Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H35/00—Delivering articles from cutting or line-perforating machines; Article or web delivery apparatus incorporating cutting or line-perforating devices, e.g. adhesive tape dispensers
  • B65H35/0006—Article or web delivery apparatus incorporating cutting or line-perforating devices
  • B65H35/0013—Article or web delivery apparatus incorporating cutting or line-perforating devices and applying the article or the web by adhesive to a surface
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
  • B44C1/16—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
  • B44C1/165—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
  • B44C1/17—Dry transfer
  • B44C1/1712—Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive
  • B44C1/1725—Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive using an intermediate support
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
  • B44C1/16—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
  • B44C1/165—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
  • B44C1/17—Dry transfer
  • B44C1/1733—Decalcomanias applied under pressure only, e.g. provided with a pressure sensitive adhesive
  • B44C1/1745—Decalcomanias applied under pressure only, e.g. provided with a pressure sensitive adhesive using an intermediate support
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
  • B44C1/16—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
  • B44C1/165—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
  • B44C1/175—Transfer using solvent
  • B44C1/1758—Decalcomanias applied under pressure only, e.g. provided with a pressure sensitive layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H37/00—Article or web delivery apparatus incorporating devices for performing specified auxiliary operations
  • B65H37/002—Web delivery apparatus, the web serving as support for articles, material or another web
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
  • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
  • B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
  • B29K2023/04—Polymers of ethylene
  • B29K2023/06—PE, i.e. polyethylene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
  • B29K2023/10—Polymers of propylene
  • B29K2023/12—PP, i.e. polypropylene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2555/00—Actuating means
  • B65H2555/30—Multi-axis
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S428/00—Stock material or miscellaneous articles
  • Y10S428/914—Transfer or decalcomania
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
  • Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1405—Capsule or particulate matter containing [e.g., sphere, flake, microballoon, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1438—Metal containing
  • Y10T428/1448—Coloring agent containing
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1467—Coloring agent
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1471—Protective layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1476—Release layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/14—Layer or component removable to expose adhesive
  • Y10T428/1481—Dissimilar adhesives
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24851—Intermediate layer is discontinuous or differential
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24851—Intermediate layer is discontinuous or differential
  • Y10T428/2486—Intermediate layer is discontinuous or differential with outer strippable or release layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24851—Intermediate layer is discontinuous or differential
  • Y10T428/24868—Translucent outer layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
  • Y10T428/2848—Three or more layers

Definitions

• U.S. Patent 5,840,407 describes pieces of optical film, each of which pieces has a layer of pressure-sensitive adhesive along one surface, and an opposite outer major surface (e.g., a grooved and/or vapor coated surface) so that the pieces visually simulate decorative glass such as glass with beveled edges, or with a groove along its length, or with a leaded appearance, or with a textured surface, or visually simulate glass related structures such as metal came.
• Such pieces of optical film have been applied to substrates (e.g., window panes) in predetermined patterns using automated application equipment, however, heretofore it has been very difficult for persons such as homeowners to apply such optical film on windows or other glass substrates with the precision needed so that it provides the desired visual simulation.
• substrates e.g., window panes
• a lubricating liquid is used to wet the substrate and/or the layers of adhesive included in the display lengths of decorative film and the layer of structured adhesive on the pre-mask material and the substrate before the step of placing the layers of adhesive included in the display lengths of decorative film and the layer of pre-mask material on the substrate.
• a portion of the lubricating liquid and/or entrained air is pressed out from between the layers of adhesive included in the display lengths of decorative film and the substrate. Most of the remaining lubricating liquid is allowed to evaporate before the step of removing the layer of pre-mask material.
