates such that said first and second chromogenic materials are in facing relationship to a coreactive chromogenic material;
(h) placing said collated paper substrates in contiguous relationship to one another to create a manifold form; and (i) finishing said manifold form.

18. A process for the production of a manifold carbonless paper form having one or more surfaces coated with chromogenic material comprising:
(a) providing a plurality of paper substrates, said plurality of paper substrates including from about 2 to about 6 paper substrates, each of said paper substrates having a front surface and a back surface;
(b) marking said front surface of each of said paper substrates of said plurality of paper substrates with a printing ink, said printing ink being applied by printing means in a pattern corresponding to a printed image;
(c) applying a first non-aqueous, solvent-free coating of a capsular first chromogenic material to at least a portion of the back surfaces of all except one of said plurality of paper substrates, said first chromogenic material being a color precursor of the electron donating type said first non-aqueous, solvent-free coating comprising said encapsulated first chromogenic material dispersed in a radiation curable material, said first coating being applied to said first surface in fluid form;
(d) applying a second non-aqueous, solvent-free coating of a second chromogenic material to at least a portion of the front surfaces of all except one paper substrate of said plurality of paper substrates, said second chromogenic material being a color developer being reactive with said color precursor to form an image said second non-aqueous, solvent-free coating comprising said color developer dispersed in a radiation curable material;
(e) setting said first and said second non-aqueous, solvent-free coatings by means of exposure to radiation;
(f) collating said plurality of paper substrates into a single manifold form such that coreactive chromogenic materials are in facing relationship, said collating being such that the front surface of the topmost substrate in said manifold substrate has said printing ink applied thereto but does not have any non-aqueous, solvent-free coating, and such that the bottommost back surface of said manifold substrate has not been coated or printed and such that the paper substrates of said plurality of paper substrates between said topmost and said bottommost paper substrates are coated on both said front and back surfaces;
(g) placing said collated paper substrates in contiguous relationship to one another to create a manifold form; and (h) finishing said manifold form, said finishing including the steps of:
(1) fixably combining said plurality of collated continuous paper substrates into a single manifold substrate;

(2) dividing said single manifold substrate into a plurality of sheets, each sheet of said plurality of sheets being dimensioned for use as a manifold carbonless form;
(3) stacking said sheets; and (4) packaging said stacked sheets.

19. A process for the production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a continuous paper substrate, said continuous paper substrate having a front and back surface;
(b) applying a printing ink to said front surface of said continuous paper substrate, said printing ink being applied in a pattern corresponding to a printed image;
(c) applying a first non-aqueous, solvent-free coating of a capsular first chromogenic material onto said back surface of said continuous paper substrate said first non-aqueous, solvent-free coating comprising said encapsulated first chromogenic material dispersed in a hot melt suspending medium, said first coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said back surface;
(d) setting said first coating by means of temperature decrease to form a printed, coated continuous paper substrate;
(e) combining said printed, coated continuous paper substrate with from about 1 to about 5 additional continuous paper substrates to form a plurality of paper substrates having a front and a back surface, a second non-aqueous, solvent-free coating of a second chromogenic material being applied to said front surface of at least one of said additional continuous paper substrates, said second non-aqueous, solvent-free coating comprising said second chromogenic material dispersed in a radiation curable material, said second coating being applied in fluid form to said front surface, said second chromogenic material being reactive with said first chromogenic material to form a color;
(f) setting said second non-aqueous, solvent-free coating by means of exposure to radiation;
(g) collating said plurality of continuous paper substrates such that said first and second chromogenic materials are in facing relationship to a coreactive chromogenic material;
(h) placing said collated paper substrates in contiguous relationship to one another to create a manifold form; and (i) finishing said manifold form.

