Patent Publication Number: US-2016236441-A1

Title: Adhesive unit for decoration and protection from wear and production method thereof

Description:
FIELD OF THE INVENTION 
     The present invention relates to an adhesive unit for decoration and protection from wear of the type having a lower layer comprising at least one adhesive film and an upper layer connected to the lower layer and comprising at least one visible leaf. 
     DESCRIPTION OF THE PRIOR ART 
     As is known, the use of adhesive units for decoration and protection, also known as labels, adhesive labels, adhesive decorations and stickers, is widespread. These are of different shapes, sizes, colours, have different designs, illustrated themes and figures and are used to decorate, customise and enliven—and also to protect from wear, scratches, fouling and the like—walls, panels, doors, windows, shop windows, appliances, vehicle parts, etc. 
     In particular, those adhesive units having a certain thickness and in any case not flat like a sheet are of superior quality and very widespread. 
     These adhesive units for decoration or labels having a certain thickness have a more pleasant and attractive appearance the thicker they are, and also, thanks to the thickness, are particularly effective at protecting the surfaces they are applied to. 
     Furthermore, the thickness can also be correlated to a certain softness, a softness that increases with the breadth of said thickness. 
     A thick, non-rigid structure of these labels is especially important when occasional physical contact with the same is envisaged. 
     For example, the application of labels having a certain thickness to the tank of motorcycles to distinguish and decorate the motorcycles according to the taste of the owner and especially to protect the tank from scratches and wear generated by contact with the rider is known of and widespread. 
     It may in fact happen that the rider&#39;s belt—or buttons or studs—abrade the tank. 
     It is known of to manufacture these special labels or adhesive units using various procedures and with different results, not fully satisfactory. 
     In fact, on the one hand the production methods may be complex and expensive, while on the other the labels or the like produced are generally not sufficiently thick or soft and pleasing to the eye. 
     Moreover, the shape is mostly irregular as regards thickness, or with a limited number of possible aesthetic solutions. 
     The known labels are structurally limited as to the possibility of effectively simulating specific or valuable materials, positively blending in with the materials they are applied to, or enhancing the appearance of objects to which the labels are applied. 
     In particular, in several cases, the same are structurally equipped with a transparent layer that covers them and gives them a high shine appearance, negatively highlighting the different structure and additional and extraneous nature of the label. 
     It should then be pointed out that the labels in question are not always satisfactory in terms of durability and strength, since in the presence of lateral or transverse forces, which are a consequence of the thickness, they may open or suffer a partial detachment of the parts composing them. 
     Specifically, in a first known case, it is provided that the adhesive units of the above kind have an upper visible portion defined by a cast resin. 
     The resins are transparent or substantially transparent and are cast on a sheet and/or an insert aesthetically characterising the label. 
     With this specific technique the resins must be applied with particular attention and have the edge removed after application. 
     One drawback of this technique is the fact that the same generates superficially shiny articles with a vitreous appearance. 
     In particular it is not possible to obtain complex and attractive aesthetic effects such as a simulation of carbon fibres or in any case of materials and fibres with a matt surface. 
     Another drawback is related to the fact that the resins allow relatively limited thicknesses, if one wishes to obtain substantially uniform thicknesses and limited smudging and waste at the edges. 
     Another known type of adhesive unit or label and production method thereof provides that the upper portion is made independently and in the form of a sheet not initially shaped and possibly surmounted by a thin transparent protective film. The upper portion is then cut, shaped and engaged to a lower portion at a later time. 
     This method makes good labels, but on the one hand of average limited thickness and on the other with a thickness varying on the same label. 
     In fact, depressions and contractions in the less extensive areas of the labels form, as regards their extension in a direction parallel to the surfaces to which they are applied. 
     In these areas, the cutting and welding operations are carried out on edges close to each other and the label is thus tensioned and depressed particularly in the areas between said close edges. 
     The depression also leads a local stiffening of labels and an unpleasant uneven appearance. 
     The presence of a transparent protective film is then negative in that it creates a shiny appearance which immediately qualifies the label as an extraneous, added accessory. 
