Method and apparatus for applying designs to a substrate

• US 20030041961A1
• Filed: 10/24/2002
• Published: 03/06/2003
• Est. Priority Date: 01/12/2001
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Piten, James F., Thunhorst, Kristin L.
• Granted Patent: US 6,984,429 B2
• Time in Patent Office: Days
• US Class Current: 156/247
• CPC Class Codes: B29C 66/472 said single elements being substantially flat
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B44C 1/1725 using an intermediate support
• CPC Class Codes: B44C 1/1745 using an intermediate support
• CPC Class Codes: B44C 1/1758 Decalcomanias applied under pressure only, e.g. provided with a pressure sensitive layer
• CPC Class Codes: B65H 2555/30 Multi-axis
• CPC Class Codes: B65H 35/0013 and applying the article or the web by adhesive to a surface B65H35/002 takes precedence
• CPC Class Codes: B65H 37/002 Web delivery apparatus, the web serving as support for articles, material or another web
• CPC Class Codes: Y10S 428/914 Transfer or decalcomania
• CPC Class Codes: Y10T 156/1089 of discrete laminae to single face of additional lamina
• CPC Class Codes: Y10T 428/1405 Capsule or particulate matter containing [e.g., sphere, flake, microballoon, etc.]
• CPC Class Codes: Y10T 428/1448 Coloring agent containing
• CPC Class Codes: Y10T 428/1467 Coloring agent
• CPC Class Codes: Y10T 428/1471 Protective layer
• CPC Class Codes: Y10T 428/1476 Release layer
• CPC Class Codes: Y10T 428/1481 Dissimilar adhesives
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/2486 with outer strippable or release layer
• CPC Class Codes: Y10T 428/24868 : Translucent outer layer
• CPC Class Codes: Y10T 428/28 : Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/2848 : Three or more layers

Abstract

A laminate from which decorative films can be precisely applied to a substrate. The laminate includes a polymeric cover sheet having opposite outer and inner major surfaces. A layer of structured pressure sensitive adhesive is adhered to the inner major surface of the cover sheet. The structured pressure sensitive adhesive has a plurality of spaced passageways extending to at least one edge of the layer of structured pressure sensitive adhesive. A decorative film is adhered to the structured pressure sensitive adhesive. A second layer of pressure sensitive adhesive is adhered to the major surfaces of the decorative film opposite the layer of structured pressure sensitive adhesive. A release liner extends substantially across the second layer of pressure sensitive adhesive and a portion of the structured pressure sensitive adhesive.

Claims

1. A laminate from which decorative films can be precisely applied to a substrate, the laminate comprising:

a polymeric cover sheet having opposite outer and inner major surfaces;

a layer of structured pressure sensitive adhesive adhered to the inner major surface of the cover sheet, the structured pressure sensitive adhesive having a plurality of spaced passageways extending to at least one edge of the layer of structured pressure sensitive adhesive;

one or more pieces of a decorative film having opposite major surfaces with one of the major surfaces of the decorative film being adhered to the structured pressure sensitive adhesive;

a second layer of pressure sensitive adhesive coextensive only with each of the pieces of decorative film adhered to the major surfaces of the decorative film opposite the layer of structured pressure sensitive adhesive; and

a release liner extending substantially across the second layer of pressure sensitive adhesive and a portion of the structured pressure sensitive adhesive.

2. The laminate of claim 1 wherein the structured pressure sensitive adhesive is adapted to be made wet during application of the decorative film to a substrate with a liquid that lubricates the adhesives so that the decorative film can be applied to a substrate at a precise position.

3. The laminate of claim 1 comprising about 3 to about 71 passageways per centimeter.

4. The laminate of claim 1 wherein the passageways comprise a width of about 50 micrometers to about 200 micrometers.

5. The laminate of claim 1 wherein the passageways comprise a height of about 15 micrometers to about 45 micrometers.

6. The laminate of claim 1 wherein the passageways comprise one of a regular pattern or an irregular pattern.

7. The laminate of claim 1 wherein the passageways comprise one of a rectangular grid of passageways, a diamond grid of passageways, a plurality of parallel passageways.

8. The laminate of claim 1 wherein the decorative film comprises a optical film with light-diffusing features that provide a beveled or v-groove cut glass appearance when adhered to a glass panel.

9. The laminate of claim 1 wherein the structured pressure sensitive adhesive is selected to form a bond to the decorative film that permits the low-adhesion release liner to be peeled away without disrupting that bond and to permit the cover sheet to be peeled cleanly from the decorative film without disrupting the adhesive bond between the decorative film and a substrate.

10. The laminate of claim 1 wherein the cover sheet comprises an opaque material.

11. A laminate adapted for use to decorate a substrate comprising:

a layer of pre-mask material comprising a cover layer and a layer of removable structured pressure sensitive adhesive firmly adhered to one surface of the cover layer; and

one or more display lengths of a decorative film, the display lengths comprising opposite first and second major surfaces with a layer of adhesive along the second major surface, the first major surface of the decorative film adhered to the structured pressure sensitive adhesive and a release liner extending across the adhesive on the second major surface of the decorative film and across a portion of the structured pressure sensitive adhesive.

12. A method for making a laminate adapted for use to decorate a substrate, the method comprising the steps of:

providing a layer of pre-mask material comprising a cover layer and a layer of removable structured pressure sensitive adhesive firmly adhered to one surface of the cover layer;

providing a supply of decorative film having opposite first and second major surfaces with a layer of adhesive along the second major surface;

forming display lengths of a decorative film of predetermined shapes and lengths; and

forming an assembly comprising the first major surface of the decorative film adhered to the structured pressure sensitive adhesive and a release liner extending across the adhesive on the second major surface of the decorative film and across a portion of the structured pressure sensitive adhesive.

13. The method of claim 12 comprising the step of forming the display lengths and end shapes using a tape applicator.

14. The method of claim 12 comprising the step of forming the display lengths and end shapes using a computer operated tape applicator.

15. The method of claim 12 comprising the step of applying the display lengths of decorative film to the first surface of the release liner in a predetermined pattern using a tape applicator.

16. The method of claim 12 comprising the step of applying the display lengths of decorative film to the first surface of the release liner in a predetermined pattern using a computer operated tape applicator.

17. The method of claim 12 comprising the step of positioning the display lengths of decorative film on the release liner using a tape applicator.

18. The method of claim 12 comprising the step of positioning the display lengths of decorative film on the structured pressure sensitive adhesive using a tape applicator.

19. A method of applying the laminate of claim 12 to a substrate comprises the steps of:

removing the release liner;

adhering the adhesive on the second major surface of the decorative film and the structured pressure sensitive adhesive to a substrate;

pressing out a portion of air from between the covering layer and the substrate; and

removing the covering layer and the structured pressure sensitive adhesive to expose the display lengths of decorative film adhered to the substrate.

20. A method of applying the laminate of claim 12 to a substrate comprises the steps of:

applying a lubricating liquid to one or more of the substrate, the structured pressure sensitive adhesive, or the second major surface of the decorative film;

removing the release liner;

adhering the adhesive on the second major surface of the decorative film and the structured pressure sensitive adhesive to a substrate;

pressing out a portion of the lubricating liquid from between the covering layer and the substrate;

allowing the lubricating liquid to at least partially dry; and

removing the covering layer and the structured pressure sensitive adhesive to expose the display lengths of decorative film adhered to the substrate.