Laminate from which decorative films can be applied to a substrate

• US 7,311,793 B2
• Filed: 10/20/2005
• Issued: 12/25/2007
• Est. Priority Date: 01/12/2001
• Status: Expired due to Fees

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Thunhorst, Kristin L., Pitzen, James F.
• Primary Examiner(s): Tucker, Philip
• Assistant Examiner(s): MCCLELLAND, KIMBERLY KEIL
• Application Number:
  US11/256,283
• Publication Number:
  US 20060032580A1
• Time in Patent Office: 796 Days
• Field of Search: None
• US Class Current: 156/249
• 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 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 pressure sensitive adhesive firmly adhered to one surface of the cover layer;

providing a supply of decorative film tape comprising a length of decorative film having opposite parallel edges and opposite first and second major surfaces, the decorative film tape further including a layer of adhesive along the second major surface of the decorative film;

providing a sheet of release liner having opposite first and second major surfaces, with the first major surface of the release liner adapted to be releasably adhered to by the removable adhesive on the cover layer and by the layer of adhesive on the decorative film;

using a computer operated tape applicator to sequentially apply to the first major surface of the release liner a plurality of parallel discrete first lengths of the decorative film tape by adhering the adhesive on the first lengths of the decorative film tape to the first major surface of the release liner;

cutting the applied parallel discrete first lengths of the decorative film tape to form display lengths of the decorative film tape from the discrete first lengths of the decorative film tape with the display lengths of the decorative film tape having end portions and to form scrap portions of the discrete first lengths between the end portions of adjacent display lengths of the decorative film tape, which end portions of adjacent display lengths of the decorative film tape are at predetermined positions for intersections along the discrete first lengths of the decorative film tape;

removing the scrap portions of the discrete first lengths of the decorative film tape from the release liner;

using the computer operated applicator to sequentially apply to the first major surface of the release liner a plurality of parallel discrete second lengths of the decorative film tape extending transverse to the display lengths formed from the parallel discrete first lengths of the decorative film tape and extending over the end portions of the display lengths formed from the parallel discrete first lengths of the decorative film tape;

cutting the applied discrete second lengths of the decorative film tape to from display lengths of the second lengths of the decorative film tape along the discrete second lengths of the decorative film tape with the display lengths of the decorative film tape having end portions and to form scrap portions of the discrete lengths between the end portions, the end portions of the display lengths formed from the second lengths of decorative film tape being at the predetermined positions for intersections along the discrete first lengths of the decorative film tape with the end surfaces on the end portions of the display lengths of the decorative film tape formed from the first and second lengths of the decorative film tape at each of the predetermined locations for intersections closely spaced from each other;

removing the scrap portions of the discrete second lengths of the decorative film tape to provide a plurality of display lengths of decorative film tape in a predetermined decorative pattern; and

adhering the layer of removable pressure sensitive adhesive on the layer of pre-mask material to the first major surfaces of the plurality of display lengths of decorative film tape in the predetermined decorative pattern and to portions of the release liner between the display lengths of decorative film tape to form the laminate.

2. The method of claim 1 wherein the step of cutting the applied discrete second lengths of the decorative film tape to form display lengths of the second lengths of the decorative film tape along the discrete second lengths of the decorative film tape forms the end surfaces on the end portions of the display lengths of the decorative film tape formed from the second lengths of the decorative film tape at each of the predetermined locations for intersections spaced in the range of 0.005 to 0.12 inch or 0.013 to 0.3 cm from the end surfaces on the end portions of the display lengths of the decorative film tape formed from the first lengths of the decorative film tape.

3. The method of claim 1 wherein the said plurality of parallel discrete second lengths of the decorative film tape are applied with the edges of the parallel discrete second lengths of the decorative film tape disposed at a 90 degree angle with respect to the edges of the display lengths formed from the parallel discrete first lengths of the decorative film tape.