• Figure 1 illustrates a first embodiment of a laminate made by a method according to the present invention, which laminate is adapted for use to decorate a substrate such as a pane or panes of glass and includes a plurality of display lengths of decorative film tape adhered to a release liner in a predetermined decorative pattern, and a layer of pre-mask material (only a fragment of which is shown) that is adhered over the display lengths of decorative film and to the release liner in areas not covered by the display lengths of decorative film tape;
• Figure 2 is an enlarged sectional view taken approximately along line 2-2 of Figure 1;
• Figure 3 is a fragmentary plan view of the laminate of Figure 1 after the release liner has been removed and the display lengths of decorative film tape and the layer of pre-mask material that is adhered over the display lengths of decorative film have been adhered to a substrate;
• Figure 4 is an enlarged fragmentary sectional view taken approximately along line 4-4 of Figure 3;
• Figure 5 is a fragmentary plan view of the display lengths of decorative film tape in the laminate of Figure 1 after they have been applied to the substrate and the overlaying layer of pre-mask material has been removed;
• Figure 6 is an enlarged fragmentary sectional view taken approximately along line 6-6 of Figure 5;
• Figure 7 illustrates a second embodiment of a laminate made by a method according to the present invention, which laminate is also adapted for use to decorate a substrate such as a pane or panes of glass and also includes a plurality of display lengths of decorative film tape adhered to a release liner in a predetermined decorative pattern, and a layer of pre-mask material (only a fragment of which is shown) that is adhered over the display lengths of decorative film and to the release liner in areas not covered by the display lengths of decorative film tape;
• Figure 8 is an isometric view of a tape applicator that can be used in the method according to the present invention, in which view a tape head included in the applicator is in a first position;
• Figure 9 is an isometric view of the tape applicator of Figure 8 in which the tape head is in a second position while applying decorative film tape to a sheet of release finer in the method according to the present invention
• Figure 10 is an enlarged isometric fragmentary view taken approximately along line 10-10 in Figure 8 which shows an x-axis actuator, a y-axis actuator, a rotary actuator, the tape head and a support arm for the rotary actuator included in the tape applicator of Figure 8;
• Figure 11 is an enlarged fragmentary isometric view of the tape applicator of Figure 8 showing the tape head rotated around a z-axis perpendicular to a planar support surface, the rotary actuator for rotating the tape head around that z-axis, and the support arm;
• Figure 12 is an enlarged fragmentary isometric view of a first side of the tape head of Figure 8.
• Figure 13 is an enlarged fragmentary isometric view of the first side of the tape head of Figure 8.
• Figure 14 is an enlarged fragmentary isometric view of a second side of the tape head of Figure 8 opposite its first side;
• Figure 18 is an enlarged fragmentary isometric view of the second side of the tape head of Figure 8, illustrating a second cutter of the tape head as it cuts the discrete length of decorative tape that was previously applied to the sheet of release liner;
• Figure 19 is a top view of a first discrete length of decorative film tape applied to a surface of the sheet of release liner, illustrating a sequence of cuts that can be made in that first discrete length of tape by the second cutter of the tape head;
• Figure 21 is a top view of a second discrete length of tape applied to the release liner illustrated in Figures 19 and 20 over the top of the first discrete length of decorative film tape after the scrap portion of that first discrete length of decorative film tape has been removed as illustrated Figure 20, which Figure 21 illustrates a sequence of cuts that can be made in the second discrete length of tape by the second cutter of the tape head;
• Figure 23 illustrates an alternate embodiment of a laminate for use to decorate a substrate such as panes of glass, made by a method according to the present invention.
• laminate 500 made by a method according to the present invention, which laminate 500 is adapted for use to decorate a substrate such as a pane or panes of glass in a window, a door, or a mirror.
• the laminate 500 includes a plurality of display lengths 502 of decorative film tape each (see Figure 2) comprising a length of decorative film 514, which display lengths 502 of decorative film tape are adhered to a major surface of a release liner 508 in a predetermined decorative pattern by layers 509 of pressure sensitive adhesive included in the display lengths 502 of decorative film tape; and a layer of pre-mask material 510 comprising a cover sheet or layer 511 and a layer 512 of removable adhesive firmly adhered to one surface of the cover layer 511 that has its surface opposite the cover layer 511 adhered to outer major surfaces of the display lengths of decorative film 514 opposite the release liner 508, and to the major surface of the release liner 508 in areas not covered by the display lengths 502 of decorative film tape.
• a layer of pre-mask material 510 comprising a cover sheet or layer 511 and a layer 512 of removable adhesive firmly adhered to one surface of the cover layer 511 that has its surface opposite the cover layer 511 adhered to outer major surfaces
• layer of pre-mask material 510 is typically coextensive with the release liner 508 and extends over all of the display lengths 502 of decorative film tape.
• the pre-mask material 510 can be opaque, translucent or transparent.
• the layer 512 can optionally be a structured adhesive, as discussed hereinafter.
