Stock material or miscellaneous articles – Layer or component removable to expose adhesive – Release layer
Reexamination Certificate
2000-02-02
2002-09-17
Morris, Terrel (Department: 1771)
Stock material or miscellaneous articles
Layer or component removable to expose adhesive
Release layer
C049S479100, C160S040000, C277S377000, C277S377000, C277S377000, C277S921000, C296S093000, C428S040100, C428S041700, C428S041900, C428S066400, C428S317100, C428S314400, C428S319300, C428S319700, C428S343000, C428S346000, C428S351000, C428S352000, C428S354000
Reexamination Certificate
active
06451398
ABSTRACT:
FIELD OF THE INVENTION
The invention relates generally to foam tapes and more particularly to a double-sided self-adhesive reinforced foam tape.
DESCRIPTION OF RELATED ART
Double-sided foam tape is well-known. This product is frequently a thick but narrow layer or strip of closed cell plastic flexible foam with layers of pressure sensitive adhesive on opposing surfaces. A release liner is provided on one adhesive surface. The tape is rolled, so that the lower side of the release liner contacts the other adhesive surface. In use, the tape is unrolled and the exposed adhesive surface is adhered to one of the two items that are to be held together. The release liner is then removed, exposing the second adhesive surface.
The tape is usually produced by a process starting with a substrate, laminating one side, coating that side with a pressure sensitive adhesive, flipping the product over, and repeating the process again on the other side. The extra handling of the product needed to complete these multiple steps results in a high percentage of scrap loss.
Alternatively, the tape can be produced by the methods discussed in U.S. Pat. Nos. 5,658,630 ('630 patent) and U.S. Pat. No. 5,660,922 ('922 patent), the disclosures of which are hereby incorporated by reference. However, the coextrusion process described in the '922 patent is also characterized by high scrap losses, especially during the start-up phase. Further, the product suffers from the deformation problems discussed below.
A second problem with traditional foam tapes is they are generally not reinforced. Thus, during both processing and application, especially if used in longer strips, deformation and stretching of the product can occur. The deformation also occurs due to the extra handling and constant turning of the product during manufacturing. This results in a product that can be difficult to handle and provides a less than perfect fit.
The '630 patent addresses this problem by providing a polyester film layer to help stabilize the tape. The problem with this polyester film-reinforced product is that it is expensive and laborious to produce, and requires the use of UV light to polymerize the foam. The process also requires the use of a start-up release paper, which is discarded after the foam is polymerized, thus adding to the scrap losses.
Thus, there is a need for a double-sided self-adhesive reinforced foam tape which overcomes these deficiencies in the prior art and a method to produce such an improved product that results in a smaller amount of scrap loss.
SUMMARY OF THE INVENTION
A double-sided, self-adhesive reinforced foam tape is provided, comprising a release liner having upper and lower surfaces, at least the upper of which is a release surface, a first layer of pressure sensitive adhesive applied to the upper release surface, a layer of flexible polymeric film applied to the first pressure sensitive adhesive layer, a layer of flexible foam thermally bonded to the flexible polymeric film layer, and a second layer of pressure sensitive adhesive applied to the flexible foam layer. The tape has a shape such that it may be used effectively as a double-sided self-adhesive foam tape.
A length of material suitable for die-cutting a double-sided self-adhesive reinforced foam tape therefrom is also provided. The material comprises a first release liner having an upper surface which is a release surface, a first layer of pressure sensitive adhesive applied to the release surface, a layer of flexible polymeric film applied to the first pressure sensitive adhesive layer, a layer of flexible foam thermally bonded to the flexible polymeric film layer, a second layer of pressure sensitive adhesive applied to the flexible foam layer, and a second release liner having a lower surface which is a release surface applied to the second layer of pressure sensitive adhesive. The length of material is at least 8 inches wide and at least 20 feet long. A method of making the length of material is also provided.
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Plastics Film Technology, W.R.R. Park, editor, Van Nostrand Reinhold Co., prior to 1971, p. 59.
Letter (2 pages) dated Dec. 9, 1999, Re: Foam-Fix Product: Notice of Prior Art, from Doreen J. Gridley to Michael Sylvester with four pages of enclosures.
Vinyl(PVC)Foam Standard Log Prices, from Gaska Tape, Inc., p. 8.
EN1101W15: Gaska Tape Product Defaults(Typical Makeup), from Gaska Tape, Inc., dated Jan. 25, 1997, 1 page.
Morris Terrel
Singh Arti
LandOfFree
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