Note: Descriptions are shown in the official language in which they were submitted.
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ARTICLES AND METHODS FOR APPLYING COLOR ON SURFACES
Field of the Invention
The present invention relates to articles and methods for applying color and,
in
particular, to articles and methods for applying a dry colorant to a surface.
Background of the Invention
It is often desirable to apply one or more colors to a surface, for example an
architectural surface such as an interior or exterior wall or the like, for
aesthetic benefits and/or
functional benefits such as water resistance. Color is typically provided by
conventional painting
with water-based or oil-based wet paints, application of wallpaper or the
like. The laborious
processes involved with wet painting and wall papering are well known.
Typically, it is necessary
to protect surrounding areas from collateral mess during such activities by
taping adjacent
surfaces where the color is not desired, arranging drop clothes to protect
floors and furniture, and
the like. Extreme care must also be exercised to avoid dripping of paint,
wallpaper paste or
primer, or other wet-applied materials. Many wet paint and wall paper products
are also
recommended for use together with one or more primers or bases to assist in
coverage and/or
durability of the desired color, thereby increasing the time and labor for
producing a desired color
effect on such a surface.
Additionally, it is typically necessary to saturate brushes, rollers or other
applicators with paint, primer, paste or the like in order to apply the
material to a surface. As a
result, a significant amount of material is wasted, as it never reaches the
intended surface, but
remains on the applicator. Cleaning of brushes, sprayers, rollers and other
tools used in
application of wet paint and wall paper once painting or wall papering is
completed, or at least
suspended for a period of time, such as overnight, is also time consuming.
Many paints adapted for application to surfaces such as architectural surfaces
include one or more volatile organic compounds. Such paints release noxious
fumes during and
after application, thereby requiring ventilation during and after application,
particularly in closed
environments such as buildings.
In structural surface covering operations that incorporate multiple strips or
sheets
of material, a seam is formed between each juxtaposed pair of strips. Seams
provide
imperfections that detract from the aesthetic appearance, or some other
property, of the facade
presented by the strips. Consequently, seam concealment is a significant
concern in such
structural surface covering operations. For example, the seams between
adjacent dry wall panels
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2
are covered with drywall tape. With regard to covering operations that apply
color to a surface,
wallpaper is applied to interior walls by pasting multiple strips adjacent to
each other. Wallpaper
may be systematically applied to an interior wall by aligning a vertical edge
of an initial strip with
a plumb line drawn on the wall. At least one of the opposite vertical edges of
the initial strip
operates as a verticality guide for the application of subsequent strips of
wallpaper. Adjacent ones
of. the strips are positioned in abutment so as to minimize the presence of
gaps between
juxtaposed margins or the occurrence of overlap. Typically, however, the
vertical seams between
adjacent pairs of strips are visibly perceptible. The visual presence of the
vertical seams detracts
from the aesthetic appearance of the color applied to the surface by the
wallpaper.
Thus, in spite of the obvious aesthetic and/or functional benefits provided by
applying color on a surface by conventional techniques such as wet painting or
wall papering, the
efforts required in connection with such procedures are inconvenient and time
consuming and,
moreover, the color applied to the surface may incorporate one or more seams
that detract from
the manifestation of the color effect to an observer.
Summary of the Invention
An object of the present invention is to provide articles and methods for
applying color on
surfaces. In accordance with an aspect of the present invention, there is
provided an article for
applying color on a surface, characterized by comprising a sheet of
dry colorant having a peripheral edge, a margin adjacent to said peripheral
edge, a front sheet
surface, and a rear sheet surface opposite the front sheet surface; and an
adhesion means on said
rear sheet surface for adhering said sheet to the surface;
optionally, wherein said sheet and said adhesion means are characterized by
having a thickness of
less than 3.3 mils, and at least said margin of said sheet is adapted to
reduce the visual
perceptibility of a seam created when said article is overlapped with a
juxtaposed second article;
optionally wherein said front sheet surface includes a printed pattern
characterized by having a
plurality of image elements and a plurality of contrasting areas, each of said
image elements
spaced from an adjacent one of said image elements by a corresponding one of
said contrasting
areas in a manner operative for reducing the visual perceptibility of said
seam when said article is
overlapped with the juxtaposed second article; and
optionally, wherein adjacent ones of said image elements are characterized by
having a spatial
distribution free of perceptible organization.
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2a
In accordance with another aspect of the invention, there is provided an
article for applying
color on a surface, characterized by comprising a sheet of
dry colorant having a peripheral edge, a margin adjacent to said peripheral
edge, a front sheet
surface, and a rear sheet surface opposite the front sheet surface; an
adhesion means on said rear
sheet surface for adhering said sheet to the surface, said margin capable of
being juxtaposed in a
non-overlapping manner with a margin of a juxtaposed second article so as to
provide a gap
therebetween;
optionally, wherein said sheet and said adhesion means having a thickness of
less than 3.3 mils;
optionally, wherein said gap is associated with a filler, said filler adapted
to reduce the visual
perceptibility of said gap;
In accordance with another aspect of the invention, there is provided a kit
article for applying color-
on a surface, characterized by comprising a sheet
of dry colorant having a peripheral edge, a margin adjacent to said peripheral
edge, a front sheet
surface, and a rear sheet surface opposite the front sheet surface; an
adhesion means on said rear
sheet surface for bonding said sheet to the surface, and an initiator
operative to promote the
reduction in visual perceptibility;
wherein, at least said margin of said sheet is adapted to reduce the visual
perceptibility of a seam
created when said article is overlapped with a juxtaposed second article;
optionally, wherein said sheet and said adhesive have a thickness of less than
3.3 mils;
optionally, wherein said kit further comprises an applicator adapted to
selectively apply said
activation liquid to said margin;
optionally, wherein said kit further comprises an applicator adapted to
selectively heat said.
margin;
optionally, wherein said kit further comprises an applicator adapted -to
selectively provide said
initiator to said margin;
optionally, wherein said applicator is incorporated into a device used to
apply the article to the
surface; and
optionally, wherein said sheet includes a selectively collapsible structure,
and said initiator
comprises a pressure applying device adapted to selectively provide
compressive pressure to said
collapsible structure.
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2b
In accordance with another aspect of the invention, there is provided a method
for applying
dry colorant to a surface, characterized by comprising
adhesively securing a first article including a sheet of dry colorant to the
surface and adhesively
securing a second article including a sheet of dry colorant to the surface in
a juxtaposed
relationship with the first article;
optionally, wherein the first and the second articles each comprise a
thickness of less than 3.3
mils;
optionally, wherein the first and the second articles each comprise respective
margins overlapped
to provide an overlapped thickness; and
optionally, wherein said method further comprises the step of reducing the
visual perceptibility of
a seam created by the overlap of the first and second articles.
In accordance with another aspect of the invention, there is provided a method
of
manufacturing an article for applying colorant to a surface,
characterized by comprising fabricating a sheet of dry colorant, the sheet
having a margin;
associating an adhesion means with the sheet of dry colorant; and modifying
the sheet for
reducing the visual perceptibility of a seam created when the sheet is applied
to the surface with
the margin in an overlapping relationship with a margin of another sheet;
optionally wherein said sheet of dry colorant and the adhesion means have a
thickness of less than
3.3 mils;
optionally, wherein the step of modifying includes printing a pattern on a
front sheet surface of
the sheet, the pattern having discrete image elements spaced apart so as to be
operative for
reducing the visual perceptibility of the seam; and
optionally, wherein adjacent ones of said image elements have a spatial
distribution free of
perceptible organization.
The present invention is directed to an article for applying color on a
surface that
includes a sheet of dry colorant having a peripheral edge, a margin adjacent
to the peripheral
edge, a front sheet surface, a rear sheet surface opposite the front sheet
surface, and an adhesive
on the rear surface for bonding the sheet to the surface. The sheet has a
thickness of less than 3.0
mils. In various embodiments of the invention, the margin of the sheet, or the
entire sheet
including the margin, is adapted to reduce the visual perceptibility of a seam
created when two
sheets are positioned with a juxtaposed relationship.
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2c
Brief Description of the Drawings
Various advantages, objectives, and features of the invention will become more
readily apparent to those of ordinary skill in the art upon review of the
following detailed
description of the preferred embodiments, taken in conjunction with the
accompanying drawings.
Fig. 1 is a diagrammatic top view of an article for applying color to a
surface
according to the present invention;
Fig. 2 is a diagrammatic end view of the article of Fig. 1;
Fig. 3 is a diagrammatic end view of two articles, as in Fig. 1, applied with
a
juxtaposed relationship to the surface such that a gap is formed between the
articles;
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Fig. 4 is a transverse cross- end view of a filler strip constructed according
to the
principles of the present invention for filling a gap between adjacent
articles as illustrated in Fig.