• the length of decorative film 514 in each display length 502 of decorative film tape can have grooves, vapor coating and/or other structure along its outer major structured surface opposite the layer 509 of pressure-sensitive adhesive along its other major surface so that the decorative film 514 visually simulates decorative glass, such as glass with a single bevel, beveled edges, or with a central groove along its length (e.g., a N shaped groove), or with a leaded appearance, or with a textured surface, or visually simulate a glass related structure such as metal came (e.g., the pieces of optical film described in U.S. Patent No. 5,840,407 issued November 24. Tapes including a length of the type of optical film disclosed in U.S. Patent No.
• Scotchcal® (trade mark) Series 7725 special effects films.
• Scotchcal® (trade mark) 7725-314 Dusted Crystal Film gives the appearance of etched glass
• Scotchcal® (trade mark) 7725-324 Frosted Crystal Film gives the decorative appearance of sand-blasted glass.
• Each of these special effects vinyl films bears a layer of aggressive pressure-sensitive adhesive and a low- adhesion carrier web that protects the adhesive.
• the pressure-sensitive adhesive is selected to form strong bonds to the substrate 518, such as for example to glass.
• the layer of pre-mask material 510 allows transmission of moisture vapor between its major surfaces by means, including, but not limited to, being vented by passageways 516 through the cover layer 511 and the layer 512 of adhesive between their major surfaces, (e.g., the layer of pre-mask material described in U.S. Patent No. 5,749,994 issued May 12, 1998.
• the layer of pre-mask material 510 could be selected to allow passage of moisture to facilitate drying of a substrate to which the display lengths 502 of decorative film tape are adhered.
• dry or “drying” means the elimination of most of the moisture by evaporation. Complete elimination of all moisture is not required.
• Suitable materials for the cover layers 511 in such layers of pre-mask material could be polymers, paper, cellulose, non- wo en fiber or other woven material; and the layers 512 of removable adhesive could be formed from randomly laid adhesive strands between which strands spaces are left that permit the passage of moisture.
• Figures 23 and 24 illustrated an alternate laminate 600 made generally by the method of the present invention.
• the laminate 600 includes a plurality of display lengths 602 of decorative film 614.
• the passageways 616 may extend the entire thickness of the structured adhesive layer 612, or some portion thereof. That is, the passageways 616 may have a cross-sectional dimension along a z-axis equal to the spacing between the cover sheet 611 and the release liner 608. Alternatively, the passageways 616 have a cross- sectional dimension (e.g., diameter) less than the spacing between the cover sheet 611 and the release liner 608.
• the pre-mask material 610 is opaque, although transparent or translucent materials can also be used.
• the thickness of the decorative film 614 creates protrusions or ridges that are visible along the outer major surface 615 of the cover layer 611. Consequently, the user knows the location of the display lengths 602 even though the cover layer 611 is opaque.
• the outer major surface 615 of the cover layer 611 is preferably printable so that installation instructions and other information can be printed thereon.
• the adhesion of the adhesive layer 612 to the decorative film 614 must also be strong enough to withstand the installation process which currently involves contact with a significant amount of soapy water or other lubricating liquid.
• the premask material 610 should not release from the decorative film 614 until the installation process is complete to prevent misalignment of the display lengths 602.
• the adhesion must be low enough to permit effective removal of the premask material 610 after the decorative film 614 has been installed on the substrate 518 (window, door, etc) while the display lengths 602 remain attached to the substrate 518.
• the adhesion of the premask material 610 also should be relatively independent of storage conditions and length of time it is in contact with the decorative film 614.
• the passageways 616 can form a regular or an irregular pattern.
• the passageways can be linear or curved.
• the passageways 616 can be arranged in a variety of patterns, including regular patterns such as rectangular grid patterns, diamond grid patterns, a plurality of parallel passageways, and combinations thereof.
• Figure 24 illustrates the passageways as being generally rectangular, the actual shape of the passageways may vary depending upon the nature of the adhesive 612 used, the method of applying the adhesive to create the required structure, and a variety of other variables.
• the cross-sectional shape of the passageways 616 is not critical and can be trapezoidal, triangular, rectangular, spherical, curvilinear or any approximation of these shapes or alternatively, irregular shapes.
• Pattern coated adhesives, embossed adhesives, or a variety of other adhesive structures can also be used to form the passageways 616 in the structured adhesive 612.
• the density of passageways 616 can range from about 3 per centimeter to about 71 per centimeter.
