[0001] The present invention relates to a process for curing and setting emulsified particles
using a new coating solution in which a remarkably superior productivity is achieved.
More specifically, the present invention relates to a carbonless pressure- sensitive
recording sheet using this process.
[0002] Hitherto, microcapsule formation is known as an effective means for curing and setting
emulsified particles. The content, the so-called core material, of microcapsules includes
pharmaceuticals, agricultural chemicals, perfumes, dyestuffs, liquid crystals, temperature-indicating
materials, adhesives and the like. The microcapsules are used in a broad field with
the view to the curing of a core material, the control of the release of a core material,
the control of a reaction, the solidification of a liquid and the like. One of the
applications in large scales lies in the field of carbonless pressure-sensitive recording
sheets, wherein the process for producing microcapsules requires high control techniques.
[0003] As the microcapsule-formation by a chemical method, the two following processes are
known.
(1) Coacervation process using a phase separation of a water-soluble polymer, such
as gelatin, etc. Only a capsule dispersion of a low consistency is obtained, and there
are difficulties in the complicate steps, the long production time, the stability,
decomposition and water-resistance.
(2) Interfacial polymerization process or in situ polymerization process forming capsule
walls composed of synthetic resin films such as polyurethane resin films, polyurea
resin films, polyamide resin films, urea-formaldehyde resin films, melamine-formaldehyde
resin films and the like.
[0004] The obtained synthetic resin film of capsules has a sufficient hardness and compactness,
and is superior in heat, humidity and solvent resistance. This film allows a high
consistency coating, which causes a wide applicability. In the reaction for forming
a synthetic resin film, the unreacted monomer, such as formaldehyde, isocyanates,
polyamines, etc. remains in the microcapsule slurry, and therefore much time and labor
is required to remove the unreacted monomers, involving the risk of injuring the capsule
film properties. In any conventional capsule-forming method, an emulsification, a
capsule-forming reaction and a capsule treating step are necessary.
[0005] Then, the coating solution produced from the microcapsules, is applied onto a flexible
substrate by using various coating means. For example, however, air knife coater,
bar coater, curtain coater, blade coater and the like are useful if a large amount
of coating is to be applied but are not suitable for a partial coating matching to
a minor production of various kinds. The partial printing with silkscreen system,
gravure system, flexo system, etc. does not provide a sufficient performance in point
of the coating characteristics of the microcapsule dispersion formed in a hydrophilic
medium, and is not suitable for the minor production of many kinds. As a result, these
are not suitable to meet various quality requirements of a minor production in using
microcapsule-forming process.
[0006] The transfer recording papers using no microcapsule-forming process are employed
in wide fields, as seen in back-carbon papers. These socalled carbonless pressure-sensitive
recording sheets using no microcapsule-forming process are as follows. In the use
of a carbonless dye precursor as a recording agent, for example, Japanese Patent Laid-Open
Application No. 57-77410 discloses a process for producing a carbonless pressure-sensitive
recording material providing, between a flexible substrate and an upper coating layer
of a curing layer, an intermediate layer of porous filling substances impregnated
in a liquid medium in which a colorless or pale-colored dye precursor is dissolved
or dispersed. Further, Japanese Patent Laid-Open Application No. 54-74111 discloses
a process for producing a carbonless pressure-sensitive recording material which uses
a coating solution composed of both a wax or a mixture of waxes dissolving a carbonless
dye precursor and an oily and/or fatty-substance as a fluidizing agent. Japanese Patent
Laid-Open Application No. 56-60289 discloses a process for producing a carbonless
pressure-sensitive recording paper which is produced by the application of an aqueous
dispersed coating solution composed of both a high oil-absorbing powder impregnated
with a hydrophobic liquid dissolving a carbonless dye precursor and a higher fatty
acid amide or a mixture of other waxes therewith.
[0007] However, the above-described carbonless pressure-sensitive recording papers exhibit
the following disadvantages in comparison with the carbonless pressure-sensitive recording
papers using a microcapsule-forming process:
(1) Insufficient preservability,
(2) Waxy luster on the coating surface,
(3) Slow coating speed, and the like.