1;
Fig. 5 is a diagrammatic end view of a juxtaposed pair of articles having
overlapping margins;
Fig. 6 is a diagrammatic end view similar to Fig. 5;
Fig. 7 is a diagrammatic end view of an article in which the margins are
thinned
according to principles of the present invention;
Fig. 8 is a diagrammatic end view of an article in which the margins are
thinned
according to principles of the present invention;
Figs. 9A and 9B are diagrammatic cross-sectional views of an article in which
the
margins are thinned according to principles of the present invention;
Fig. 10 is a diagrammatic cross-sectional view of a portion of an article
having
microparticles according to principles of the present invention;
Fig. 11 is a diagrammatic end view of a portion of an article having
projections
according to principles of the present invention;
Fig. 12 is a diagrammatic cross-sectional view of a portion of an article
having a
cellular structure according to principles of the present invention;
Fig. 13 is a diagrammatic view of a portion of an article having contoured
peripheral edges according to principles of the present invention;
Fig. 14 is a diagrammatic view of a portion of an article having a pattern
according to the principles of the present invention;
Fig. 15 is a diagrammatic cross-sectional view of a portion of an article
having a
three-dimensional topography according to the principles of the present
invention; and
Fig. 16 is a schematic diagram of one process for producing an article for
applying color on a surface according to the principles of the present
invention.
Detailed Description
The present invention is directed to articles and methods for applying color
on a
surface. As employed herein, the term "color" is used to refer to a color
effect, i.e., a difference in
color or visual perception. In a specific embodiment, the color effect is a
substantially permanent
color effect, i.e., a color effect which is not removed upon casual contact,
light washing, or the
like. Thus, a substantially permanent color effect is distinguished from a
temporary color effect
which can be easily removed or reduced, such as that provided by chalk or
crayons. The terms
"colorant" and "color component" are used synonymously herein to refer to the
component of the
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inventive articles, which provides the color effect. Specifically, the
colorant is any composition
that provides opacity coverage to a surface to which it is applied and,
generally, the colorant
comprises a dry pigment or dye, alone or in combination with additional
components. For
example, the colorant may be a dry paint including pigment particles, other
conventional paint
components, and a liquid carrier that has been substantially removed by
vaporization during the
process to providing the dry paint.
As another example, the colorant may be an engineered sheet or laminate formed
from suitable thermoplastic resins and including a substance, such as pigment
particles or dye
molecules, in a sufficient concentration and with an appropriate distribution
to produce a color
effect. Specifically, the colorant may be formed from thermo-formable
engineering polymer
resins, including but not limited to acrylics, urethanes, polyvinyl chloride
(PVC), polyvinylidene
fluoride (PVDF) and polyvinylidene chloride (PVDC). The various layers of the
colorant may
possess differing compositions and/or properties effective to apply color to a
surface.
The term "surface" is used herein to refer to any outer layer or boundary of
an
object or substrate which is capable of receiving a color component thereon.
Suitable surfaces
may be substantially two-dimensional and flat or substantially three-
dimensional and including
curves, angled portions or the like. In one embodiment, the surface to which
color component is
applied using the articles and methods of the invention comprises an
architectural surface, i.e., a
surface of a building, a building fixture (i.e., appliances), furniture, and
the like. The architectural
building surface may be an interior surface within the building or an exterior
surface on an outer
portion of the building. Substantially three-dimensional architectural
surfaces can include, for
example, edge treatments of two-dimensional surfaces such as moldings (e.g.,
moldings around
windows or doorways), floorboards, appliances, furniture, and the like. The
architectural surface
may be permanently installed or may be temporarily installed or portable. The
products of the
present invention can further be applied to surfaces of articles to give them
the same or different
texture and/or appearance of architectural surfaces. For example, the products
hereof can be used
to apply a color layer to appliances, furniture, and other architectural
articles. Additional surfaces
suitable for application of color using the articles and methods of the
present invention will be
apparent to those skilled in the art in view of the present disclosure.
With reference to Figs. 1 and 2, an article 10 for applying color on a surface
(not
shown) according to the present invention includes a planar sheet 12 of a dry
colorant or dry color
component and a layer 25 of an adhesive or bonding agent. The sheet 12 has a
front sheet surface
14, a rear sheet surface 16 opposite the front sheet surface 14, four
peripheral edges 20, 22, 24,
26, and a margin 18 disposed adjacent to peripheral edges 20, 22, 24, 26. The
margin 18 defines
CA 02485281 2007-10-26
an annular strip or band of dry colorant extending circumferentially about the
peripheral edges 20,
22, 24, 26 of the sheet 12 and inwardly a given dimension or width toward the
center of the sheet
12.
The article 10 may
be a laminate formed from multiple layers of thermoplastic resins, as
indicated by reference
numeral 19 and shown in dot-dashed lines in Fig. 2. Generally, the average
thickness of the sheet
12 and the adhesive layer 25 is less than or equal to about 3 mils.
The adhesive layer 25 is applied to a substantial portion of the rear sheet
surface
16 of sheet 12. The adhesive layer 25 may be any bonding agent operative for
creating a secure
adhesive bond between the article 10 and a surface (not shown). A particularly
suitable adhesive
is pressure-sensitive so that the article 10 can be secured to the surface and
repositioned before
applying a pressure of a magnitude sufficient to create a final adhesive bond
with the surface.
The article 10 may be wound into a roll and applied to the surface with a
suitable applicator (not
shown) operative for dispensing the article 10 in a controlled manner.
Alternatively, the article 10
may be applied to the surface manually without the use of an applicator. It is
appreciated that the
applicator may facilitate, or otherwise implement, certain embodiments of the
present invention
for eliminating, reducing, or otherwise lessening the visual perceptibility of
seams between an
adjacent pair of articles 10.
Because the dimensions of the article 10 are limited, multiple articles 10 are
positioned with an adjoining or juxtaposed relationship to apply color to
certain surfaces, such as
architectural surfaces including interior and exterior walls of residential
and commercial
buildings. As a result, one of the peripheral edges 20, 22, 24, 26 of one
sheet 12 is positioned
adjacent to one of the peripheral edges 20, 22, 24, 26 of another adjacent
sheet 12. Depending
upon the precise placement of the sheets 12, the respective margins 18 of the
juxtaposed pair of
sheets 12 are overlapping, abutting, or separated or spaced apart by a groove
or gap so as to create
a seam. The seam presents an irregularity in the otherwise smooth,
uninterrupted coverage of the
surface by the articles.
Seams tend to be visually perceived or discerned by an observer and, if
uncorrected, degrade the aesthetic appearance of color supplied by the
articles 10 to the surface.
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According to the principles of the present invention, the visual
perceptibility of the seam may be
lessened, reduced or eliminated by modifying one or more properties or
characteristics of article
10. The change in visual perceptibility of the seam may be promoted by a
physical mechanism, a
chemical mechanism, an optical mechanism, or combinations thereof.
Adjacent articles 10 may be overlapped or gapped due to, for example,
imprecision during application to the surface. Overlaps or gaps between
adjacent articles 10 may
also be introduced due to dimensional irregularities in the surface to which
the articles 10 are
being applied. For example, architectural surfaces can bow in and out, sway,
lean and frequently
lack plumb inner and outer corners. Furthermore, features such as windows and
doors present in
most architectural surfaces are often out of vertical plumb, sometimes
dramatically, and the
ceiling line can sway and dip unevenly. These irregularities can be produced
by settling of the
structural components of the building or by construction errors. Overlap is
also present when a
custom dimensioned article is used to patch an existing color effect on a
surface to, for example,
cover or conceal a mark or to cover a small area from which the original color
has been removed.
With reference to Fig. 3 in which certain dimensions are exaggerated for
purposes
of illustration, a plurality of, for example, two articles 10 may be applied
to a surface 28 so as to
create a gap or groove 30 between each juxtaposed pair of articles 10. The
adhesive layer 25 of
each article 10 contacts a confronting portion of the surface 28 and promotes
an adhesive bond
therebetween. When the articles 10 are applied to the surface 28, margin 18 of
one sheet 12 is
juxtaposed in a non-overlapping manner with margin 18 of the adjacent sheet 12
so as to generate
the groove 30. The groove 30 may have uniform width or a varying width and may
be linear or
non-linear along extent of the juxtaposition.
According to principles of the invention, a filler may be introduced into the
groove 30 after the articles 10 are applied to surface 28. The filler may have
any suitable
structure or form having one or more characteristics capable of reducing the
visual perceptibility
of the groove 30.
