Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1995-11-28
2001-10-23
Johnstone, Adrienne C. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S212000, C156S285000, C156S475000, C156S477100, C156S580000, C156S583910, C264S500000, C264S510000, C264S557000, C264S570000, C425S503000, C425S387100
Reexamination Certificate
active
06306237
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to the field of lamination, and, more particularly, to a method and system for laminating a thin or flexible film or rolled sheet material to a substrate surface using the step of conforming the film or sheet to the substrate using a pressurized liquid.
BACKGROUND OF THE INVENTION
Lamination is commonly defined as a process of applying, in a relatively permanent manner, a thin film or sheet of material to an underlying substrate. Lamination has been used in single or multiple applications to either provide a surface finish different from the underlying substrate, or to provide additional protection to the underlying substrate, or to enhance certain properties of the underlying substrate. Examples of laminated products include snow and water skis, furniture, airplane interiors, etc. Historically, such processes have involved applications to substantially smooth surfaces, at the time of lamination. Vacuum press application and other laminating processes used for laminating to a substrate with a detailed, textured or embossed surface, which surface has multiple surface plane deviations, of differing heights and depths, suffer limitations particularly on a continuous manufacturing basis. While some technological advancements have been made in batch process lamination for finished pieces with textured surfaces, the process is very labor and time intensive, with resultant higher costs and lower output. There are significant cost advantages for a process that can provide the desired finish textured product in a continuous manufacturing process, but such processes have heretofore been unavailable.
Continuous laminating processes have used conforming pressures exerted by various types of rollers, to seal the laminate against the substrate. However, such processes are most suitable for use with substrates that are substantially smooth, flat or plane surfaces, and to some extent curved and angled surfaces. In the case of a solid roller system, a uniform or near uniform conforming pressure must be continuously exerted by the rollers (or set of rollers) in order to properly bond the film to the substrate. However, solid roller technology, while a continuous process, has the limitation of being incapable of the substantial pressure needed to force the film on and into a rough or textured substrate surface and of being inapplicable where the film or substrate will not tolerate the substantial pressure needed. Also, if the substrate has an embossed or textured surface, a solid roller may fail to adequately reflect or telegraph all details of the surface. Solid rollers are also incapable of providing differential pressures on a textured surface, and so can cause undue pressure to be exerted at high points of the substrate (damaging or compromising the adhesive film and/or substrate), and insufficient pressure in the low points (causing incomplete bonding of the film to the substrate). Thus, lamination with rollers typically results in uneven pressure distribution and uneven adhesion. Vacuum/bladder technology can be used to perform lamination of uneven surfaces, however, the technology can only be performed in a batch process, resulting in the low throughput and high costs, and, therefore, is limited to end products with a relatively high intrinsic value.
While laminating procedures may exist to apply film to flat, contoured and slightly uneven surfaced substrates, there has been no suggestion of previously known technology which provides the attributes and benefits of the current invention including the ability to laminate films or sheet to embossed or textured surfaces in a continuous process using pressurized liquid, with fine telegraphing of the surface.
The potential commercial value is enormous for a process that manufactures a laminated textured product in a continuous process. The current invention provides such a process and addresses the previously noted shortcomings or inadequacies in present laminating processes and technology.
SUMMARY OF THE INVENTION
The present invention provides a method and system for lamination that have unique advantages over prior processes in the art and particularly in regard to processes for continuous lamination (but can also be done in batch) of a substrate so as to finely and definitively reflect surface embossments or textures, without tearing or structurally compromising the laminating film or sheet. The underlying substrate and the laminating film or sheet is combined with (or without) chemical interaction to produce a material with structural or functional properties different from those of the individual constituents. The present invention also provides improved temperature control with superior quench attributes, competitive capital cost, high production level, flexibility in application and use, and cost effective operation. Along with the novel application of laminating material to an embossed or textured surface through the present invention, this invention can also be used for laminating to smooth, curved or angled surfaces, as well as to any surface of wide or narrow profile. The present invention also allows for wrapping of edges on a continuous production basis.
The invention comprises a method in which liquid, heated or cooled as necessary, is applied under pressure through a manifold system and by way of application nozzles to laminate the film or sheet to the underlying substrate. Several factors may be adjusted to optimize the application of the laminating film or sheet to the underlying substrate, depending on materials used, including: 1) the height and size of the manifolds and nozzles to adjust the liquid curtain or stream; 2) the angle of nozzles for application of the liquid pressure; 3) the temperature of the liquid, film and substrate; 4) the type of liquid used; 5) the type of adhesive used; 6) impact, which is a combination of pressure, flow rate and temperature; and 7) additives to the liquid to modify surface appearance and to provide definitive or desired characteristics. Variations in materials include the laminating film or sheet, underlying substrate and adhesive. Because the present invention allows for the relatively easy adjustment of these factors, the use and applicable materials is quite broad.
To further enhance the continuous process aspects of the present invention, various parts can be enhanced to improve operations or ensure the continuous nature, including using manifolds with a self-cleaning device to prevent blockage; installing the manifolds on movable shafts enabling the ability for the spray pattern to be moved on all axis to accommodate the most difficult of patterns, sizes or structures of the underlying substrate or desired end product; and operating the manifolds in such a manner as to activate specified nozzles or channels of nozzles to allow for selected or differential levels of lamination. An optional and additional feature of the present laminating process is integration of the process with a fluid collection and recycling system to further provide the user with the ability to capture and recover fluid used in the process for recycling, resulting in low fluid loss and high energy efficiency, particularly with heated liquids.
Combined with conventional pre-heating/cooling of the substrate and heating/cooling of the laminating film or sheet to meet defined parameters of the materials including the adhesive, the present invention has the ability to provide superior temperature control and quench facilities enabling the user to modify the processes to meet variables in the underlying substrate, adhesive and other materials, and still obtain a finished product with superior lamination even to a highly embossed or textured surface.
While laminating procedures may exist to apply film to flat, contoured and slightly uneven surfaced substrates, there has been no suggestion of previously known technology which provides the attributes and benefits of the current invention including the ability to laminate films or sheet to embossed or textured surface
Johnstone Adrienne C.
Summit Law Group
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