Therefore, they are not brought to the market, and not put into practical use.
[0008] As examples of photopolymerization curable capsules, Japaneses Patent Laid-Open Application
No. 60-7931 discloses a process for a microcapsule-forming reaction in a short time
by irradiating a reaction vessel with light, in which the time is too long to achieve
a practically useful capsule production (production of 100 kg/hr)
[0009] The present invention, which changes remarkably the conception about curing and setting
the conventional emulsified particles, provides both a process for curing and setting
the emulsified particles efficiently and a pressure-sensitive recording paper obtainable
in high productivity by using this process.Practically, the present invention has
following advantages.
(1) The microcapsule-forming process does not require a complicated and high-level
control.
(2) Superior curing and release control without a microcapsule -forming process.
(3) Applicability of various coating methods.
[0010] The above subjects are achieved by a process for curing and setting emulsified particles
contained in an emulsion comprising a photo- or radiation- curable material, which
process comprises curing the photo- or radiation- curable material by the irradiation
with light or radiation in a coating process.
[0011] Further, the carbonless pressure-sensitive recording sheet of the present invention
is obtained by the application of the above process for curing and setting emulsified
particles in an emulsion containing a carbonless dyestuff, a coat-surface treating
agent composed of at least a white color pigment or filler, a buffer agent for a pressure-sensitive
recording paper and a binder. The carbonless pressure-sensitive recording sheet of
the present invention allows a partial printing, which was only insufficiently possible
with the conventional carbonless pressure-sensitive recording sheets.
[0012] Fig. 1 shows a process-diagram indicating the process-time of the Examples and the
Comparative Example.
[0013] In the present invention, a photo- or radiation- curable material is cured by the
irradiation with light or radiation in a coating process. In this case, "the coating
process" means "before, in, or after" adhesion of the emulsion on a substrate. The
photo- or radiation-curable material of the present invention includes any of the
well-known photo- or radiation curable materials, and is preferably at least one of
monomers and oligomers having following properties.
(1) Soluble or dispersible in emulsified particles.
(2) Compatible with the ingredients in the emulsified particles.
(3) Very slight toxity and odor after curing by light or radiation.
(4) Film formability, and possibility of enclosing a liquid as emulsified particles
in the film.
In applying the process of the present invention to a carbonless pressure-sensitive
recording sheet, the following points must be satisfied.
(5) Neither coloring hinderance nor desensitized function for a color-developing agent.
(6) Almost no skin irritation.
[0014] Practically, taking the use and its condition of the emulsion into consideration,
the following compounds are used, for example, aliphatic methacrylate, cyclic aliphatic
di(meth)acrylate, aliphatic di(meth)acrylate, aliphatic tri(meth)acrylate, aliphatic
tetra(meth)acrylate, aromatic (meth)acrylate, epoxy(meth)acylate, glycerol(meth)acrylate,
2-hydroxyalkyl(meth)acrylate,methoxyalkylene (meth)acrylate, methoxydialkylene(meth)acrylate,
methoxy-tri-alkylene (meth)acrylate, methoxytetraalkylene (meth)acrylate, methoxy
polyalkylene (meth)acrylate, oligoester (meth)acrylate, pentaerythritol (meth)acrylate,
pentaerythritol tetra(meth)acrylate, alkylmodified dipentaerythritol tetra(meth)acylate,
alkylmodified dipentaerythritol penta (meth)acrylate,
phenoxyalkyl(meth)acrylate, polyalkylene glycol (meth)acrylate, polyalkyleneglycol
di(meth)acrylate, phenoxy dialkylene glycol (meth)acrylate, alkyleneoxide modified
phosphoric acid di(meth)acrylate, alkyleneoxide modified phosphoric acid tri(meth)acrylate,
alkylene modified phthalic acid (meth)acrylate, polybutadiene (meth)acrylate, polybutadiene
urethane (meth)acrylate, polyester (meth)acrylate, polyoxyalkyl di(meth)acrylate,
alkylene oxide modified trimethylol alkyl(meth)acrylate, alkylene oxide modified trimethylol
alkyl di(meth)acrylate, alkylene oxide modified trimethylol alkyl tri(meth)acrylate,
urethane (meth)acrylate, polyester (meth)acrylate, epoxy (meth)acrylate, alkylene
modified bisphenol A, di (meth)acrylate, metal di(meth)acrylate, N-vinyl pyrrolidone.