In one embodiment, the filler is a grout 31 composed of a spreadable material
that
has physical attributes at ambient temperature, such as a suitably low-
viscosity to promote
spreadability, suitable for being received into the groove 30. The grout 31,
after application and
curing, may be any material having visual characteristics similar to the
visual characteristics of
the sheet 12 of the adjacent articles 10 and, preferably, any material that is
imperceptible or
indistinguishable in visual appearance with the visual appearance of sheet 12
of the adjacent
articles 10. To that end, the grout 31 may incorporate a polymer or resin
similar to the polymer or
resin forming the base material of the sheet 12 or the base material of at
least one layer of the
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sheet 12 that is laminated. The grout 31 typically incorporates a substance,
such as a pigment or a
dye, operative to provide the desired visual characteristics and a suitable
solvent or other
spreading agent. After the grout 31 is received in the groove 30, a portion of
the spreading agent
preferably evaporates over a characteristic curing time during which, among
other things, the
viscosity of the grout 31 is significantly reduced.
The present invention contemplates that the grout 31 may be applied to the
groove 30 between juxtaposed articles 10 either manually or with the
assistance of an applicator
(not shown). Specifically, for manual application, grout 31 is introduced or
injected into groove
30 and wiped or troweled to remove any excess so that the residual grout 31 is
generally co-planar
with the respective front sheet surfaces 14 of sheets 12. An applicator
suitable for use in this
aspect of the present invention includes a reservoir, which may be refillable,
holding a quantity of
the grout 31, a dispensing element for introducing the grout 31 at a regulated
uniform rate into the
groove 30, and a troweling or wiping element for removing any excess grout 31
not received in
the groove 30.
In another embodiment of the invention and with reference to Fig. 4, another
suitable filler according to the present invention is a filler strip 32 having
any form capable of
being associated with the groove 30 in a manner that eliminates, reduces, or
lessens the visual
perceptibility of groove 30. As illustrated, the filler strip 32 includes a
center portion 34 and
opposed thinner, flexible marginal portions 36, 38 flanking the center portion
34. The center
portion 34 is adapted to be at least partially received into the groove 30
with each of the marginal
portions 36, 38 overlapping a corresponding one of the margins 18 of the two
sheets 12. In one
embodiment, the center portion 34 is rigid and the marginal portions 36, 38
are malleable or
conformable. Preferably, the filler strip 32 substantially fills the groove 30
in a manner that
resists substantial removal forces after application. As illustrated, the
thickness of the marginal
portions 36, 38 is less than a thickness of each sheet 12 so that the marginal
portions 36, 38 add a
minimal incremental thickness to the overall thickness of the adjacent
articles 10. Alternatively,
the marginal portions 36, 38 of the filler strip 32 may be optically
transparent or translucent such
that the color provided by sheets 12 is visible therethrough.
With reference to Figs. 5 and 6 in which certain dimensions are exaggerated
for
purposes of description, multiple articles 10 may be applied for delivering a
color to a surface
such that the margin 18 adjacent one of the peripheral edges 20, 22, 24, 26 of
one sheet 12 has an
overlapping relationship with the margin 18 adjacent one of the peripheral
edges 20, 22, 24, 26 of
another sheet 12. As illustrated in Figs. 5 and 6, a portion of the margin 18
of the overlying sheet
12 provides an overseam 44 with an exposed surface visible to an observer and
a portion of the
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margin 18 of the underlying sheet 12 is captured as an underseam 46 between
the overseam 44
and the surface 28. Typically, the overlap between overseam 44 and underseam
46 will be less
than or equal to about 0.5 inches, although the present invention is not so
limited as it is
contemplated that the overlap between the articles 10 could extend over the
entire area of sheet
12. The average thickness of the overlapping overseam 44 and underseam 46 is
less than about 6
mils. Collectively, the overseam 44 and underseam 46 form a seam that, if not
modified
according to one or more embodiments of the present invention, would otherwise
likely be
visually perceived by an observer of the color effect provided to the surface
28.
With continued reference to Figs. 5 and 6, the overseam 44 and underseam 46
may be characterized in three dimensions by a height in a z-direction, a width
in the x-direction,
and a length in the y-direction. It is appreciated that the seam, formed by
overseam 44 and
underseam 46, extends in the y-direction into the plane of the page of Figs.
5, 6 and that the
effective dimension of the seam in the x-direction typically varies in the y-
direction. The
incremental height added by the overseam 44 in the z-direction is
substantially equal to the
thickness of margin 18. A portion of the seam may have a non-contacting
relationship with the
surface 28 so that a cavity 48 is created between a portion of the margin 18
and the surface 28.
Another portion of the overseam 44 creates an abrupt, sharp edge at peripheral
edge 24. The
discontinuity in the otherwise substantially planar surface of the juxtaposed
articles 10 introduced
by the presence of edge 24 provides an observable or perceptible visual
indication of the location
of edge 24 to a viewer of surface 28.
According to the principles of the present invention, the entire sheet 12 or
at least
the margin 18 of sheet 12 near at least one of the peripheral edges 20, 22,
24, 26 is modified in a
manner that eliminates, reduces or lessens the visual perceptibility of the
overseam 44 created by
the overlap between the respective margins 18 of a juxtaposed pair of sheets
12. It is
contemplated that the various principles of the present invention may be
combined for achieving
the elimination, reduction or lessening of the visual perceptibility of the
seam provided by the
overlapping overseam 44 and underseam 46.
In one embodiment of the present invention, the margin 18 adjacent at least
one
of the peripheral edges 20, 22, 24, 26 is thinner, before application to
surface 28, than other
portions of sheet 12 laterally disposed between the margins 18. Typically, the
average thickness
of the margin 18 adjacent at least one of the peripheral edges 20, 22, 24, 26
may be reduced to
about one-half of the thickness of the remaining portions of the dry colorant
sheet so that, after
overlapping, the composite thickness of the sheets is uniform or substantially
uniform. However,
the present invention is not so limited. All regions of the article 10,
including the overlapping
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overseam 44 and underseam 46 when the margin 18 is overlapped with the margin
18 of another
sheet 12, should have an opacity index ranging from about 0.95 to 1.0, as
measured according to
ASTM D2805 entitled "Standard Test Method for Hiding Power of Paints by
Reflectometry
(Spectrometer)."
Referring to Fig. 7 and according to one specific embodiment of the present
invention in which the margin is thinned, the margin 18 of sheet 12 is beveled
or tapered
outwardly toward peripheral edges 20, 24. It is appreciated that the margin
may be tapered
adjacent to any of the peripheral edges 20, 22, 24, 26. As illustrated in Fig.
7, the margin 18 is
tapered toward the front sheet surface 14 toward peripheral edge 20 and
tapered toward the rear
sheet surface 16 adjacent peripheral edge 24. The tapering of margin 18
provides oppositely
oriented wedge-shaped surfaces 40, 42 that extend into and out of the plane of
the page of Fig. 7.
Specifically, margin 18 tapers from a first thickness at each of respective
common boundaries 41,
43 shared with a peripherally inward portion of the sheet 12 to a second
lesser thickness at the
respective peripheral edges 20, 24. As a result, the thickness of the margin
18 decreases in a
direction from each of the common boundaries 41, 43 to the corresponding one
of the peripheral
edges 20, 24. It is appreciated that the margin 18 may be tapered with a non-
uniform taper angle
so that the thickness of the wedge-shaped surfaces 40, 42 is not monotonically
varying as
illustrated in Fig. 7. For example, the margin 18 near at least one of the
peripheral edges 20, 22,
24, 26 may be feathered so that the thickness in the z-direction and lateral
width in the x-direction
of the thinning vary randomly with location.
In another specific embodiment in which the margin is thinned and with
reference
to Fig. 8, the margin 18 of sheet 12 is shaped as a joint half 45 at
peripheral edge 20 and as a
complementary joint half 47 at the opposite peripheral edge 24. When the
margin 18 of one
article 10 is overlapped with the margin 18 of another article 10 and
adhesively secured, the joint
halves 45, 47 provide a complete lap joint. The overlapping lap joints 45, 47
preferably have an
effective thickness that produces a flush or continuous surface with the
peripherally inward
portions of each of the juxtaposed articles 10. It is appreciated that joint
halves 45, 47 may have
any complementary structure capable of being associated as a lap joint and is
not limited to the
specific embodiment depicted in Fig. 8.
With reference to Figs. 7 and 8, an average thickness of the margin 18
illustrated
in Figs. 7 and 8 is less than an average thickness of peripherally-inward
portions of sheet 12. It is
contemplated by the invention that the margin 18 may be thinned by, for
example, providing
wedge-shaped surfaces 40, 42 or joint halves 45, 47, during manufacture of the
article 10 by the
forming process (e.g., printing of the sheet 12) or by a mechanical or wet
chemical process, after
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forming, that selectively removes a suitable thickness of the sheet 12.