20. A process for the production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a continuous paper substrate, said continuous paper substrate having a front and back surface;
(b) applying a printing ink to said front surface of said continuous paper substrate, said printing ink being applied in a pattern corresponding to a printed image;
(c) applying a first non-aqueous, solvent-free coating of a capsular first chromogenic material onto said back surface of said continuous paper substrate said first non-aqueous, solvent-free coating comprising said encapsulated first chromogenic material dispersed in a radiation curable material, said first coating being applied in fluid form;
(d) setting said first coating by means of exposure to radiation to form a printed coated continuous paper substrate;
(e) combining said printed, coated continuous paper substrate with from about 1 to about 5 additional continuous paper substrates to form a plurality of paper substrates, each of said additional continuous paper substrates having a front and a back surface, a second non-aqueous, solvent-free coating of a second chromogenic material being applied to and set on said front surface of at least one of said additional continuous paper substrates, said second non-aqueous, solvent-free coating comprising said second chromogenic material dispersed in a hot melt suspending medium, said second coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said second coating composition to said front surface, said second chromogenic material being reactive with said first chromogenic material to form a color;
(f) setting said second non-aqueous, solvent-free coating by means of temperature decrease;
(g) collating said plurality of continuous paper substrates such that said first and second chromogenic materials are in facing relationship to a coreactive chromogenic material;
(h) placing said collated paper substrates in contiguous relationship to one another to create a manifold form; and (i) finishing said manifold form.

21. A process for the production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a continuous web said continuous web having a first and second surface;
(b) marking said second surface of said continuous web with a pattern;
(c) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of said continuous web said first non-aqueous, solvent-free coating comprising said first chromogenic material dispersed in a hot melt suspending medium, said coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said first surface;
(d) setting said first coating by means of temperature decrease to form a marked, coated continuous web;
(e) combining said printed, coated continuous web with at least one additional continuous web to form a plurality of continuous webs, (i) each of said additional continuous webs having a first and second surface, (ii) each of said additional continuous webs being characterized by having at least a portion of the second surface thereof coated with a second chromogenic material, said second chromogenic material being coreactive with said first chromogenic material to form a color, (iii) each of said additional continuous webs being further characterized by at least a portion of the first surface thereof being coated with at least one non-aqueous, solvent-free coating of said first chromogenic material, said non-aqueous, solvent-free coating on said first surface of each of said additional continuous webs comprising said first chromogenic material dispersed in a hot melt suspending medium, (iv) said coating on said first surface of each of said additional continuous webs being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application thereof, (f) setting said coating on said first surface of each of said additional continuous webs by means of temperature decrease;
(g) collating said plurality of printed, coated continuous webs such that coreactive chromogenic materials are in facing relationship; and (h) placing said collated continuous webs in contiguous relationship to one another to create a manifold carbonless form.

22. A process for the production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a continuous web said continuous web having a first and second surface;
(b) marking said second surface of said continuous web with a pattern;
(c) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of said continuous web said first non-aqueous, solvent-free coating comprising said first chromogenic material dispersed in a radiation curable material, said first coating being applied to said first surface in fluid form;
(d) setting said first coating by means of exposure to radiation to form a marked, coated continuous web;
(e) combining said printed, coated continuous web with at least one additional continuous web to form a plurality of continuous webs, (i) each of said additional continuous webs having a first and second surface, (ii) each of said additional continuous webs being characterized by having at least a portion of the second surface thereof coated with a second chromogenic material, said second chromogenic material being coreactive with said first chromogenic material to form a color;
(iii) each of said additional continuous webs being further characterized by at least a portion of the first surface thereof being coated with at least one non-aqueous, solvent-free coating of said first chromogenic material, said non-aqueous, solvent-free coating on said first chromogenic material dispersed in a radiation curable material;
(iv) said coating on said first surface of each of said additional continuous webs being applied in fluid form;
(f) setting said coating on said first surface of each of said additional continuous webs by means of exposure to radiation;
(g) collating said plurality of printed, coated continuous webs such that coreactive chromogenic materials are in facing relationship; and (h) placing said collated continuous webs in contiguous relationship to one another to create a manifold carbonless form.

23. A process for the continuous production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a plurality of continuous webs; each of said continuous webs having a first and second surface;
(b) advancing each web of said plurality of continuous webs at substantially the same speed, said plurality of continuous webs being spaced apart and being advanced in a cooperating relationship with one another;
(c) marking at least one surface of at least one web of said plurality of continuous webs with a pattern;
(d) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of at least one web of said plurality of continuous webs, said first non-aqueous, solvent-free coating comprising said first chromogenic material dispersed in a hot melt suspending medium, said coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said first surface;
(e) setting said first coating by means of temperature decrease;
(f) applying a second coating of a second chromogenic material to at least a portion of said second surface of at least one web of said plurality of continuous webs, said second coating comprising said second chromogenic material dispersed in a hot melt suspending media, said second coating being heated to a temperature above the melting point of said hot melt suspending media to permit fluid application of said second coating composition to said second surface, said second chromogenic material being reactive with said first chromogenic material to form a color;
(g) setting said second coating by means of temperature decrease;
(h) collating said plurality of continuous webs such that said first and said second chromogenic materials are in facing relationship to a coreactive chromogenic material;
and (i) placing said collated continuous webs in contiguous relationship to one another to create a manifold form.

