Method of enhancing coating speed

Details Method of enhancing coating speed Method of enhancing coating speed

2003-01-27

2004-10-12

Pianalto, Bernard (Department: 1762)

Coating processes

Coating remains adhesive or is intended to be made adhesive

C427S208200, C427S208400, C427S208600, C427S261000, C427S264000, C427S270000, C427S275000, C427S299000

Reexamination Certificate

active

06803072

ABSTRACT:

This invention relates to a method for applying a liquid composition to a structured surface. More particularly, the inventions relates to a method for applying adhesive compositions to a structured release liner.
BACKGROUND
Pressure sensitive adhesive-backed films may be imaged and adhered to a substrate for decorative purposes. For example, large graphics or smaller decals may be placed on vehicles or may be used as signs for identification, promotional or decorative objectives. However, the tacky and aggressive pressure sensitive adhesives used in these applications cause considerable handling and application problems. Ideally, the film is adhered conformably and evenly on the application substrate. Adhesive-backed articles that adhere with the slightest contact can often be particularly difficult to reapply if they inadvertently adhere to the substrate in an undesired position. In addition, even if one section of the adhesive backed article is properly positioned on a substrate, and the film is firmly adhered, air or other fluids may be trapped under the article. The trapped air forms a bubble in the article, and cannot be easily removed without de-bonding or perforating the article.
The adhesive backed graphic articles described in U.S. Pat. No. 5,897,930, WO 98/29516 and U.S. Ser. No. 09/311,101 (3M File No. 54528USA2A) include an adhesive layer with a plurality of replicated recessed interconnecting microchannels that allow egress of fluids trapped under the article during registration with the substrate. A typical article
10
of this type is shown in
FIG. 1
, and includes a film
12
having opposed surfaces
14
and
16
. The surface
14
of the film
12
is imaged to form a graphic
13
. A layer of a pressure sensitive adhesive
18
is bonded to the surface
16
of the film
12
. The pressure sensitive adhesive
18
includes a surface
20
that can be bonded to a substrate. The pressure sensitive adhesive
18
includes structures
22
that define a network of channels
24
. A release liner
26
is releasably attached to the pressure sensitive adhesive
18
. The release liner
26
includes protrusions
28
that form the corresponding channels
24
and structures
22
in the pressure sensitive adhesive
18
. The release liner
26
, shown in a partially removed state, is fully detachable when pulled in the direction of arrow A and is used to protect the pressure sensitive adhesive prior to application of the article
10
on a substrate.
A portion of a major surface of a liner used in making the article
10
is shown in FIG.
2
. The surface of the liner
26
includes a pattern of ridges
28
. The surface of the liner
26
includes a series of land areas
23
separated by the substantially continuous ridges
28
. The ridges
28
have a substantially hemispherical cross sectional shape.
One convenient method for making the adhesive backed articles
10
includes knife or bar coating solutions of a pressure sensitive adhesive onto a structured surface of a release liner. Referring to
FIG. 3
, an apparatus
70
is shown that may be used to manufacture the adhesive article
10
. A release liner
26
with a structured surface including ridges
28
is fed between a take up roll
72
rotating in the direction of arrow B and a back up roll
74
rotating in the direction of arrow C. A liquid adhesive
75
from a holding tank
76
adheres to the rotating take up roll
72
and is applied to the structured side of the release liner
26
. A knife or bar
78
removes a portion of the adhesive
75
and forms a substantially continuous adhesive layer
79
on the release liner
26
.
SUMMARY
As adhesive is applied to a structured release liner during the manufacture of adhesive backed articles using a knife or bar coating process, the adhesive flows over the structures on the surface of the release liner and fills in the land areas between the structures. In this process coating speed must be controlled to prevent entrapment or agglomeration of air bubbles in the adhesive as it flows into the individual cell-like regions in the land areas between the structures on the release liner. The entrapped air can degrade the performance of the coated adhesive layer and reduce the appearance and printability of the film layer, particularly for high resolution images. These defects detract from the overall appearance of products based on the adhesive backed articles. In addition, the reduced coating speeds are not economical and increase production costs.
The coating process of the invention uses a release liner having features that are mechanically modified to reduce air bubble formation during coating operations and enhance coating speed. The release liners used in the coating process of the invention have structures with geometries designed to reduce air bubble formation during coating and increase coating speed without sacrificing the application, bonding and visual properties of the final graphic film product.
In a first embodiment, the invention is a method for coating including applying an adhesive to a surface, wherein the surface comprises an arrangement of structures thereon. The structures extend upward from a plane of the surface and have at least one sidewall that makes an angle with respect to the plane of the surface of greater than 0° and less than 90° selected to reduce air bubble formation for a coating solution of a selected rheology. Preferably, the at least one sidewall makes an angle with respect to the plane of the surface of less than about 60°.
In a second embodiment, the invention is a method for making an adhesive backed article, including applying an adhesive to a release liner, wherein the release liner includes an arrangement of structures thereon. The structures extend upward from a plane of the surface and have at least one sidewall that makes an angle with respect to the plane of the surface of greater than 0° and less than 90° selected to reduce air bubble formation for a coating solution of a selected rheology.
In a third embodiment, the invention is a method for reducing air entrapment in a coating process, including applying an adhesive to a surface with an arrangement of structures thereon. The structures extend upward from a plane of the surface and have at least one sidewall that makes an angle with respect to the plane of the surface of greater than 0° and less than 90° selected to reduce air bubble formation for a coating solution of a selected rheology.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.


REFERENCES:
patent: RE24906 (1960-12-01), Ulrich
patent: 3239478 (1966-03-01), Harlan, Jr.
patent: 3935338 (1976-01-01), Robertson
patent: 4181752 (1980-01-01), Martens et al.
patent: 4952650 (1990-08-01), Young et al.
patent: 5169727 (1992-12-01), Boardman
patent: 5296277 (1994-03-01), Wilson et al.
patent: 5462765 (1995-10-01), Calhoun et al.
patent: 5650215 (1997-07-01), Mazurek et al.
patent: 5897930 (1999-04-01), Calhoun et al.
patent: 6524649 (2003-02-01), Sher et al.
patent: WO 98/29516 (1998-09-01), None
patent: WO 00/44843 (2000-08-01), None
patent: WO 00/69985 (2000-11-01), None

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