• the passageways 616 have a height relative to the liner 608 of about 15 to about 45 micrometers and a width of about 50 micrometers to about 200 micrometers.
• the cross-sectional area of the passageways is preferably about 1000 square micrometers to about 10,000 square micrometers.
• structured adhesive refers to an adhesive layer having a plurality of passageways or channels, at least a portion of which extend to an edge thereof.
• the structured adhesive is typically formed on tooling with structural features that are the mirror image of the desired passageways. Since the structured adhesive can change and flow after leaving the tooling, reference to specific shapes, dimensions and other features of the structured adhesive are typically made with respect to the tooling.
• passageways can also be provided by discontinuous adhesive layers, provided, for example, by the application of adhesive material in stripes, dots, or other like patterns. Passageways may also be provided by use of adhesive microspheres or nonadhesive particulates incorporated into adhesive layers. Roughened adhesive layers, wherein the adhesive surface contains random bumps or other protrusions of adhesive material, can also provide passageways. Bumps or other protrusions can also be added to adhesive layers by printing or otherwise depositing adhesive or nonadhesive materials onto previously formed adhesive layers or by applying an adhesive over an adhesive or nonadhesive material (which may be in the shape of dots, strings or other types of protrusions).
• Passageways may also be provided in the adherent layer by use of open- structured materials such as open structured adhesives and open structured adhesive sublayers.
• open structured material refers to a material which, when placed between two surfaces, holds such surfaces apart while also providing an open path suitable for fluid flow between the spaced apart surfaces.
• Open structures can be provided by, for example, fibrous or porous adhesives.
• Adhesives provided in the form of blown microfibers can be used to provide an open structured adhesive layer having significant void space for fluid flow.
• Multi-layer adhesive systems are also contemplated.
• an open structured sublayer can be attached to a major surface of a film backing, with a porous or otherwise air transmissive adhesive layer attached to the sublayer.
• Suitable materials for the sublayer include blown microfiber structures and open celled foam materials.
• a commercially available structured adhesive is available from 3M Company of St. Paul, Minnesota under the trade designation "Comply”.
• a suitable pre-mask 610 with a structured adhesive is available from 3M Company of St. Paul, MN under the product designation VCC8198.
• Non-limiting examples of adhesives that can be used for the present structured adhesive include pressure sensitive adhesives, hot melt or heat activated adhesives that are pressure sensitive at the time of application such as pressure sensitive adhesives disclosed in U.S. Pat. No.
• the present structured adhesive 612 can be used with a variety of cover layers 611, such as polymers, paper, cellulose, non-woven fiber or other woven materials. In one embodiment, the structured adhesive 612 is used in combination with the perforated cover sheet 511 of Figure 1.
• the laminates 500 and 600 are assembled manually.
• Various fixtures and/or templates can be used to cut the decorative film to the required lengths and shapes, and to accurately position the decorative film on the release liner and/or the pre-mask.
• the fixtures and/or templates can be used to position the decorative film in the desired configuration prior to attaching the release liner and/or the pre-mask.
• the assembly of pre-mask, decorative film, release liner and adhesive layers is removed from the fixture and/or template and laminated using heat and/or pressure.
• the assembly can be laminated while still located on the fixture and/or template.
• the substrate or glass sheet 518 to which the display lengths 502 of decorative film tape are to be attached should be cleaned (e.g., with a liquid glass cleaner), and the wetting a lubricating liquid or solution (e.g., V ⁇ % (by weight) dishwashing detergent in water) from a squirt bottle should then be used to wet the layers of adhesive 508 and 512 included in the pieces of decorative film tape and in the layer of pre-mask material 510 and to wet the substrate 518.
• a lubricating liquid or solution e.g., V ⁇ % (by weight) dishwashing detergent in water
• Figure 7 illustrates an alternate embodiment of a laminate 600 made by a method according to the present invention, which laminate 600 is adapted for use to decorate a substrate such as a pane or panes of glass in a window, a door, or a mirror.
• the laminate 600 includes a plurality of display lengths 502 of the decorative film tape described above each adhered to a major surface of a sheet of the release liner 508 described above in a predetermined decorative pattern by layers 509 of pressure sensitive adhesive included in the display lengths 502 of decorative film tape; and a layer of the pre-mask material described above that is adhered to outer major surfaces of the display lengths 502 of decorative film 514 opposite the release liner 508, and to the major surface of the release liner 508 in areas not covered by the display lengths 502 of decorative film tape.