24. The process of claim 23 further comprising the step of finishing said collated, contiguous webs wherein said finishing step includes:
(a) fixably combining said plurality of collated, contiguous webs into a single manifold substrate;
(b) dividing said single manifold substrate into a plurality of sheets, each sheet of said plurality of sheets being dimensioned for use as a manifold carbonless form;

(c) stacking said sheets; and (d) packaging said stacked sheets.

25. The process of claim 23 wherein said continuous webs are paper.

26. The process of claim 23 wherein said plurality of continuous webs comprise from about 2 to about 6 continuous webs.

27. The process of claim 23 wherein said marking is by means of printing.

28. The process of claim 23 wherein said marking is by offset printing means.

29. The process of claim 23 wherein said application of said first non-aqueous, solvent-free coating is by means of printing.

30. The process of claim 23 wherein said hot melt suspending media comprises a low molecular weight polar wax.

31. The process of claim 23 wherein said first coating composition is applied to from about 30% to about 70% of the surface area of at least one continuous web of said plurality of continuous webs.

32. A process for the continuous production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a plurality of continuous webs; each of said continuous webs having a first and second surface;
(b) advancing each web of said plurality of continuous webs at substantially the same speed, said plurality of continuous webs being spaced apart and being advanced in a cooperating relationship with one another;
(c) marking at least one surface of at least one web of said plurality of continuous webs with a pattern;

(d) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of at least one web of said plurality of continuous webs, said first non-aqueous, solvent-free coating comprising said first chromogenic material dispersed in a hot melt suspending medium, said coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said first surface;
(e) setting said first coating by means of temperature decrease;
(f) applying a second coating of a second chromogenic material to at least a portion of said second surface of at least one web of said plurality of continuous webs, said second coating comprising said second chromogenic material dispersed in a radiation curable material, said second coating being applied to said second surface in fluid form, said second chromogenic material being reactive with said first chromogenic material to form a color;
(g) setting said second coating by means of exposure to radiation;
(h) collating said plurality of continuous webs such that said first and said second chromogenic materials are in facing relationship to a coreactive chromogenic material;
and (i) placing said collated continuous webs in contiguous relationship to one another to create a manifold form.

33. The process of claim 32 wherein said radiation curable material comprises a mixture of ethylenically unsaturated organic compounds, a portion of said compounds having one terminal ethylenic group per molecule and another portion of said compound having more than one terminal ethylenic group per molecule.

34. The process of claim 32 wherein said radiation is ultra-violet radiation.

35. The process of claim 32 wherein said radiation is electron beam radiation.

36. A process for the continuous production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a plurality of continuous paper substrates, each of said continuous paper substrates having a first and second surface, said plurality of continuous paper substrates including from about 2 to about 6 continuous paper substrates;
(b) advancing each substrate of 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) applying a printing ink to said second surface of at least one continuous paper substrate of said plurality of continuous paper substrates, said printing ink being applied in a pattern corresponding to a printed image;
(d) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of at least one web of said plurality of continuous webs, said first non-aqueous solvent-free coating comprising said first chromogenic material in capsular form dispersed in a hot melt suspending medium, said first coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said first surface;
(e) setting said first coating by means of temperature decrease.
(f) applying a second non-aqueous, solvent-free coating of a second chromogenic material to at least a portion of said second surface of at least one web of said plurality of continuous webs, said second non-aqueous, solvent-free coating comprising said second chromogenic material dispersed in a hot melt suspending medium, said second coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said second coating composition to said second surface, said second chromogenic material being reactive with said first chromogenic material to form a color;
(g) setting said second coating by means of temperature decrease;
(h) collating said plurality of continuous webs such that said first and said second chromogenic materials are in facing relationship to a coreactive chromogenic material;
(i) placing said collated continuous webs in contiguous relationship to one another to create a manifold form;
(j) finishing said manifold form, said finishing including the steps of:
(1) fixably combining said plurality of collated contiguous paper substrates into a single manifold substrate;
(2) dividing said single manifold substrate into a plurality of sheets, each sheet of said plurality of sheets being dimensioned for use as a manifold carbonless form;
(3) stacking said sheets; and (4) packaging said stacked sheets.