[0015] The above compounds are used alone or in combination.
[0016] The addition amount of a photo- or radiation- curable material varies with the intended
use , but is in the range of 1-20 % by weight, based on the emulsified particles,
in the carbonless pressure- sensitive recording sheet. In using light for cure-action,
a photo-curing initiator and a sensitizer must be used in addition to the above photo-
or radiation curable material. The photo-curing initiator, which is the conventional
agent for UV curing,includes, for example, acrylated benzophenone, benzil, benzoylalkylether,
benzophenone, xanthone thioxanthone, acetophenone, hydroxy phenyl ketone and the like.
The addition amount of the photo-curing initiator is in the range of 0.1-20 % by weight,
based on the photo- or radiation- curable material. In using radiation for cure-action,
the above photo-or radiation- curable material can be employed, wherein the amount
used is in the range of 1-20 % by weight, based on the hydrophobic substance. If necessary,
the photo-curing initiator and sensitizer used for the above photo-curing can be applicable
again.
[0017] In carbonless pressure-sensitive recording sheets, the emulsified particles are formed
by dissolving a colorless dyestuff for carbonless pressure-sensitive recording sheets
in a hydrophobic liquid composed of the usual oil for carbonless pressure-sensitive
recording sheets, and the emulsion is obtained by emulsifying the above particles
in the aqueous solution of a water soluble emulsifier as a hydrophobic core substance.
In this case, the photo- or radiation-curable material is preferably added to the
hydrophobic core substance by dissolution, but it can also be added to the continuous
phase of the emulsion or to both.
[0018] The water-soluble emulsifier, which is preferably that for the usual process of pressure-sensitive
recording capsules, includes, for example, an acrylic acid polymer, maleic anhydride
copolymer, styrene-sulfonic acid copolymer ,polyvinyl alcohol, gelatin,carboxy methylcellulose,
casein, starch, gum arabic and the like. If necessary, a small amount of a surface
active agent can be used.
[0019] The size of the emulsified particles varies with the uses,but is most preferably
in the range of 0.1-5µ. In the use of carbonless pressure-sensitive recording papers,
a size of less than 0.1µ provides an inferior color-forming effect, which tends to
cause troubles in obtaining multiple copies. A size of more than 5µ causes troubles
in stabilizing the emulsified particles in the coating, so that an uniform coating
is difficult to achieve. Further, a particle size of more than 5µ on a substrate is
not preferable, since it causes a smudge in the color-formation by unusual pressure.
[0020] In a process for producing a carbonless pressure-sensitive recording sheet obtained
by the process for curing and setting the emulsified particles of the present invention,
a coat-surface-treating agent must be added into the continuous phase of the emulsion.
[0021] The coat-surface-treating agent has the five following functions.
(1) Effective prevention of the permeation of the emulsified substance into a substrate,
(2) Improvement of the film-forming effect by light or radiation,
(3) Acquirement of printability,
(4) Improvement of whiteness,
(5) Control of sheet formation,
[0022] For this purpose, coating pigments and paper fillers are effectively used. The above
pigments and fillers include, for example, kaolin, calcium carbonate, magnesium carbonate,
titanium dioxide, aluminum hydroxide, aluminum oxide, amorphous silica and silicate,
satin white, talc, zinc oxide, barium sulfate and plastic pigment. These pigments
and fillers can be used alone,but preferably in combination. Practically, the use
of at least 10% of titanium dioxide, based on pigment and filler, provides the aimed
sheet.
[0023] In the process for producing carbonless pressure-sensitive recording sheets, a buffer
agent must be added thereto. The buffer agent, which is that for a pressure-sensitive
recording sheet, includes, for example, pulp powder, starch particles, glass beads,
plastic beads, polyolefine particles, etc. These agents are appropriately added thereto
for the purpose of preventing the rupture of the emulsified particles after forming
films by the irradiation with light or radiation.