Alternatively, it is
appreciated that mechanical and wet chemical thinning of the margin 18 may be
performed at the
point of application of article 10 to the surface. Mechanical thinning
processes generally rely on
mechanical action, such as abrasion or cutting, for material removal whereas
wet chemical
thinning processes generally rely on a chemical reaction that etches,
dissolves or otherwise
removes material. For chemical thinning, the thickness of removed material may
be controlled,
for example, by regulating the exposure time of the dry colorant of the margin
18 to the etchant
chemical. To that end, the etchant chemical may be applied with a suitable
applicator and
removed with a device, such as a wet vacuum, or by simple wiping with an
appropriate absorbent
article or other removal device when the exposure time lapses. It is
contemplated that the etchant
chemical may be provided to the consumer in a kit also containing the article
10 for applying
color and that the applicator for the etchant chemical and/or the removal
device may be
incorporated into the applicator for applying the articles 10 to the surface
28 (Fig. 5).
With reference to Fig. 9A and in accordance with the principles of the present
invention, the sheet 12 of article 10 is formed from a plurality of, for
example, five layers 50-54
and is effectively thinned in vicinity of the margin 18 by contouring at least
the respective
peripheral edges 20, 24 so as to provide a tiered or rounded edge structure.
To that end, the center
layer 52 of sheet 12 projects in a laterally outward direction beyond layers
50, 51, 53 and 54 and
layers 51 and 53 project laterally outward beyond layers 50 and 54. When a
juxtaposed pair of
the articles 10 is applied to surface 28 (Fig. 5) with margin 18 at, for
example, peripheral edge 20
of one of the articles 10 overlapped with, for example, peripheral edge 24 of
another of the
articles 10, the overlapping thickness of the overseam 44 and underseam 46
will be significantly
reduced due to the contact between the respective rounded edge structures. In
addition, the tiering
of the margin 18 at edges 20, 24, when viewed at a typical viewing distance
from surface 28,
provides a rounded appearance that operates to further eliminate, reduce or
otherwise lessen the
visual perceptibility of edges 20, 24.
In an alternative embodiment and with reference to Fig. 9B, the sheet 12 of
article 10 is
formed from a plurality of, for example, four layers 55-58 and is rounded in
vicinity of the margin
18 by contouring at least the respective peripheral edges 20, 24 so as to
provide a tiered or
rounded edge structure. Specifically, the laterally outward projection of
layers 55-58
progressively decreases from layer 55 to layer 58 so that layer 55 projects
outwardly the least
relative distance and layer 58 projects outwardly the greatest relative
distance. Similar to the
embodiment of the present invention illustrated in Fig. 9A, when a pair of the
articles 10 are
applied to surface 28 (Fig. 5) an edge 20 of one of the articles 10 overlapped
with another edge 24
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of another of the articles 10, the overlapping thickness will be significantly
reduced. In addition,
the tiering of edges 20, 24, when viewed by an observer at a typical viewing
distance from surface
28, provides a rounded appearance that operates to further eliminate, reduce
or otherwise lessen
the visual perceptibility of edges 20, 24.
When margin 18 having one of the constructions illustrated in Figs. 7, 8, 9A
and
9B is overlapped with a margin 18 of another juxtaposed article 10, which may
have a
complementary reduced-thickness construction, the average opacity index of the
entire surface of
the article 10 is between about 0.95 and 1.0, as measured according to ASTM
D2805. The
average thickness of the overlapping portions of the respective margins 18 of
a juxtaposed pair of
articles 10 is less than 6 mils.
According to another embodiment of the present invention and with renewed
reference to Figs. 1 and 2, the visual perceptibility of overlapped margins 18
of adjacent articles
is eliminated, reduced or otherwise lessened by incorporating an additive
operative to modify
the rheology of the sheet 12. The rheology-modifying additive is operative to
promote selective
coalescence, densification or fusion of the overlapped portions of the margin
18 of juxtaposed
sheets 12. The action of the rheology-modifying additive may occur
spontaneously or with the
assistance of an initiator. A compressive pressure may also be applied to
margin 18 at the point of
application without departing from the spirit and scope of the invention. The
rheology-modifying
additive may be any chemical agent that temporarily increases the workability
and flexibility of
the sheet 12. The rheology-modifying additive should be inactive, or otherwise
dormant, while
the article 10 is stored and before application to the surface 28 (Fig. 5).
The rheology-modifying
additive may volatize or evaporate from the margin 18, after a characteristic
working period, or
may remain resident in the article 10 after the coalescence is concluded. Once
coalescence is
concluded, the rheology-modifying additive should be no longer present or
should remain present
in a concentration such that the article 10 is not overly susceptible to
mechanical damage.
It is appreciated that the rheology-modifying additive may be dispersed
throughout the dry colorant forming sheet 12 or may be locally confined to dry
colorant forming
the margin 18. In either instance, the application of compressive pressure, if
required to provide
the coalescence, can be restricted to the margin 18 by using a suitable roller
of the like of a
limited width. It is further appreciated the article 10 may need to be stored
in a controlled
environment after manufacture so as preserve the chemical action of rheology-
modifying
additives that are volatile. For example, articles 10 containing such volatile
rheology-modifying
additives may be stored after manufacture in a sealed container (not shown),
such as a Mylar bag.
The fluid impermeable walls of such sealed containers would prevent or
otherwise inhibit loss due
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to volatilization, evaporation or vaporization of the rheology-modifying
additives until the article
is unsealed from the container at the point of application for providing color
to the surface 28
(Fig. 5). It is appreciated that any loss of the rheology-modifying additive
due to volatilization is
significantly reduced if the article 10 is merely tightly rolled.
In certain embodiments of the invention, the rheology-modifying additive may
be
a plasticizer added to the formulation of the material forming the sheet. The
plasticizer would
allow the dry colorant of the sheet 12 to flow for a period until the
concentration of temporary
plasticizer is sufficiently reduced by volatilization. Typically, the
plasticizer will be present in the
dry colorant of sheet 12 after manufacture at a concentration of less than
about 30 wt.%.
Plasticizers suitable for use in the present invention include propylene
glycol, ethylene glycol,
dibutyl phthalate and tricyresyl phosphate. Another plasticizer suitable for
use in the invention is
benzyl phthalate, which is available commercially under the SANTICIZER
tradename from
Ferro Corporation (Cleveland, Ohio). In addition, the rheology of
thermoplastic polymers used to
form article 10 may be modified by, for example, varying the type of polymer
resin, blending
various different polymer resins, or varying the molecular weight of the
polymer.
In other embodiments of the invention and with continued reference to Figs. 1
and 2, the rheology-modifying additive is a liquid-sensitive chemical agent
operative to coalesce
the margin 18, when selectively exposed to a suitable initiator consisting of
an activation liquid at
the point of application, after the article 10 is applied to the surface 28
(Fig. 5). The activation
liquid promotes a chemical reaction with the liquid-sensitive chemical agent
that coalesces the dry
colorant forming the margin 18 so that the thickness of the overlapped
overseam 44 and
underseam 46 (Fig. 5) is reduced and so that the exposed edge 24 of the
overseam 44 is rounded
or curved. Both effects are believed to reducing the visual perceptibility of
the overlapping ones
of margins 18 of a juxtaposed pair of articles 10.
The chemical reaction between liquid-sensitive chemical agent and the
activation
liquid is controlled to provide a predetermined thickness reduction of the
overseam 44 and
underseam 46 and/or rounding of the exposed edge of the overseam 44 (Fig. 5).
Preferably, after
a predetermined reduction and/or rounding is achieved, the activation liquid
is consumed or spent
and the chemical reaction ceases or otherwise halts. Alternatively, the
activation liquid may be
removed or a sufficient amount of an appropriate neutralizing agent may be
added. The liquid-
sensitive chemical agent and the activation liquid should be compatible with
the chemistry of the
dry colorant forming the sheet 12 such that the physical properties and color
of the article 10 are
not significantly affected once coalescence is induced and concluded. The
liquid may be applied
to sheet 12 at ambient temperature or heated before application. It is
appreciated that the liquid-
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13
sensitive chemical agent may be dispersed throughout the dry colorant forming
sheet 12 or may
be localized in the dry colorant forming the margin 18. If the entire sheet 12
contains the liquid-
sensitive chemical agent, the application of the activation liquid should be
controlled to wet only
the margin 18, such as by employing a suitable applicator of a restricted
effective application
width. It is contemplated that the activation liquid may be provided in a kit
also containing the
article 10 for applying color and that the applicator for the activation
liquid may be incorporated
into the applicator for applying the article 10 to the surface 28 (Fig. 5).
In other embodiments of the invention and with continued reference to Figs. 1
and 2, the rheology-modifying additive is a thermally-activated chemical agent
activated, at the
point of application to surface 28 (Fig. 5), when heated above ambient
temperature. The
thermally-activated chemical agent has a characteristic activation temperature
that must be
exceeded to initiate the coalescence. Below the activation temperature, the
thermally-activated
chemical agent is substantially inactive or inactive. The activation
temperature of the thermally-
activated chemical agent is selected such that article 10 does not experience
any significant
physical degradation or color change when heated to the activation
temperature. Such thermally-
activated chemical agents cause the dry colorant of the overlapped overseam 44
and underseam
46 to become more densely packed or to level by spreading for reducing the
composite thickness
and rounding the exposed peripheral edge 24 of the overseam 44 (Fig. 5).