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

(a) providing a plurality of continuous paper substrates, each of said continuous paper substrates having a first and second surface, said plurality of continuous paper substrates including from about 2 to about 6 continuous paper substrates;
(b) advancing each web of said plurality of continuous webs at substantially the same speed, said plurality of continuous webs being spaced apart and being advanced in a cooperating relationship with one another;
(c) applying a printing ink to said second surface of at least one continuous paper substrate of said plurality of continuous paper substrates, said printing ink being applied in a pattern corresponding to a printed image;
(d) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said second surface of at least one web of said plurality of continuous webs, said first non-aqueous, solvent-free coating comprising said first chromogenic material in capsular form dispersed in a hot melt suspending medium, said first coating being heated to a temperature above the melting point of said hot melt suspending medium to permit fluid application of said first coating composition to said second surface;
(e) setting said first coating by means of temperature decrease;
(f) applying a second non-aqueous, solvent-free coating of a second chromogenic material to at least a portion of said second surface of at least one web of said plurality of continuous webs, said second non-aqueous, solvent-free coating comprising said second chromogenic material dispersed in a radiation curable material, said second coating being applied to said second surface in fluid form, said second chromogenic material being reactive with said first chromogenic material to form a color;
(g) setting said second non-aqueous, solvent-free coating by means of exposure to radiation;
(h) collating said plurality of continuous webs such that said first and said second chromogenic materials are in facing relationship to a coreactive chromogenic material;
(i) placing said collated continuous webs in contiguous relationship to one another to create a manifold form;
(j) finishing said manifold form, said finishing including the steps of:
(1) fixably combining said plurality of collated contiguous paper substrates into a single manifold substrate;
(2) dividing said single manifold substrate into a plurality of sheets, each sheet of said plurality of sheets being dimensioned for use as a manifold carbonless form;
(3) stacking said sheets; and (4) packaging said stacked sheets.

38. A process for the continuous production of a manifold carbonless form having two or more surfaces coated with chromogenic material comprising:
(a) providing a plurality of continuous paper substrates, each of said continuous paper substrates having a first and second surface, said plurality of continuous paper substrates including from about 2 to about 6 continuous paper substrates;
(b) advancing each substrate of said plurality of continuous substrate at substantially the same speed, said plurality of continuous substrates being spaced apart and being advanced in a cooperating relationship with one another;
(c) applying a printing ink to said second surface of at least one continuous paper substrate of said plurality of continuous paper substrates, said printing ink being applied in a pattern corresponding to a printed image;
(d) applying a first non-aqueous, solvent-free coating of a first chromogenic material to at least a portion of said first surface of at least one web of said plurality of continuous webs, said first non-aqueous, solvent-free coating comprising said first chromogenic material in capsular form dispersed in a radiation curable material, said first coating being applied to said first surface in fluid form;
(e) setting said first coating by means of exposure to radiation;
(f) applying a second non-aqueous, solvent-free coating of a second chromogenic material to at least a portion of said second surface of at least one web of said plurality of continuous webs, said second non-aqueous, solvent-free coating comprising said second chromogenic material dispersed in a radiation curable material, said second coating being applied to said second surface in fluid form, said second chromogenic material being reactive with said first chromogenic material to form a color;
(g) setting said second coating by means of exposure to radiation;
(h) collating said plurality of continuous webs such that said first and said second chromogenic materials are in facing relationship to a coreactive chromogenic material;
(i) placing said collated continuous webs in contiguous relationship to one another to create a manifold form;
(j) finishing said manifold form, said finishing including the steps of:
(1) fixably combining said plurality of collated contiguous paper substrates into a single manifold substrate;

(2) dividing said single manifold substrate into a plurality of sheets, each sheet of said plurality of sheets being dimensional for use as a manifold carbonless form;
(3) stacking said sheets; and (4) packaging said stacked sheets.

39. The process of claim 32 wherein said first coating composition is applied to from about 30% to about 70% of the surface area of at least one continuous web of said plurality of continuous webs.