[0024] As binders, photo- or radiation-curable binders are effective, in addition to binders
for pressure-sensitive recording sheets. The usual binders include, for example, water-soluble
natural polymers such as gelatin, albumine, caseins, starch powder, celluloses, gums
and the like; and water-soluble synthetic polymers such as polyvinyl alcohol, polyvinyl
pyrrolidone, polyacrylic acid copolymers, maleic anhydride copolymers,polyacrylic
amide and the like. Further, binders include latexes, such as styrene-butadiene copolymer,
acrylonitrile-butadiene copolymer, acrylic ester-base latex, vinyl acetate-base latex,
methyl methacrylate butadiene-base latex and carboxylated latex thereof, etc.
[0025] The photo- or radiation-curable binders include, for example, partial cinnamoyl esters
of polyvinyl alcohol, amylose, starch, alginic acid and the like; cinnamylidene acetic
ester; cyanocinnamylidene acetic ester; water-soluble acrylic esters; polyalkylene
glycol acrylamides; and the like. The above binders can be used alone or in combination.
[0026] To the binder, there are added, optionally, dispersing agents, surface active agents,
antifoamers, antiseptics, fluorescence dyestuffs, cross-linking agents, photo initiators,
sensitizers and the like.
[0027] The obtained emulsified substance can be applied onto a substrate by mass production
coaters, for example, air knife coater, roll coater, blade coater, bar coater, curtain
coater, etc. In printing systems, the coating can be applied by a printer, such as
gravure-, flexo-, screen- or letterpress-printers fitted with a light-irradiation
or radiation installation.
[0028] In the process for coating a substrate with the emulsified substance containing a
photo- or radiation-curable material, these curable material is promptly polymerized
to form a cure-film, which cures and sets emulsified particles in an emulsion.
(Examples)
[0029] Examples for carbonless pressure-sensitive recording sheets are described in order
to explain the present invention . However, the present invention is in no way limited
to these Examples.
[0030] Hereinafter, parts and % mean parts by weight and % by weight, respectively.
Example 1
(Preparation of an emulsion containing both a color-forming agent and a photo- or
radiation-curable material)
[0032] 85 parts of a 10% aqueous polyvinyl alcohol(trade name:Gosenol GL-05, manufactured
by The Nippon Synthetic Chemical Industry., Ltd.) and 30 parts of water were charged
in a vessel with an agitator to prepare a hydrophilic medium for the emulsification.
132 parts of isopropyl naphthalene (trade name: KMC oil, manufactured by Kureha Chemical
Industry Co., Ltd.), and 4 parts of crystal violet lactone were dissolved in the hydrophilic
medium. On the other hand, a hydrophobic solution was prepared by dissolving 10 parts
polyurethane acrylate(trade name: Beam Set 575, manufactured by Arakawa Kagaku Kogyo
Co.) as a photo-curable material and 1 part of hydroxymethyl propiophenone(trade name:Daro
Cure 1173, manufactured by Merck Co.) as a photo-curing initiator. The obtained hydrophobic
solution was added to the hydrophilic medium, and was emulsified to an average particle
size of 2.1 µ to prepare a stable hydrophilic emulsion.
(Preparation of a coating solution)
[0033] A coat-surface-treating agent was prepared from 10 parts of a 60% aqueous dispersed
titanium dioxide solution and 25 parts of a 60% aqueous dispersed aluminum hydroxide
solution. 35 parts of wheat starch as a buffer agent were added to the coat-surface-treating
agent with agitation. After complete dispersing, 10 parts (as solid) of styrene-butadiene
base latex, 167 parts of the beforehand prepared emulsion containing both a color-forming
agent and a photo-curable material and 60 parts of water were further added thereto
to produce a coating solution.