• the release liner 508 is supported on the support surface 22 to position its major surface opposite the support surface 22 in the application plane.
• Discrete lengths 501 of the decorative film tape are applied to the release liner 508 in a predetermined pattern typically (but not necessarily) with portions of certain of the discrete lengths 501 of decorative film tape overlapping each other by, for each discrete length 501, (1) positioning an end portion of the supply length 92 of decorative film tape along the application surface 121 of the application member 120 when the application member 120 is in its release position, (2) moving the application member 120 to its application position and moving the frame 106 of the tape head 100 over the application plane in straight line movement with the leading end 107 of the frame 106 leading to pull the supply length 92 of decorative film tape along the path and apply a straight discrete length 501 of the decorative film tape to the surface of the release liner 508 as the application member 120 moves over it, and (3) operating the severing means or first cutter 116 to form an end 96 for the applied discrete length 501 of decorative film tape and
• the tape applicator 10 includes a frame 12 for holding the tabletop 21 that has the planar support surface 22.
• the tabletop 21 can be tilted as illustrated to allow an operator to easily place a sheet of material such as the release liner 508 on the support surface 22.
• the tape applicator 10 may include a vacuum system (not shown) for holding the sheet material or release liner 508 stationary on the support surface 22.
• Such a vacuum system could include small spaced openings through the tabletop 21 and support surface 22, which small spaced openings communicate with a source of air pressure well below atmospheric air pressure (i.e., a vacuum) beneath the tabletop 21.
• the release liner 508 could be held stationary on the support surface 22 through the use of static electricity, or the use of pressure sensitive adhesive coated tape (e.g., masking tape).
• the support surface 22 and frame 12 are sized to handle desired sizes of release liners such as the release liner 508 illustrated, and to support the tape head 100 and actuators 30, 32, and 34 that are included in means for moving the tape head over the support surface 22.
• the tape applicator 10 includes a support arm 18 for supporting and moving the tape head 100 to different locations on the tabletop 21.
• the support arm 18 extends parallel to the y-axis and moves in a direction parallel to the x-axis along first slide rods 19a, 19b.
• the end of the support arm 18 opposite the first slide rods 19a, 19b includes a leg 54 and a wheel 56 rotatably mounted on the leg 54 that helps to support the support arm 18 above the tabletop 21 while allowing the support arm 18 to move along the support surface 22 in a direction parallel to the x-axis.
• the support arm 18 also includes second slide rods 60a, 60b, which are located on the side of the support arm 18 adjacent the tabletop 21 and extend in a direction parallel to the y-axis.
• the tape head 100 can move in a direction parallel to the y-axis along the slide rods 60a, 60b of the support arm 18.
• the tape head moves along the second slide rods 60a, 60b that are located on the side of the support arm 18 adjacent the support surface 22.
• the tape applicator can move the tape head 100 to a first location along the support surface 22, adhere an end portion of the supply length 92 of decorative film tape to the sheet of release liner 508 on the support surface 22, and then apply a discrete length 501 of the decorative film tape to the sheet of release liner 508 on the support surface 22 by moving the tape head 100 in a straight line to a second location along the support surface 22.
• the motor 31 for the x-axis actuator is can be a step motor (e.g., the step motor sold under the trade name Compumotor, part number CP*S57-102-MO-25, which is commercially available from Braas Company, St. Paul, MN.
• a step motor e.g., the step motor sold under the trade name Compumotor, part number CP*S57-102-MO-25, which is commercially available from Braas Company, St. Paul, MN.
• Figure 12 illustrates a first side 109 of the tape head 100.
• the rotary actuator 34 for rotating the tape head 100 around an axis parallel to the z-axis is not shown.
• the tape head 100 includes the frame 106 that has an upper portion 106a and a lower portion 106b.
• a tape roll holder 102 and a second tape guide roller 108 are rotatably mounted on the upper portion 106a.
• the tape roll holder 102 will receive a roll 90 of the supply length 92 of decorative film tape that has a release liner 94 releasably adhered along its coating 509 of pressure sensitive adhesive.
• the tape roll holder 102 includes a friction clutch 103 to provide back tension on the supply length 92 of decorative film tape as it unwinds from the tape roll 90.