To initiate coalescence, the margin 18 is exposed to a suitable heat source,
such
as a flow of heated air from a blower, a heated applicator or roller, or a
laser, for a duration and at
a temperature sufficient to cause the desired thickness reduction of the
overlapped overseam 44
and underseam 46 and/or rounding of peripheral edge 24 of overseam 44 (Fig.
5). Optionally, a
compressive pressure may be applied to margin 18 to assist the action of the
thermally-activated
chemical agent. If the entire sheet 12 contains thermally-activated chemical
agent, the application
of heat may be controlled so that only the margin 18 is heated to the
characteristic activation
temperature. For example, a heated roller of a suitable effective rolling
width may be utilized.
However, it is appreciated that the heat source may be operative to transfer
heat by convection,
conduction, radiation, or any combination thereof.
The chemistry of the thermally-activated chemical agent should be compatible
with the chemistry of the dry colorant such that the physical properties of
the dry colorant are not
significantly affected by the presence of the thermally-activated compound,
unless heat activated.
Exemplary thermally-activated chemical agents appropriate for use in the
invention as a
copolymer include ethylene-vinyl acetate copolymer and polyvinyl acetate
copolymer. Suitable
ethylene-vinyl acetate resins are available under the tradename Ultrathen from
Equistar (Houston,
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TX). Suitable polyvinyl acetate resins are available under the tradename
VINNAPAS from
Wacker Polymer Systems (Adrian, Michigan). Generally, ethylene-vinyl acetate
copolymer and
polyvinyl acetate copolymer are known to have a softening range between about
50 C and about
125 C. It is contemplated that other suitable copolymers could be selected
that would have
differing softening ranges for heat activation depending upon the specific
application.
Sheets 12 formed of engineered films containing thermoplastic resins are
readily
deformed or placed in a state suitable for deformation by the application of a
compressive
pressure, when heated to a sufficiently high temperature. It follows that the
rheology-modifying
additive may be intrinsic to the formulation of the thermoplastic resin. For
example, the base
thermoplastic resin of the sheet 12 may be blended with another thermoplastic
resin to provide the
requisite heat sensitivity for inducing coalescence.
It is appreciated that the rheology-modifying additive may be enclosed in
microcapsules for release and activation upon the application of an external
trigger. Any suitable
method of microencapsulation may be used to divide the rheology-modifying
additive into minute
liquid particles and to surround particles of the rheology-modifying additive
with rupturable
enveloping walls formed of a material having a suitable composition. The
material forming the
enveloping walls should be sufficiently thick and/or of a suitably compatible
material to resist
chemical attack by the encapsulated rheology-modifying additive and,
preferably, is inert to the
chemical action of the encapsulated rheology-modifying additive. At the least,
the material of the
enveloping walls should be impermeable to the confined rheology-modifying
additive for a
sufficient shelf life after manufacture to permit the articles 10 to be
applied to the surface and
release of the rheology-modifying additive. The microencapsulated particles of
rheology-
modifying additive may be evenly distributed with a uniform density in the
sheets 12 or may be
localized in the margin 18.
One method of initiating the action of the microencapsulated chemical agent is
to
provide frangible enveloping walls sufficiently thin to rupture upon
mechanical or physical
manipulation, such as a compressive pressure, during or shortly after
application of the article 10
to surface 28. The enveloping walls should have a thickness sufficient to
prevent premature
release of the chemical agent by accidental rupture under the physical
manipulation occurring
during mixing and sheet fabrication and during storage. Other initiation or
activation triggers
include, but are not limited to, release by dissolving the enveloping walls
with a suitable solvent
and release by selectively exposing the enveloping walls to radiant energy
such as heat or light.
In another embodiment of the invention and with continued reference to Figs. 1
and 2, the rheology-modifying additive is a solvent at the point of
application and operative to
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coalesce the dry colorant of margin 18. Such solvents promote a chemical
reaction with the dry
colorant forming the margin 18 that coalesces the polymer or resin base
material of the dry
colorant so that the thickness of the overlapped overseam 44 and underseam 46
(Fig. 5) is reduced
and the exposed edge 24 of the overseam 44 (Fig. 5) is rounded or curved. The
action of the
solvent is controlled to provide a predetermined degree of thickness reduction
and/or level of
rounding. The solvent should be compatible with the formulation of the dry
colorant such that the
physical properties and color of the article 10 are not significantly affected
in a permanent manner
after the coalescence is conclude. The application of the solvent is
preferably regulated so that the
only the margin 18 is wetted. For sheets 12 formed from thermoplastic resins,
suitable solvents
include, but not limited to, toluene, methylethyl ketone, methyl isobutyl
ketone, and ethanol,
capable of providing the desired coalescence.
In another embodiment of the invention, the visual perceptibility of the seam
created by the overlapping overseam 44 and underseam 46 of the respective
margins 18 (Fig. 5) is
reduced or eliminated by providing the article 10 (Fig. 5), in at least the
vicinity of margin 18,
with an additive or structure that mechanically compresses or collapses upon
the application of a
compressive pressure of a sufficient magnitude as an initiator after
application of article 10 to the
surface 28 (Fig. 5). Generally, the magnitude of the compressive pressure,
manually-applied and
unaided by mechanical assistance, is less than about 50 pounds per square inch
(PSI) and,
typically, is less than about 10 PSI. The compressive pressure may be applied
using a pressure-
applying device, such as a roller, of a suitable width that increases the
magnitude of the applied
compressive pressure due to the mechanical assistance in excess of the
magnitude of the
equivalent compressive pressure applied to the device. It is appreciated that
the suitable width
may be the entire width of the article 10. The selective collapse of the
collapsible structure
reduces the effective thickness of the overlapping overseam 44 and underseam
46 after a
juxtaposed pair of articles 10 is applied to surface 28.
The compressive pressure may be a differential pressure consisting of a first
pressure applied in the margin 18 and a lesser pressure applied to
peripherally inward portions of
the article 10. Alternatively, the compressive pressure may be applied
uniformly in those specific
embodiments of the invention in which the margin 18 is more susceptible to the
effects of the
compressive pressure than the remainder of the article 10. In the latter
embodiments of the
invention, the entire article 10 is modified so that the thickness is reduced
by the application of a
compressive pressure and the margin 18 is adapted to have a greater response
to that compressive
pressure so that the margin 18 experiences a greater thickness reduction than
peripherally inward
portions of the article 10. At the point of manufacture, the collapsible
structure or additive is
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introduced into the formulation of the dry colorant or into the formulation of
the material forming
adhesive layer 25 (Fig. 5) or, as may be the case, is provided by a suitable
forming process at the
point of manufacture.
In one specific embodiment of the invention and with reference to Fig. 10, the
article 10 includes a plurality of microparticles 60, usually gas-filled, that
are engineered to
collapse or crush upon the application of a force at the point of application
to surface 28 (Fig. 5).
It is appreciated that the gas-filled microparticles 60 may be incorporated in
the sheet 12 of dry
colorant as shown in Fig. 10, in the adhesive layer 25 as indicated by
microparticles 61 shown in
phantom lines in Fig. 10, or in both of these components of the article 10. It
is appreciated that
the microparticles 60, 61 may be positioned so as to span the boundary or
interface between the
adhesive layer 25 and the sheet 12 of dry colorant. The material forming the
microparticles 60, 61
and the gas filling the interiors of the microparticles 60, 61 should be inert
or otherwise non-
reactive with the components of the sheet 12 and/or adhesive layer 25.
Individual gas-filled
microparticles 60, 61 may be of any closed geometrical shape, such as
spheroidal.
The microparticles 60, 61 should have a sufficiently small dimension such that
their presence does not introduce outwardly-extending irregularities
perceivable by an observer
viewing the front sheet surface 14 after the article 10 is applied to the
surface 28 (Fig. 5) for
which a color benefit is desired. Typically, the microparticles 60, 61 should
have a maximum
dimension less than about 75% of the thickness of the sheet 12 and may have a
distribution of
particle sizes in which a maximum particle size is less than about 75% of the
thickness of the
sheet 12. The microparticles 60, 61 may be dispersed uniformly throughout the
volume of the
sheet 12 and/or adhesive layer 25 (Fig. 5). Any fragments originating from the
collapsed
microparticles 60, 61 are retained within the sheet 12 or the adhesive layer
25, as may be the case.