(Coating and film-curing processes)
[0034] The above coating solution was coated on a fine paper of 40g/m² by means of a Meyer
bar to prepare a coated paper having a coating amount of 3.4 g/m². Then, the coated
paper was irradiated with UV rays in an irradiation distance of 10 cm and in a conveyer
speed of 1.5 m/min. by means of a 3 kW high voltage metal halide lamp to cure the
film. Thus, a top sheet for carbonless pressure-sensitive recording sheets was obtained.
The process and test results are summarized in Fig. 1 and Table 1.
Example 2
(Preparation of an emulsion containing a color-forming agent and a photo- or radiation-curable
material)
[0035] The emulsion of Example 2 was prepared in the same manner as the emulsion of Example
1 but without the photo-curing initiator.
(Preparation of a coating solution)
[0036] A coating solution was prepared in the same procedure as in Example 1.
(Coating and film-curing process)
[0037] The above coating solution was coated on a fine paper of 40 g/m² by means of a Meyer
bar to prepare a coated paper having a coating amount of 3.5 g/m². Then, a film curing
treatment was made using an acceleration voltage of 175 kV, an electron beam amount
of 5 M rad and an irradiation speed of 20 m/min. to prepare a top sheet for carbonless
pressure-sensitive recording papers. The process and test results are summarized in
Fig. 1 and Table 1.
Example 3.
(Preparation of an emulsion containing a color-forming agent and a photo- or radiation-curable
material)
[0038] 35 parts of a 25% aqueous acrylic acid-styrene sulfonic acid-acrylic ester copolymer
and 80 parts of water were charged in a vessel with an agitator to prepare a hydrophilic
medium for the emulsification. 132 parts of phenylxylylethane (main ingredient of
HYSOL SAS 296-trade name-, manufactured by NIPPON PETROCHEMICALS CO., LTD. ), 4 parts
of crystal violet lactone were dissolved in the hydrophilic medium, and further a
solution (as a hydrophobic substance) dissolving 10 parts of a polyfunctional oligoester
(trade name: Aronix M-400, manufactured by Toagosei Chemical Industry Co., Ltd.) as
an electron beam-curable material was added thereto. Then, the obtained solution was
emulsified to an average particle size of 1.5µ to prepare a stable hydrophile emulsion.
(Preparation of a coating solution)
[0039] A coat-surface treating agent was prepared from 10 parts of a 60% beforehand dispersed
titanium dioxide solution and 25 parts of a 60% aqueous calcium carbonate dispersion.
35 parts of wheat starch as a buffer agent were added to the coat-surface-treating
agent with stirring. After complete dispersing, 10 parts (as solid) of acrylic ester
base latex, 167 parts of the above hydrophilic emulsion containing a color-forming
agent and a radiation- curable material and 60 parts of water were added thereto to
prepare a coating solution.
(Coating and film-curing process)
[0040] The coating and film-curing processes were made according to the same procedure as
in Example 2 to prepare a top sheet for pressure-sensitive recording papers.
[0041] The processes and test results are summarized in Fig. 1 and Table 1.
Example 4
(Preparation of an emulsion containing a color-forming agent and a photo- or radiation-curable
material)
[0042] The emulsion of Example 4 was prepared in the same manner as in Example 1 except
that the hydrophilic emulsion of Example 1 was emulsified to an average particle size
of 0.5µ .
(Preparation of a coating solution)
[0043] A coat-surface-treating agent was prepared by mixing 20 parts of a 60% aqueous dispersed
titanium dioxide solution and 35 parts of a 60% aqueous calcium carbonate dispersion
having an average particle size of 1.7µ with stirring. After complete dispersing,
15 parts of acrylic ester base latex as a binder, 167 parts of the beforehand prepared
emulsion containing a color-forming agent and a photo-curable material and 20 parts
of water were added thereto to prepare a coating solution.
(Coating and film-curing process)
[0044] The above coating solution was coated on a fine paper of 40 g/m² in a coating amount
of 1.5g/m² by means of a flexo printer installed with an UV-irradiation equipment
(Irradiation condition: 3 kW metal halide lamp) under a coating speed of 5 m/min.