• the application roller 120 is rotatably mounted on a bracket 130, which bracket 130 is mounted on the lower portion 106b of the frame 106 for pivotal movement about a shaft 133 so that it can be moved by operation of an air cylinder 131 connected between the bracket 130 and the frame 106 to move the peripheral or application surface 121 of the application roller 120 adjacent the support surface 22 between an application position with its application surface 121 along and biased against a surface such as that of the release liner 508 along the application plane, and a release position with its application surface 121 spaced above the application plane.
• the liner take-up roller 136 includes a friction clutch 138 driven by a motor 137 through gears in a speed reducer 139 to provide tension in the release liner 94 as it is wound onto the liner take-up roller 136.
• the decorative film tape and release liner 94 are threaded through the tape head 100 along the tape path outlined above.
• the pinch roller 118 is mounted on the end of a mounting slide 132.
• the mounting slide 132 may be slid away from the first tape guide roller 110 to allow the supply length 92 of the decorative film tape and the liner 94 to be positioned in the nip between the pinch roller 118 and the first tape guide roller 110.
• the liner 94 is separated from the supply length 92 of decorative film tape near the pivotal decorative film tape guide 122.
• the liner 94 is then wound around the pinch roller 118 and wound around the liner roller 136.
• the release liner 94 is separated from the decorative film tape at a sharp edge 126 of the guide surface 124 between the two tape edge guides 128.
• the guide surface 124 of the pivotal tape guide 122 can be pivoted to the position best seen in Figure 13 at which the guide surface 124 directs the decorative film tape over the fixed blade 112 of the first cutter 116.
• the moveable blade 114 is pivoted away from the fixed blade 112 to allow the decorative film tape to pass between the blades 112, 114 of the first cutter 116.
• the discrete length 501 of decorative film tape is then applied to the surface of the release liner 508 by the application roller 120.
• the tape head 100 is then moved over the stationary release liner 508 so that the decorative film tape is pulled by such movement along the tape path through the tape head 100 and is applied to the release liner 508 by movement of the application surface 121 along the discrete length 501 of decorative film tape being applied.
• the tape roll holder 102 and the first and second tape guide rollers 110 and 108 then freely rotate (i.e., the first tape guide roller 110 rotates without rotating the motor 164 because of the one way clutch between the motor 164 and the first tape guide roller 110).
• the x-axis and y-axis actuators 30 and 32 have moved the blade 156 to a predetermined position along the applied discrete length 501 of optical film tape, and the rotary actuator 134 (not shown) has rotated the tape head 100 about an axis parallel to the z-axis to a desired angle relative to the applied discrete length 501 of optical film tape to accurately position the blade 156 of the second cutter 154 at a desired position and angle relative to the applied discrete length 501 of optical film tape on the release liner 508.
• Figures 19 illustrates the first discrete length 501a of decorative film tape adhered to the release liner 508 and a sequences of cuts 1-12 that can be made by the second cutter 154 to sequentially form the straight end surface portions 208, 209, 210, and 211 on new closely spaced end portions 204a and 205a of the display lengths 502a and 502b of decorative film tape made from that first applied discrete length 501a of decorative film tape, while leaving a scrap piece 98 of the applied discrete length 501a of decorative film tape between those new end portions 204a and 205a.
• the tape head 100 is then rotated through angle ⁇ , which as illustrated is about 90°, and starts cutting a second end surface portion 210 on the second end portion 205 a and a second end surface portion 211 on the first end portion 204a which is done with the sequence of cuts 7-12 that is performed in essentially the same manner as the sequence of cuts 1-6 described above.
• That sequences of cuts 1- 12 is essentially the same as the sequence of cuts 1-12 described above for forming the end surface portions 208, 209, 210, and 211 on the end portions 204a and 205a of the display lengths 206a and 207a of decorative film tape made from the first applied discrete length 501a of decorative film tape, and also leave a scrap piece 99 of the applied discrete length 501b of decorative film tape between those new end portions 204b and 205b.
• That distance "b” can be between 0.005 inch and 0.12 inch or 0.013 cm and 0.3 cm, and preferably is around 0.01 inch or 0.025 cm.
• the release liner 508 can be reinforced at such cuts in it by adhering a length of pressure sensitive adhesive coated tape over each cut in the release liner 508 on the surface of the release liner 508 opposite the display lengths 502a, 502b, 502c, and 502d of decorative film tape formed by those cuts.