It is appreciated that, in the alternative, the incorporation of
microparticles 60, 61
into the dry colorant of the sheet 12 and/or adhesive layer 25 (Fig. 5) may be
limited to the
vicinity of margin 18. If the microparticles 60, 61 are present only in the
margin 18 (Fig. 5) or in
the adhesive layer 25 beneath margin 18, the thickness of the overlapped
overseam 44 and
underseam 46 (Fig. 5) will be reduced by the application of a compressive
pressure thereto. If the
microparticles 60, 61 are present throughout in the entire sheet 12, a
differential compressive
pressure is applied at the point of application so that the overlapped
overseam 44 and underseam
46 and/or adhesive layer 25 are subjected to a greater compressive pressure
than other portions of
the article 10. Microspheres in the margin of the article 10 will have a
reduced survival rate under
the action of the differential pressure so that the overseam 44 and underseam
46 will be thinned
collectively more than the remainder of the sheet 12.
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Each of the microparticles 60, 61 has an outer wall 63 formed of any suitable
material that is sufficiently thick and/or mechanically strong to resist
crushing or collapse until the
application of compressive pressure of a sufficient magnitude at the point of
application after the
article 10 is adhesively secured to the surface 28 (Fig. 5). Microparticles
60, 61 formed of hollow
glass spheriods are conventional and readily apparent to a person of ordinary
skill in the art.
Exemplary microparticles 60, 61 in the form of hollow glass bubbles having a
density in the range
of 0.05 g/cc to 0.10 g/cc and a diameter ranging between 40 microns and 177
microns are
disclosed in U.S. Patent No. 6,194,064 (Keeley et al.). Engineered hollow
glass microspheres of
soda-lime-borosilicate glass composition are available commercially under the
tradename
SCOTCHLITE Glass Bubbles from Minnesota Mining & Manufacturing Co. (St. Paul,
Minn.).
In an alternative embodiment and with reference to Fig. 11, the article 10 may
include a plurality of projections 62 extending outwardly from the rear sheet
surface 16 toward
the surface 28 (Fig. 5) when the sheet 12 is applied thereto. The projections
62 may be, for
example, truncated conical or frustoconical protrusions that taper from a base
near rear sheet
surface 16 toward an opposite tip and that have either a circular, oval or
polygonal cross-sectional
profile when viewed normal to the rear sheet surface 16. It is appreciated
that the projections 62
may assume other geometries capable of collapsing, such as a semi-
hemispherical shape or
elongate ridges, without departing from the spirit and scope of the present
invention. Adjacent
ones of the projections 62 are spaced with a suitable spacing so that the
collapse of adjacent ones
of the projections 62 is not interfering. The projections 62 are provided with
a tensile strength
susceptible to collapse or buckle along an axis substantially parallel to a
surface normal of the
surface 28 when a compressive pressure of a sufficient magnitude is applied in
a direction
generally toward the surface 28.
In certain embodiments, the projections 62 may be uniformly distributed across
the rear sheet surface 16 and the projections 62 in the margin 18 (Fig. 5) may
be configured to be
more susceptible to collapse. As a result, the application of a uniform
compressive pressure to the
article 10 would provide the desired thinning and edge-rounding for overseam
44 and underseam
46 (Fig. 5). In other embodiments of the invention, the projections 62 may
have uniform
construction and a greater thickness reduction achieved in the margin 18 by
selectively applying a
differential compressive pressure consisting of a larger compressive pressure
applied to the
overlapping overseam 44 and underseam 46 than in other areas of the article
10. In certain more
specific embodiments, the projections 62 may be provided only in the vicinity
of the margin 18 of
the sheet 12 so that the thickness reduction due to collapsing projections 62
is limited to the
margin 18.
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In an alternative embodiment, the adhesive layer 25 (Fig. 5) may be printed
onto
the rear sheet surface 16 (Fig. 5) of the sheet 12 with a pattern of
projections comparable to
projections 62, which are collapsible by a compressive pressure applied at the
point of
application. Sufficient space is provided between adjacent projections of
adhesive layer 25 to
allow space for the adhesive layer 25 to expand when the compressive pressure
is applied to
precipitate the collapse.
In yet another alternative of the invention and with reference to Fig. 12, the
sheet
12 or a portion of sheet 12 may be provided with a cellular structure
including a plurality of cells
64, which may be open and interconnected or isolated and closed. The cells 64
are susceptible to
collapse or buckling when a compressive pressure of a sufficient magnitude is
applied in a
direction generally toward the surface 28 (Fig. 5). Typically, the cells 64
include contiguous rigid
cell walls 65 that surround a hollow interior cavity filled with a gas, such
as air. Individual cells
64 may be provided with larger dimensions and/or more fragile cell walls 65 in
the margin 18
(Fig. 5) than individual cells 64 in peripherally inward portions of the sheet
12 and, as a result,
collapse to a thinner final structure upon the application of a compressive
pressure than
peripherally inward portions of sheet 12. Alternatively, the individual cells
64 may have a
uniform susceptibility to collapse and a differential pressure may be employed
during application
to the surface such that the degree of collapse is greater in the margin 18
than in the peripherally
inward portions of the sheet 12. Alternatively, the margin 18 of sheet 12
alone may be provided
with the cellular structure so that only the thickness of the margin 18 is
significantly modified by
the application of a compressive pressure. In yet another alternative and as
shown in dot-dashed
lines in Fig. 12, the adhesive layer 25 may be provided with a plurality of
cells 67, constituting a
cellular structure, in addition to, or instead of, the cellular structure of
the sheet 12.
In yet another embodiment of the invention and with reference to Fig. 13 in
which the dimensions are enlarged for purposes of illustration, one or more of
the outer peripheral
edges 20, 22, 24 26 of the margin 18 of sheet 12 are contoured or shaped in a
pattern having a
plurality of repeat elements 66. The repeat elements 66 comprise the
individual components of
the pattern that collectively provide the contoured edges 18, 22. The repeat
elements 66 have any
configuration, arrangement and/or dimension operative for reducing the visual
perceptibility of
the overlapping overseam 44 and underseam 46 (Fig. 5). For monochromatic or
nearly-
monochromatic colors, the repeat elements 66 and the transitions between
adjacent ones of the
repeat elements 66 are smoothly curved so that pointed or jagged portions are
absent, although the
present invention is not so limited. For articles 10 provided with a patterned
front sheet surface
16 (Fig. 5), repeat elements 66 having, or separated by, jagged edges may be
acceptable,
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according to the principles of the invention, so as to be complementary to a
printed pattern 68
(Fig. 14).
The repeat elements 66 may be either periodic with a constant frequency and
amplitude or aperiodic (i.e., random) with a variable, irregular frequency and
amplitude. Repeat
elements 66 having an amplitude and a wavelength of about 15 ^m to about 12 mm
are believed
to be acceptable. The repeat elements 66 may be created in sheet 12 during the
manufacturing
process using any suitable device as would be recognized by a person of
ordinary skill in the art,
including but not limited to cutting implements such as pattern shears and
laser cutting devices.
Alternatively, the repeat elements 66 may be provided at the point of
application by, for example,
a hand-held tool or applicator device or by a blade or cutter incorporated
into an applicator used to
apply the article 10 to the surface 28 (Fig. 5). The repeat elements 66 alter
the linear nature of the
peripheral edge 24 of the overseam 44 (Fig. 5). The ability to perceive the
overseam 44 is
reduced by the presence of the repeat elements 66 because the human eye tends
to perceive an
irregular edge less readily than a linear edge.
In yet another embodiment of the invention and referring to Fig. 14, a printed
pattern, indicated generally by reference numeral 68, is provided on the front
sheet surface 14 of
the sheet 12. The printed pattern 68 contains various shaded areas or image
elements 70
surrounded by contrasting areas 72. The image elements 70 and contrasting
areas 72 may be
configured to provide the printed pattern 68 with a visual perception of depth
or may be
configured to provide a three dimensional appearance to an observer.
Alternatively, the printed
pattern 68 may be provided with an actual depth or texture in three-dimensions
by utilizing certain
printing techniques known to persons of ordinary skill in the art. The image
elements 70 and
contrasting areas 72 may collectively form any geometrical shape or design
effective for reducing
the visual perceptibility of overlapping margins 18. It is contemplated by the
invention that a
printed pattern 68 of greater complexity may be created on the front sheet
surface 14 by providing
multiple different types of image elements 70 and/or multiple different types
of contrasting areas
72.
The printed pattern 68 may be generated on the front sheet surface 14 by
applying
any ink or dye composition, either solvent-based or water-based, that is
compatible with the dry
colorant material forming the sheet 12. Conventional methods for applying the
printed pattern
include gravure, flexography, Mayer rod procedures, slot die applicators, roll
coaters, and digital
printing, each of which is particularly well-suited useful for applying a
printed pattern to sheet
material conveyed past a printing station.
Sheets 12 of dry colorant formed from thermoplastic polymer resins may be
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provided with a printed image by any suitable printing technique familiar to
persons of ordinary
skill in the art. Furthermore, the printed image formed on such sheets 12 may
have a relief that
provides a textured appearance in addition to a characteristic pattern
provided by image elements
70 and contrasting areas 72.