The coating was irradiated with UV rays in an irradiation distance of 7 cm to cure
a film. Thus, a particle coated top sheet for carbonless pressure-sensitive recording
papers was obtained. The process and test results are summarized in Fig. 1 and Table
1.
Comparative Example 1.
(Preparation of an capsule emulsion containing a color-forming agent)
[0045] 150 parts of a 3% aqueous ethylene maleic anhydride copolymer solution (trade name:EMA-31,
manufactured by Monsanto Chemical Co.) were adjusted to a pH-value of 4 with a 20%
aqueous sodium hydroxide solution to prepare a hydrophilic medium. 100 parts of alkylnaphthalene
(trade name: KMC oil, manufactured by Kureha Chemical Co.) and 37 parts of crystal
violet lactone were dissolved in the hydrophilic medium, and then emulsified to an
average particle size of 4.5µ .
(Encapsulating reaction)
[0046] A melamine-formaldehyde prepolymer , which was produced from 30 parts of formalin
and 10 parts of melamine at 60°C, was added to the above emulsion. The temperature
of the system was held at 60-70°C for 3 hours. After cooling to room temperature,
the system was adjusted to a pH-value of 7.5 by adding a 28% aqueous ammonia solution
thereto to prepare a microcapsule dispersion. The time required for preparing this
solution was 5 hours.
(Preparation of the coating solution)
[0047] 35 parts of wheat starch, 15 parts(as solid) of styrenebutadiene base latex and 2
parts (as solid) of polyvinyl alcohol were added to 100 parts of the microcapsule
dispersion. The obtained dispersion (the system) was diluted to 15% solids with water.
(Coating process)
[0048] The coating solution was coated on a base paper of 40 g/m² in a coating amount of
3.5 g/m² by means of a Meyer bar, and dried in an oven at 105°C for 60 sec. to prepare
a top sheet for pressure-sensitive recording papers. The process and test results
are summarized in Fig. 1 and Table 1.
(Comparative test of qualities)
[0049]
(1) Color-forming ability
An experimental top sheet was laid on a bottom sheet (manufactured by JUJO PAPER CO.,
LTD., No. 40) in such a way that the coated surfaces faced each other. The sheets
were treated by means of a supercalender to produce a color. After one hour, the image
density was measured by a Macbeth densitometer. (High value means a better color formation)
(2) Smudge caused by wearing
The experimental top sheet was laid on the above bottom sheet in such a way that the
coated surfaces faced each other. Then , the sheets were rubbed with each other 5
times under a load of 4kg/cm² . The color density of the coated surface of the bottom
sheet caused by the smudge was measured by means of color-difference meter.
( A lower value means a slight smudge)
(3) Smudge caused by static pressure
An experimental top sheet was laid on a bottom sheet in such a way that the coated
surfaces faced each other. The sheets were loaded under a pressure of 20 kg/cm² for
30 sec. The color density of the coated surface of the bottom sheet caused by the
smudge was measured by means of color-difference meter.
(A lower value means a slight smudge)
(4) Printability
In the coated part and the uncoated part of the experimental top sheet , shrinkage
and curl of the coated sheet were observed visually.

(Effects of the Invention)
[0050] A process for curing and setting emulsified particles contained in an emulsion by
irradiating with light or radiation was impossible hitherto.
[0051] The setting of the emulsified particles, which had been achieved only by an encapsulation
process, was performed very simply in the present invention. The present invention
provides carbonless pressure-sensitive recording papers which, as compared to conventional
pressure-sensitive recording paper have equal copying suitablity and can be prepared
in a simpler process and in a shorter time.The partial coating of the carbonless pressure-sensitive
recording sheet is possible owing to the improvement of printability.
[0052] From the above facts, the present invention provides the following effects:
(1) Simple preparation process and short preparation time owing to the omission of
a microencapsulating process which requires complicate and high-level control and
(2) a broad field of application in, for example, curing, release-control, reaction-control,
solidification of liquids, and the like with regard to pharmaceuticals, agricultural
chemicals, perfumes, dyestuffs, liquid crystals, temperature-indicating materials,
adhesives, etc. since the present invention provides a process for curing and setting
the emulsified particles.