• the opposed end surface portions 208-212, 210-214, 209-213, 211-215 of the end portions 204a, 204b, 205a and 205b on the display lengths 502a, 502b, 502c, and 502d are cut to fit together to give a desired appearance for the intersection 220.
• Angles ⁇ and ' which are both 45° as illustrated (so that the end surface portions on each end portion are disposed at 90° with respect to each other) may be changed for a desired appearance of the intersection.
• angle may be 30° and angle ' may be 60°, or other combinations of angles for ⁇ and ' may be used.
• the tape applicator 10 can be used to apply a plurality of discrete lengths 501 of the decorative film tape to the release liner 508 and to form a plurality of intersections 220 between those discrete lengths 501 in the manner illustrated in Figures 19 through 22 to form many decorative patterns including the decorative patterns for the laminates illustrated in Figures 1 and 6.
• the tape applicator 10 first sequentially applies two parallel discrete lengths 501a of decorative film tape along the length of the sheet of release liner 508.
• the tape applicator 10 then cuts those discrete lengths 501a of decorative film tape to form first and second end portions 204a and 205a for display lengths 501 of decorative film tape along the discrete lengths 501a of decorative film tape at the locations that intersections 220 are to be made by the steps described above with reference to Figures 19 and 20.
• the opposite ends of the two applied discrete lengths 501a of decorative film tape are at 90° angles relative to the lengths of the tape, as cut by the first cutter 116.
• those opposite ends could also be cut obliquely to the lengths of the first applied discrete lengths 501a of decorative film tape by the second cutter 154 if that were desired.
• the tape applicator 10 then returns the head 100 to its "home position" along the support surface 22, as illustrated in Figure 1, to allow a user to remove the scrap portions 98 of the first discrete lengths 501a of decorative film tape at each intersection 220 being formed along its length.
• the tape applicator 10 moves the tape head 100 to sequentially apply five parallel discrete lengths 501b of decorative film tape transverse to the display lengths 502 of decorative film tape formed from the first two discrete lengths 501a of decorative film tape at a 90° angle to their edges and extending across the end portions 204a and 205a at the intersections 220.
• the tape applicator 10 then sequentially cuts those discrete lengths 501b of decorative film tape to form first and second end portions 204b and 205b for display lengths 501 of decorative film tape from the second discrete lengths 501b of decorative film tape at the intersections 220 using the steps described above.
• the tape head 100 returns to its "home position" to allow the operator to remove the scrap portions 99 thus formed at each intersection 220.
• the tape applicator 10 first sequentially applies eight parallel discrete lengths 501a of decorative film tape at an angle along the length of the sheet of release liner 508. The tape applicator 10 then cuts those discrete lengths 501a of decorative film tape to form first and second end portions 204a and 205 a for display lengths of decorative film tape along the discrete lengths 501a of decorative film tape at the locations that intersections 220 are to be made by the steps described above with reference to Figures 19 and 20. The opposite ends of each applied discrete length 501a of decorative film tape is cut obliquely to the length of that applied discrete length 501a of decorative film tape by the second cutter 154.
• the tape applicator 10 then returns the head 100 to its "home position" along the support surface 22, as illustrated in Figure 1, to allow a user to remove the scrap portions 98 of the first discrete lengths 501a of decorative film tape at each intersection 220 being formed along its length and at the opposite ends of the discrete lengths 501a.
• the tape applicator 10 moves the tape head 100 to sequentially apply eight parallel discrete lengths 501b of decorative film tape transverse to the display lengths 502 of decorative film tape formed from the first two discrete lengths 501a of decorative film tape at a 90° angle to their edges and extending across the end portions 204a and 205a at the intersections 220, which discrete lengths 501b are long enough to also extend across the opposite ends of the discrete lengths 501a.
• the tape apphcator 10 uses the second cutter 154 to sequentially cut those discrete lengths 501b of decorative film tape to form first and second end portions 204b and 205b for display lengths 501 of decorative film tape from the second discrete lengths 501b of decorative film tape at the intersections 220 using the steps described above, and to cut opposite ends of each applied discrete length 501a of decorative film tape obliquely to the length of that applied discrete length 501a of decorative film tape to form ends for display lengths 501 that are closely spaced from the ends of display lengths formed from the first discrete lengths 501a of decorative film tape.
• the tape head 100 returns to its "home position" to allow the operator to remove the scrap portions 99 thus formed at each intersection 220 and at each end of the applied discrete length 501a of decorative film tape.