The image elements 70 of printed pattern 68 may be spaced apart by a distance
and with a frequency that reduces the visual perceptibility of the overlapping
overseam 44 and
underseam 46 (Fig. 5). The image elements 70 constituting the printed pattern
68 typically have
any dimension and spacing compatible with seam concealment and configured or
arranged so that
the printed pattern 68 has no readily perceived organization. Adjacent ones of
the image elements
70 in the printed pattern 68 may have a periodic, two-dimensional spacing with
a lengthy
periodicity so as to not be readily perceived at a normal observation
distance. Preferably,
however, the image elements 70 will be any printed pattern 68 of image
elements 70 that exhibits
no readily perceived organization, regularity, directionality, or orientation
of the constituent
image elements 70. In such an amorphous or non-ordered pattern, the
orientation and
arrangement of one image element 70 with regard to a neighboring image element
70 bears no
predictable or discernable angular or spatial relationship to that of the next
succeeding image
elements 70 beyond. In one specific embodiment of the present invention, the
printed
pattern 68 on the front sheet surface 14 may comprise a matrix of pixels, as
understood by persons
of ordinary skill in the art. The printed pattern 68 will have a given pixel
density measured in
dots per inch. Each pixel in the printed pattern 68 is characterized by a hue
within the visible
electromagnetic spectrum and a pixel size, typically in the range of about 30
^m to about 100
^m. The printed pattern 68 of pixels may be printed on the front sheet surface
14 of the sheet 12
with an appropriate printing device, such as a dot matrix printer, laser
printer or an ink jet printer,
as understood by persons of ordinary skill as being operative to apply the ink
or dye composition
onto the surface.
In another embodiment of the invention and with reference to Fig. 15 in which
feature sizes are exaggerated for illustration, the front sheet surface 14
(Fig. 2) of the sheet 12 is
textured with a three-dimensional topography consisting of multiple surface
features 74 either
relieved into and projecting outwardly from the sheet 12. More specifically,
the surface features
74 are formed, on a statistical average, above and/or below a plane containing
the front sheet
surface 14 and are spatially distributed in either a random fashion or a
repeating pattern. The
profiles of the surface features 74 are of any configuration or combination of
configurations, such
as angular, curvilinear, irregular, or the like.
The surface features 74 may be aperiodic or amorphous or may be added as an
CA 02485281 2007-10-26
21
intentional or a deliberate pattern having a period that exhibits no readily
perceived organization.
Preferably, the pattern of surface features 74 is amorphous in that the
surface features are non-
uniform with regard to their size, shape, orientation, and spacing between
adjacent feature centers.
In a completely amorphous pattern, as would be preferred, the center-to-center
spacing of adjacent
surface features 74 is random, at least within a designer-specified bounded
range, such that there
is an equal probability of the nearest neighbor to a given surface feature 74
occurring for any
arbitrary angular orientation within the plane of the sheet 12.
One method of creating the surface features 74 is to add a plurality of
particulates, such as deformable wax prills or granules of a non-compressible
material such as
sand, to the article 10. The particulates may be located in the dry colorant
of sheet 12 or in the
adhesive layer 25 (Fig. 5) applied to the rear sheet surface 16 of the sheet
12. The spatial
distribution of the particulates determines the topography of the dry
colorant, which is preferably
aperiodic or amorphous. The particulates have a maximum dimension greater than
the thickness
of the article 10 and, typically, have a particle size range of about 0.15 m
to about 150 m. After
the article 10 is applied to the surface 28 (Fig. 5), the particulates are
visually perceived as
outwardly-projecting irregularities.
Alternatively, the textured pattern of surface features 74 may be stamped,
imprinted, embossed or impressed on and/or into the sheet 12 using, for
example, a stamp or an
embossing roller whose relief portions represent the texture as a negative
image. The embossing
may be accomplished by the application of sufficient heat and/or sufficient
pressure to impart the
texture. The textured pattern of surface features 74 may be applied at the
point of application or
at the point of manufacture, either before or after the sheets 12 are mounted
to the surface 28 (Fig.
5). The embossing of an amorphous textured pattern in planar articles during
manufacture is
described in commonly-owned U.S. Patent No. 6,193,918 (McGuire, et al.).
At the point of application, the textured pattern of
surface features 74 may be applied by heat and/or pressure using any suitable
hand-held tool, such
as an embossing roller or an applicator for article 10 that incorporates an
embossing roller in its
construction.
In another embodiment of the present invention, a textured backing layer (not
shown) may be associated with the rear sheet surface 16 of the sheet 12 (Fig.
2) either during
manufacture or at the point of application. The textured backing layer may be
formed of any
suitable material in which an impressed pattern may be conveyed, such as paper
and other
cellulosic materials, polymer films and woven or nonwoven fabrics, textile
fabrics, glass or
ceramic fabrics, and metallized layer(s). Alternatively, the backing layer may
be one layer of a
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22
laminate. The backing layer should exhibit sufficient flexibility to allow
bending, rolling and
other similar manipulations of the article 10 which are required during
manufacture and at the
point of application. In one specific embodiment, the textured backing sheet
is distinct from the
sheet 12 and is associated with the article 10 at the point of application. To
that end, the textured
backing sheet is adhesively secured to the surface 28 (Fig. 5), and the
article 10 is adhesively
bonded to the exposed surface of the textured backing sheet.
In yet another embodiment and with reference to Figs. 1 and 2, the dry
colorant
forming the margin 18 is adapted to transmit incident electromagnetic
radiation having
wavelengths in the visible portion of the spectrum. The article 10 is applied
to surface 28 (Fig. 5)
with an optically opaque margin 18 of one juxtaposed article 10 providing the
underseam 46 (Fig.
5) and the optically transmitting margin 18 of the other juxtaposed article 10
providing the
overseam 44 (Fig. 5). In that case, the color of margin 18 of the underlying
juxtaposed sheet 12
will be visible through the overlying optically transmitting margin 18 of the
other juxtaposed
sheet 12. The optically transmitting margin 18 may be a transparent medium
having a high
optical transmission so that incident electromagnetic radiation traverses the
margin thickness with
little interference, such as absorption or reflection. It is appreciated that
total optical transparency
is not required and, to that end, the margin 18 of the overlying juxtaposed
sheet 12 may be
optically translucent so that the light reflected from the underlying opaque
margin 18 is diffused.
It is also contemplated by the invention that the entire sheet 12 may be
transmissive of radiation
having wavelengths in the visible portion of the electromagnetic spectrum.
In yet another embodiment of the invention, a light diffusing substance may be
added to the formulation of the dry colorant forming sheet 12 (Figs. 1, 2).
One specific light
diffusing substance is a pearlescent material capable of producing pearlescent-
type effects, such
as luster, depth, iridescence, metallic sheen, and multiple-color play.
Pearlescent materials
include, but are not limited to, ethylene glycol distearate (EGDS), light
diffusing microbeads,
mica flakes coated with a metal oxide, pearl essence originating from fish
scales or artificially
produced, lead carbonate, lead hydrogen arsenate, and bismuth oxychloride. The
pearlescent
material produces color-effects by interference, transmission and absorption
of light. It is
appreciated that articles 10 having laminated structures may incorporate that
light diffusing
substance into one or more individual layers. In addition and with reference
to Figs. 9A and 9B,
the light diffusing substance may be provided only in the margin 18 of one of
the visible layer
edges of a laminated sheet 12, as shown in Figs. 9A and 9B.
It is appreciated that the thickness of the dry colorant forming the sheet 12
will
affect the perceptibility of the seam formed by the overlapped overseam 44 and
underseam 46.
CA 02485281 2007-10-26
23
Accordingly, thinning the dry colorant of the entire sheet 12 and the adhesive
layer 25 to a
thickness less than about 3 mils may reduce the visual perceptibility of the
seam.
It is contemplated by the present invention that the various approaches
described
herein for eliminating, reducing, or lessening the visual perceptibility of
the seam created by the
overlap of overseam 44 and underseam 46 (Fig. 5) may be combined without
limitation to provide
the desired seam concealment. As specific examples, the approach of providing
a printed pattern
(Fig. 14) may be used in combination with thinning the dry colorant forming
the sheet or the
margin (Figs. 7 and 8) and contouring the peripheral edge of the margin (Fig.
