Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Adhesive outermost layer
Reexamination Certificate
2000-11-29
2002-11-05
Chen, Vivian (Department: 1773)
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Adhesive outermost layer
C428S343000, C428S354000, C428S3550EN, C428S421000, C428S422000, C428S424200, C428S424600, C428S457000, C428S461000, C428S463000, C428S515000, C428S520000, C428S522000
Reexamination Certificate
active
06475616
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to multilayer films used as appliques, for example, for paint replacement applications.
BACKGROUND OF THE INVENTION
Paint on an aircraft can serve to protect the outer surface as well as to provide decorative features. Paint is applied in a controlled environment to alleviate environmental and health hazards, which results in significantly high costs. Current aircraft paint technology uses large volumes of volatile organic compounds for application and removal, such as methylene chloride and methyl ethyl ketone, and heavy metals, such as chromium. Such materials are potentially hazardous to workers and the environment. As a result, there is a desire to eliminate the need to paint aircraft.
Over the past 30 years, tapes have been used to protect aircraft substrates as an alternative to paint systems. For example, polyurethane tapes have been used to protect aircraft leading edge substrates from damage from rain, sand, sleet, and other airborne particle damage. Cushioned versions of polyurethane tapes have been used to absorb the impact energy of small rocks and debris and provide protection for antennas, fuselage panels, and composite wing flaps. Thin film tapes capable of being printed with graphics have been used for aircraft markings and decals. Such tapes include polymer backings and adhesives that have significant advantages; however, they are typically limited in their applications because few environments are as demanding as the exterior of an aircraft due to temperature variances, fluid exposures, conformance to various contoured and/or complex surfaces, etc. Thus, a need exists for paint replacement technologies that can withstand the harsh environments to which aircraft are exposed while maintaining acceptable film appearance characteristics (specifically, high gloss retention, gouge and scratch resistance) and can be used on the entire surface of the aircraft.
SUMMARY OF THE INVENTION
The present invention provides an applique that comprises a fluorinated polymer backing having two treated surfaces and having an adhesive layer on one treated surface and a cured urethane coating layer on the other treated surface, the cured urethane coating layer comprising urethane polymer and optionally, additives such as colorants, UV absorbers, etc. The adhesive preferably is a pressure-sensitive adhesive which preferably comprises an acrylate copolymer comprising at least one monofunctional alkyl (meth)acrylate monomer (also known as a “repeat unit” when describing a copolymer) and at least one monofunctional free-radically copolymerizable acid-containing reinforcing monomer whose homopolymer glass transition temperature is higher than that of the alkyl (meth)acrylate homopolymer.
In another embodiment of the present invention, an applique comprises a fluorinated polymer backing that is not perfluorinated, an adhesive layer on one treated surface of the backing and a cured urethane coating layer on the other treated surface, the cured urethane coating layer comprising urethane polymer, and optionally, additives such as colorants, UV absorbers, etc. The adhesive is preferably a pressure-sensitive adhesive which preferably comprises an acrylate copolymer comprising at least one monofunctional alkyl (meth)acrylate monomer and at least one monofunctional free-radically copolymerizable acid-containing reinforcing monomer whose homopolymer glass transition temperature is higher than that of the alkyl (meth)acrylate homopolymer.
The present invention also provides an airplane comprising an outer surface and an applique thereon, wherein the applique comprises a fluorinated polymer backing having two treated surfaces, an adhesive layer on one treated surface and a cured urethane coating layer on the other treated surface, the cured urethane coating layer comprising urethane polymer and, optionally additives such as colorants, UV absorbers, etc. The adhesive is preferably a pressure-sensitive adhesive and preferably comprises an acrylate copolymer comprising copolymerized monomers comprising at least one monofunctional alkyl (meth)acrylate monomer and at least one monofunctional free-radically copolymerizable acid-containing reinforcing monomer having a homopolymer glass transition temperature higher than that of the alkyl (meth)acrylate homopolymer.
The appliques of the invention have a gloss retention of greater than or equal to 10 percent, preferably greater than or equal to 30 percent, more preferably greater than or equal to 40 percent, as measured at an angle of 60° with respect to the applique surface and greater than or equal to 30 percent, preferably greater than or equal to 45 percent, more preferably greater than or equal to 60 percent, as measured at an angle of 85° with respect to the applique surface for glossy and semi-glossy surfaces.
Preferably, the initial gloss is greater than 10, more preferably 35 or greater, even more preferably, 40 or greater, and even more preferably 50 or greater when measured at an angle of 60° with respect to the applique surface. The appliques of the invention are also both conformable and removable and exhibit resistance to hydrocarbon fluids. Preferably, the applique of the present invention exhibits resistance to hydraulic fluids and has a film hardness of greater than or equal to 6B.
Appliques of the present invention preferably provide a uniform coating thickness having a tight tolerance; for example, a cured urethane coating layer having a thickness of 52.1 micrometers may have a tolerance of plus or minus 1.5 micrometers. Preferably, the coating thickness of the cured urethane coating layer may range from about 12 micrometers to about 254 micrometers. The adhesive is preferably a pressure-sensitive adhesive which preferably comprises an acrylate copolymer having at least one monofunctional alkyl (meth)acrylate monomer and at least one monofunctional free-radically copolymerizable acid-containing reinforcing monomer whose homopolymer glass transition temperature is higher than that of the alkyl (meth)acrylate monomer.
Advantages of the appliques of the invention include: improved gloss retention and improved gouge and scratch resistance as compared to fluoropolymer backing alone; and the appliques are more easily removable from substrates than conventional paints so that the appearance of the substrate may be changed as desired with less labor than required with conventional paints.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to appliques, particularly appliques for replacing paint on substrates. Such appliques are useful on vehicles, such as planes, trains, and automobiles, boats, and ships. They can be used on painted, primed (e.g., epoxy primer, chromated primer), or bare surfaces. They can be used on metal surfaces, particularly aluminum surfaces, which can be an anodized surface, a chromate-treated surface (which results from treatment with Alodine 1200, available from Amchem Products, Inc., Abmoler, Pa., or otherwise treated surface. They can be used on surfaces of composite materials, such as carbon fiber reinforced plastics, for example.
The appliques of the present invention can be in a variety of shapes, sizes, and thicknesses. They can be in the form of sheet materials or they can be in the form of three-dimensional shaped articles, such as a thermal-formed boot. Such three-dimensional shaped appliques can be used on the wingtip or nose of an airplane, for example. If in the form of a sheet material, the applique typically has a thickness of about 12-760 micrometers, whereas if in the form of a three-dimensional object, the applique typically has a thickness of about 170-760 micrometers.
The appliques of the present invention can be used as decals and decorative appliques or they can be used as protective appliques to reduce corrosion, gouge, and scratch damage, for example. They can be used in multiple layers, such as a protective applique over a decal or a decal over a protective applique, for example. Significantly, the appliques of the pre
Dietz Timothy M.
Gustafson Donald E.
Weigel Mark D.
3M Innovative Properties Company
Bardell Scott A.
Chen Vivian
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