• Figures 1 and 6 are only illustrative of patterns of display lengths of decorative film tape that can be adhered to a sheet of release liner by the tape applicator 10 in the method according to the present invention for making a laminate according to the present invention.
• the tape applicator 10 may create almost any pattern of straight display lengths of decorative film tape on a sheet of release liner because of the versatility with which the tape head 100 can be moved across the support surface 22 to apply discrete lengths of decorative film tape at any angle along a release liner on the support surface 22, and (if necessary) to cut the applied discrete lengths of decorative film tape at any angle after they have been applied to the release liner to form the display lengths from those applied discrete lengths.
• the tape applicator 10 includes a computer processor and a controller for sending appropriate signals to the actuators 30, 32, 34 to move the tape head 100 relative to the support surface 22 and to operate the tape head 100 as necessary to form a desired pattern of display lengths of the decorative film tape on a sheet of release liner.
• a computer processor for sending appropriate signals to the actuators 30, 32, 34 to move the tape head 100 relative to the support surface 22 and to operate the tape head 100 as necessary to form a desired pattern of display lengths of the decorative film tape on a sheet of release liner.
• an operator may want to make the pattern of display lengths of decorative film tape on a sheet of release liner illustrated in either Figure 1 or Figure 6.
• the operator enters a set of commands into the computer processor that indicate the shape of the pattern to be made.
• the computer processor and controller determines which way to direct the actuators 30, 32, 34 to move the tape head 100 to apply the discrete lengths of decorative film tape to the release liner and to cut the applied discrete lengths of decorative film tape after they have been applied to the release liner to form the display lengths of decorative film tape .
• the computer processor and controller can include an "open loop" system, which calculates where the tape head 100 is located on the tabletop 21, based on a known series of moves. For example, the ball screw in either the x-axis actuator 30 or y-axis actuator 32 will move the tape head 100 a known distance per one rotation of the ball screws.
• the computer processor knows the initial location of the tape head 100, like the "home position" for instance, it can determine where the final location of the tape head 100, based on how many rotations the ball screw in the actuator actually rotated.
• the computer processor will send a signal to the x-axis and y-axis actuators 30, 32 to turn the ball screws a certain number of rotations to move the tape head 100 a certain distance in a particular axis.
• the computer processor can also send signals to the rotary actuator 36 indicating where and when to rotate the tape head 100 around an axis parallel to the z-axis of the support surface 22.
• a suitable controller is a controller sold under the trade name Compumotor, which is commercially available from Braas Company located in St. Paul, MN, sold under part number 6K4.
• the computer processor could include a "closed loop" system, which calculates where the tape head 100 is at all times on the support surface 22 of the tabletop 21.
• the actuators 30, 32, 34 include sensors to determine the initial location of the tape head 100 on the tabletop 21. Suitable sensors for the actuators 30, 32, 34 are Prox Sensors sold under the trade name Omron, which is commercially available from Braas Company located in St. Paul, MN, sold under part number E2E-X1R5E1-M1-N.
• Modifications of the tape applicator 10 so that it could be used in this method would comprise changing the positions of the fixed blade 112 and the moveable blade 114 of the first cutter 116, and positioning the liner take-up roller 136 including its friction clutch 138 and the motor 137 by which it is driven through the speed reducer 139 on the opposite side of the tape path, together with providing an application surface 121 on the roller 120 that would not adhere to the layer 509 of pressure sensitive adhesive on the supply length 92 of decorative film tape.

Landscapes

• Laminated Bodies (AREA)
• Adhesive Tapes (AREA)

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Applications Claiming Priority (2)

Publications (2)

Family

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• 2002
  • 2002-10-24 US US10/279,334 patent/US6984429B2/en not_active Expired - Fee Related
• 2003
  • 2003-10-20 AU AU2003286547A patent/AU2003286547A1/en not_active Abandoned
  • 2003-10-20 WO PCT/US2003/033340 patent/WO2004037554A2/en not_active Ceased
  • 2003-10-20 EP EP03777749A patent/EP1556230A2/en not_active Withdrawn
  • 2003-10-20 JP JP2004546965A patent/JP2006503732A/ja not_active Withdrawn
• 2005
  • 2005-10-20 US US11/256,283 patent/US7311793B2/en not_active Expired - Fee Related

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