13), the approach of
thinning the dry colorant forming the sheet or the margin (Figs. 7 and 8) may
be used in
combination with contouring the peripheral edge of the margin (Fig. 13), the
approach of thinning
the dry colorant forming the sheet or the margin (Figs. 7 and 8) may be used
in combination with
providing a printed pattern (Fig. 14), the approach of thinning the dry
colorant forming the sheet
or the margin (Figs. 7 and 8) may be used in combination with rounding the
peripheral edge of the
margin (Figs. 9 and 9A), the approach of thinning the dry colorant forming the
sheet or the margin
(Figs. 7 and 8) may be used in combination with adding a light diffusing
substance to the dry
colorant, the approach of thinning the dry colorant forming the sheet or the
margin (Figs. 7 and 8)
may be used in combination with providing a texture with a three-dimensional
topography of
surface features (Fig. 15), the approach of thinning the dry colorant forming
the sheet or the
margin (Figs. 7 and 8) may be used in combination with providing a collapsible
structure (Figs.
and 11), and the approach of adding a rheology-modifying additive, such as a
thermally-
activated chemical agent, to the dry colorant may be used in combination with
providing a texture
with a three-dimensional topography of surface features (Fig. 15).
It is also appreciated that the seam collectively formed by the overlapped
overseam 44 and underseam 46 may be an integral part of a pattern formed on
the surface when
the article 10 is applied thereto. For example, the seam may participate in
forming a pattern such
as if each article is shaped as a square or block and multiple blocks are
applied to the surface in a
tiled pattern. As another example, the article 10 may have a pattern of
vertical stripes that
accommodate the vertical seam created between juxtaposed articles 10 as a
feature in the pattern.
CA 02485281 2007-10-26
24
Generally, various
additives and structures described herein may be provided to the dry color
component and/or to
the adhesive, as may be the case, during the manufacturing process producing
article 10.
In view of the above, it will be apparent that the articles according to the
present
invention may be formed by a variety of methods and techniques. One such
method is disclosed
herein for illustrative purposes only. More particularly, with reference to
Fig. 16, a small,
laboratory scale, semi-automated process is shown. A releasable liner 100 is
provided in roll form
and is unrolled to travel through assembly 102 via rollers 104, 106, 108, 110,
112 and 114 to form
a completed article 116 which is wound on roll 118. As will be described in
further detail below,
trimmed portions 120 are directed to roll 122. The releasable liner 100 is
pulled as a web 101
through the assembly by a combination of the rolls 118 and 122 and a conveyer
124, for example
a vacuum conveyor. A suitable vacuum conveyor may comprise a continuous
conveyor belt with
two pulleys having an array of spaced holes that are exposed to the vacuum
chamber immediately
below. Negative pressure (vacuum) is created by a forced air blower. As the
belt passes over the
chamber, a negative pressure is created at each hole such that the releasable
liner 100 is securely
held to the belt as it passes over the belt. This effect assists in preventing
wrinkles in the
releasable liner 100 as the applied color component dries. The vacuum conveyor
belt speed may
be matched to that of the drive rolls 118 and 122 driven by a drive 119. The
shaft of a roller 126
from which the releasable liner 100 is supplied is connected with a friction
clutch 128 which may
be adjusted to obtain sufficient tension in the web 101 for smooth travel
through the process. A
Fife guiding unit 130 may be provided to track the web travel through the
assembly.
A color component, such as wet paint, is applied to the web 101 of the
releasable
liner adjacent roller 106 using an applicator 132. The paint or other color
component may be
water-based or solvent-based as desired. In one embodiment, the applicator 132
comprises a #50
wire wound rod which may be held against the roller 106 by spring tension or
the like such that
the web 101 passes between the roller 106 and the applicator 132. The color
component, such as
paint, is introduced at the upstream side of the wire wound rod applicator 132
by a manifold 134.
The manifold is fed by tubing 136 from a peristaltic pump 138 which draws the
wet paint from a
reservoir 140. To form the sheet of dry color component, the paint is dried on
the web 101, for
example as it passes over the vacuum conveyor 124 by the use of dryers. In the
embodiment of
Fig. 16, the dryers comprise two infrared heaters 142 which are aided by a
forced ambient air duct
144. The air duct 144 may conveniently blow the exhaust from the vacuum
conveyor 124. One
skilled in the art will readily appreciated that solvent or other carrier
removed during the drying
process may be captured and recycled as desired. A sheet of dry color
component is thus formed
CA 02485281 2004-11-08
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on the releasable liner web.
An adhesive is then applied to the sheet of dry color component on the surface
opposite the releasable liner. For example, in the assembly 102 of Fig. 16,
adhesive is applied to
the surface of the sheet of dry color component on the web 101 at roller 108
by an applicator 148
which may comprise, for example, a #20 wire wound rod. The wire wound rod
applicator 148
may be held against the roller 108 by spring tension or the like such that the
web 101 passes
between the roller and the applicator. Liquid adhesive is introduced at the
upstream side of the
wire wound rod applicator 148 by a manifold 146. The manifold 146 is fed by
tubing 150 from a
peristaltic pump 152 which draws the liquid adhesive from a reservoir 154. The
liquid adhesive
in a reservoir 154 is continuously stirred by a mixer 156. With the adhesive
applied thereon, the
web 101 travels to an oscillating fabric covered roller 158 which traverses
back and forth in the
machine direction above a slider plate 160 to impart a texture to the liquid
adhesive applied to the
sheet of dry color component on the web 101. A textured adhesive may allow the
article to be
more easily repositioned prior to permanent bonding. The adhesive is then
dried, for example, by
passing the web 101 under an infrared heater 162 at roller 110.
In a preferred embodiment, the web 101 travels through rollers 112 and 114,
one
of which is preferably in the form of a rotary cutting knife. In a more
specific embodiment, roller
114 comprises two rotary cutting knives which are arranged adjacent the edges
of the web in
order to trim the web edges and provide the final article with the homogenous
edges. In another
embodiment, the roller 114 comprises a plurality of rotary cutting knife sets
which are arranged so
as to cut the web into two or more strips to provide smaller sized articles
adapted for applying
color to smaller sized areas as discussed above. The resulting article 116 is
then wound on the
roll 118 while the trimmed edges 120 are wound on the roll 122. As set forth
above, the described
assembly 102 and preparation process is illustrative only and variations
thereof will be apparent to
those skilled in the art. For example, release agents in the form of coatings,
layers or the like may
be provided in the process. Additionally, the sheet of dry color component may
be provided in
the final article in the absence of a release liner. For example, the sheet of
dry color component
may be formed on a processing web or forming belt and then separated from the
processing web
or forming belt prior to storage in roll or sheet form.
In an alternate embodiment, the articles according to the invention may be
formed
using a modified version of the process as described above wherein two
releasable liner webs are
employed. For example, a topcoat composition for forming a topcoat layer may
be applied to a
releasable liner web by reverse roll, extrusion coating or the like
techniques, and dried thereon,
for example with heat. A color component may then be applied to the dried
topcoat layer, for
CA 02485281 2007-10-26
26
example by reverse roll, gravure coating, printing, or the like techniques,
and dried with heat. The
adhesive may then be applied to a second releasable liner web, followed by
laminating the
releasable liner-topcoat-dry color component member with the adhesive-
releasable liner member,
with the dry color component and adhesive in facing relationship. Heat may be
provided
throughout this process by any suitable means including convection or
radiation, for example
infrared, ultraviolet or the like. One of ordinary skill in the art will also
appreciate that this
method may be used to provide an article including a single releasable liner
by merely removing
the second releasable liner from the adhesive once the releasable liner-
topcoat-dry color
component member and the adhesive-releasable liner member have been assembled.
Additional or alternative apparatus and/or processing steps will be apparent
to
one skilled in the art in view of this description and are within the scope of
the present invention.
For example, the color component or adhesive could be applied as a single
layer or in multiple
layers using a variety of known application techniques including extrusion,
spraying, printing,
reverse roll, gravure coating, roll application and others known in the art.
It is appreciated that the
application may provide the sheet with a printed pattern. The layers may have
the same properties
or various layers, different from each other, may be employed to combine
various properties such
as color, strength, opacity, and the like. A blocking agent as described above
may be applied to
the adhesive surface and/or may be mixed with the adhesive. Heating may be
provided by
infrared, convection, or radiation apparatus or other techniques known in the
art.
The color component may incorporate additional components, such as a light
diffusing substance, particulates, microparticles, or a rheology-modifying
additive of the
invention. Texturization may be provided on or in one or more layers of the
article to provide a
three-dimensional topography by incorporating a stamp or an embossing roller
into the
manufacture processes described herein. In addition, the manufacturing
processes described
herein may incorporate a cutting implement for contouring or shaping at least
one of the outer
peripheral edges of the sheet of dry color component. The manufacturing
process may also
include a structure for thinning the margins according to the principles of
the invention.
The citation of any document is not to be construed as an
admission that it is prior art with respect to the present invention.
While particular embodiments of the present invention have been illustrated
and
described, it would be obvious to those skilled in the art that various other
changes and
modifications can be made without departing from the spirit and scope of the
invention. It is
therefore intended to cover in the appended claims all such changes and
modifications that are
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27
within the scope of this invention.
