Protective sheets, articles, and methods

• US 10,265,932 B2
• Filed: 10/23/2006
• Issued: 04/23/2019
• Est. Priority Date: 10/21/2005
• Status: Active Grant

• Current Assignee: PPG Advanced Surface Technologies LLC
• Original Assignee: Entrotech, Inc.
• Inventors: McGuire, Jr., James E.
• Primary Examiner(s): Shosho, Callie E
• Assistant Examiner(s): English, Patrick N
• Application Number:
  US12/090,574
• Publication Number:
  US 20080286576A1
• Time in Patent Office: 4,565 Days
• Field of Search: None
• CPC Class Codes: B29C 2043/3644 Vacuum bags; Details thereof, e.g. fixing or clamping
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 37/0025 Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing moulding on preformed layers as inserts B29C70/68; applying fluent material to surfaces in general B05
• CPC Class Codes: B29C 43/12 using bags surrounding the moulding material or using membranes contacting the moulding material
• CPC Class Codes: B29C 51/28 for applying pressure through the wall of an inflated bag or diaphragm
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29C 70/44 using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
• CPC Class Codes: B29K 2105/0854 in the form of a non-woven mat
• CPC Class Codes: B29K 2105/243 Partially cured
• CPC Class Codes: B29L 2009/001 the layers being loose
• CPC Class Codes: B29L 2031/52 Sports equipment ; Games; Articles for amusement; Toys B29L2031/54 takes precedence
• CPC Class Codes: B32B 2307/4023 on the layer surface, e.g. ink
• CPC Class Codes: B32B 2307/714 Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/752 Corrosion inhibitor
• CPC Class Codes: B32B 2509/00 Household appliances
• CPC Class Codes: B32B 2603/00 Vanes, blades, propellers, rotors with blades
• CPC Class Codes: B32B 2605/18 Aircraft
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/322 : comprising halogenated polyolefins, e.g. PTFE
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/239 : Complete cover or casing
• CPC Class Codes: Y10T 428/24364 : with transparent or protective coating
• CPC Class Codes: Y10T 428/249939 : Two or more layers
• CPC Class Codes: Y10T 428/26 : Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/31507 : Of polycarbonate
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Abstract

Multi-layer protective sheets of the invention are extensible. They are useful in a range of indoor and outdoor applications in, for example, the transportation, architectural and sporting goods industries. The protective sheets can advantageously be applied to at least a portion of a surface of any article where protection is desired. Methods of the invention include those for forming protective sheets of the invention and applying them to articles.

Claims

1. A multi-layer protective sheet consisting essentially of:

a polyurethane-based carrier layer;

an essentially uncrosslinked topcoat layer that is not an extrusion-grade polyurethane, wherein crosslinkers and reaction products thereof are not discernible in the topcoat layer when using chemical analysis;

wherein an outermost adhesive later is present on a side of the carrier layer opposite from that of the topcoat layer;

and

optionally, a carrier film on an exterior surface of the topcoat layer, wherein the sheet is extensible, has a substantially uniform thickness throughout, and is essentially invisible on a substrate to which it is applied.

2. The sheet of claim 1, wherein the carrier layer comprises multiple individual film layers.

3. The sheet of claim 1, wherein the carrier layer is essentially uncrosslinked, wherein crosslinkers and reaction products thereof are not discernible in the carrier layer when using chemical analysis.

4. The sheet of claim 1, wherein the topcoat layer is polyurethane-based.

5. The sheet of claim 1, wherein the topcoat layer comprises a polycarbonate-based polyurethane.

6. The sheet of claim 1, wherein the topcoat layer comprises a silicone polymer.

7. The sheet of claim 1, wherein the adhesive layer comprises a pressure-sensitive adhesive.

8. The sheet of claim 1, wherein a release film is present on an exterior surface of the adhesive layer.

9. The sheet of claim 1, wherein the carrier film on an exterior surface of the topcoat layer is present.

10. The sheet of claim 1, wherein the sheet is capable of elongating more than 200% before breaking.

11. The sheet of claim 1, wherein the sheet exhibits essentially no plastic deformation when stretched up to about 125% of its initial length.

12. The sheet of claim 1, wherein the sheet exhibits essentially no plastic deformation when stretched up to about 150% of its initial length.

13. The sheet of claim 1, wherein the sheet exhibits greater than about 300% elongation at break when tested according to ASTM D638-95.

14. The sheet of claim 1, wherein the sheet exhibits greater than about 350% elongation at break when tested according to ASTM D638-95.

15. The sheet of claim 1, wherein a force of less than about 40 Newtons is required to elongate the sheet to 150% its initial length.

16. An article comprising at least one surface having on at least a portion thereof the sheet of claim 1.

17. The article of claim 16, wherein the article comprises a motorized vehicle.

18. The article of claim 16, wherein the article comprises a bicycle.

19. A method of using the sheet of claim 1 to protect a surface on a motorized vehicle, the method comprising:

providing the sheet of claim 1; and

applying the sheet to the surface of the motorized vehicle.

20. The method of claim 19, wherein the surface is at least partially painted.

21. A method of protecting a non-planar surface, comprising:

providing the sheet of claim 1; and

applying the sheet to the non-planar surface.

22. A method for forming the protective sheet of claim 1, the method comprising steps of:

forming the carrier layer;

forming the adhesive layer on a first side of the carrier layer;

forming the topcoat layer on the carrier film;

thermally bonding the topcoat layer to a second side of the carrier layer opposite from the adhesive layer to form an assembly; and

optionally, removing the carrier film from the topcoat layer.

23. A method for forming the protective sheet of claim 1, the method comprising steps of:

forming the carrier layer;

forming the adhesive layer on a first side of the carrier layer; and

forming the topcoat layer on a second side of the carrier layer opposite from the adhesive layer.

24. The method of claim 23, further comprising steps of:

contacting the topcoat layer with a smooth plastic film; and

heating the topcoat layer and plastic film to form a smooth surface on the topcoat layer.

25. The sheet of claim 1, wherein the carrier layer has a thickness of about 120 microns to about 180 microns.

26. The sheet of claim 1, wherein the topcoat layer has a thickness of about 20 microns or less.

27. The sheet of claim 1, wherein the topcoat layer has a thickness of about 5 microns to about 15 microns.

28. The sheet of claim 1, wherein the carrier layer is based on a polyurethane with a backbone having at least about 80% urethane and/or urea repeat linkages formed during its polymerization.

30. The sheet of claim 1, wherein no visible yellowing is observed by an unaided human eye when tested for weathering for 250 hours according to ASTM D4329.

31. The sheet of claim 1, wherein no visible yellowing is observed by an unaided human eye when tested for weathering for 500 hours according to ASTM D4329.

32. The sheet of claim 1, wherein no visible deglossing is observed by an unaided human eye after placement of the sheet in an outside environment in Florida or Arizona for one year.

29. A multi-layer protective sheet consisting of:

a polyurethane-based carrier layer;

an essentially uncrosslinked topcoat layer that is not an extrusion-grade polyurethane, wherein crosslinkers and reaction products thereof are not discernible in the topcoat layer when using chemical analysis;

optionally, an adhesive layer;

optionally, a release film on an exterior surface of the adhesive layer; and

optionally, a carrier film on an exterior surface of the topcoat layer,

wherein the protective sheet is extensible, has a substantially uniform thickness throughout, and is essentially invisible on a substrate to which it is applied.