The present invention provides a thermal paper composite precursor comprising (a) a substrate layer; and (b) a base layer positioned on the substrate layer, the base layer comprising a binder and at least one porosity improver wherein the thermal paper composite precursor has a thermal effusivity that is at least about 2% less than the thermal effusivity of porosity improver-less thermal paper composite precursor. The thermal paper composite precursor is useful in making thermal paper composite.
1. Thermal paper composite comprising:
(1) an active layer containing image forming components; and
(2) a thermal paper composite precursor comprising
a) a substrate layer; and
(b) a base layer positioned on the substrate layer, the base layer comprising a binder, calcined kaolin, and at least one porosity improver, wherein said thermal paper composite precursor has a thermal effusivity that is at least about 2% less than the thermal effusivity of porosity improver-less thermal paper composite precursor,
wherein said calcined kaolin in said base layer has at least one of: at least about 70% by weight of the particles having a size of 2 microns or less, at least about 50% by weight of the particles have a size of 1 micron or less, a surface area of at least about 5 m 2 /g, and a pore volume of at least about 0.1 cc/g,
wherein if said at least one porosity improver is not a calcined clay then said at least one porosity improver has at least one of: at least about 70% by weight of the particles have a size of 2 microns or less, at least about 50% by weight of the particles have a size of 1 micron or less, a surface area of at least about 10 m 2 /g, and a pore volume of at least about 0.1 cc/g; and if said at least one porosity improver is a calcined clay then said at least one porosity improver has at least one of: at least about 70% by weight of the particles having a size of 2 microns or less, at least about 50% by weight of the particles have a size of 1 micron or less, a surface area of at least about 5 m 2 /g, and a pore volume of at least about 0.1 cc/g.
2. The thermal paper of claim 1 wherein said at least one porosity improver in said base layer is calcined bentonite.
3. The thermal paper of claim 1 wherein said at least one porosity improver in said base layer is selected from the group consisting of silica, silica gel, and zeolite.
4. The thermal paper of claim 1 wherein said thermal paper composite precursor has a thermal effusivity that is at least about 5% less than the effusivity of porosity improver-less thermal composite precursor.
5. The thermal paper of claim 1 wherein said thermal paper composite precursor has a thermal effusivity that is at least about 10% less than the effusivity of porosity improver-less thermal composite precursor.
6. The thermal paper of claim 1 wherein said thermal paper composite precursor has a thermal effusivity that is at least about 15% less than the effusivity of porosity improver-less thermal composite precursor.
7. The thermal paper of claim 1 wherein said at least one porosity improver is silica.
8. The thermal paper of claim 1 wherein said at least one porosity improver is zeolite.
9. The thermal paper composite of claim 1 wherein said at least one porosity improver is selected from the group consisting of flash calcined kaolin, calcined bentonite, acid treated bentonite, high surface area alumina, hydrated alumina, boehmite, flash calcined alumina trihydrate, silica, silica gel, zeolite, zeotypes, non-zeotype molecular sieves, clathrasils, macroporous particles, mesoporous particles, macroporous particles, alumina phosphates, metal alumina phosphates, mica, and pillared clays.
10. The thermal paper composite of claim 1 , wherein the pore volume of the base layer is between 0.170 cc/g and 0.225 cc/g.
11. The thermal paper composite of claim 1 , wherein said at least one porosity improver is selected from the group consisting of silica and zeolite, and wherein the pore volume of the base layer is about 0.225 cc/g.