     SUMMARY OF THE INVENTION 
     In this situation the technical purpose of the present invention is to devise an adhesive unit or label—and production method thereof—able to substantially overcome the drawbacks mentioned. 
     Within the sphere of said technical purpose one important aim of the invention is to devise an adhesive unit that is sufficiently thick or soft. 
     Another important aim of the invention is to devise a label which has a mainly regular and uniform shape in terms of thickness. 
     Yet another aim is to devise an adhesive unit or label able to effectively simulate specific or valuable materials, and therefore able to blend in with the materials which it is applied to. 
     A further, no less important aim of the invention is to provide a label which is reliable in terms of resistance to transverse stresses and durable over time. 
     Said technical purpose and specified aims are achieved by an adhesive unit for decoration and protection from wear, of the type having a lower layer comprising at least one adhesive film and an upper layer connected to a lower layer and comprising at least one visible leaf, the upper layer and the lower layer an intermediate layer is positioned comprising a plurality of soft laminas in synthetic foam without the interposition of adhesive material between the soft laminas which are thus able to reciprocally slide. 
     Preferred embodiments are evident from the dependent claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The characteristics and advantages of the invention are clearly evident from the following detailed description of preferred embodiments thereof, with reference to the accompanying drawings, in which: 
         FIG. 1  is an example of a label of the prior art having a transparent resin on the surface; 
         FIG. 2  shows an adhesive unit or label according to the invention, in a perspective view from above; and 
         FIG. 3  is a detailed view, in cross-section and exploded, of a portion of the adhesive unit according to the invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference to the drawings,  FIG. 1  shows, merely by way of example, a label according to the method of the prior art having for example a circular shape suitable to avoid local depressions and a thick layer of resin or transparent material on the surface, such as to give a shiny and vitreous appearance. 
       FIGS. 2 and 3  instead show an adhesive unit or label  1  according to the invention and in particular  FIG. 2  shows, by way of example, a very complex shape of label and with various narrow areas  1   a , i.e. with opposite edges close together. 
     Advantageously—as explained below—even at the narrow areas  1   a  depressions and irregularities of thickness are substantially avoided. 
     The structure devised makes it possible to do without the resin layer and thus the label is able to simulate a valuable material, so as to be applied in full view for example on a motorcycle tank, and also has a thickness and a softness able to increase its attractiveness. 
     In detail, in the preferred embodiment shown, the label  1  comprises, as shown in  FIG. 3 , various superposed and originally configured elements. 
     In particular, it has an upper layer  2  substantially defined by a visible leaf  3 , an upper sheet  4  placed under the visible leaf  3 , and by a film of glue  5  inserted between the visible leaf  3  and the upper sheet  4 . 
     The leaf  3  can be variously structured and for example may be defined by a laminate which imitates a valuable material. 
     The laminate may also be found on the market, such as the thin laminate of 3M Italia Srl called 3M DI-NOC. 
     The laminate in question in one embodiment effectively simulates the surface of a black carbon fibre material. 
     Under the leaf  3  said upper sheet  4  is provided, which is preferably made of transparent PVC, for example having a thickness of 0.5 millimetres. 
     The film of glue  5  interposed between the leaf  3  and the upper sheet  4  may be already provided together with the leaf  3 , or applied specifically. 
     It has for example a thickness of 0.3 mm and is preferably made with hot acrylic glue (hot melt). 
     Overall the upper layer  2  is compact and durable. 
     The label  1 , on the opposite side to the upper layer  2 , has a lower layer  6  intended to be—in situ—substantially in contact with the surface to which the label is applied. 
     The bottom layer  6  preferably comprises a base sheet  7 , an adhesive film  8  and a removable protective element  9 . 
     The base sheet  7  is preferably similar to the upper sheet  4  and therefore in transparent PVC with a thickness for example of 0.5 millimetres. 
     The adhesive film  8  is preferably a neutral charge glue of the type suitable to engage an element in silicone material. 
     It is in fact provided—in a manner known per se—that before application the label  1  has the adhesive film  8  covered and protected by a removable protective element in silicone material  9 , for example silicone-coated paper. 
     Innovatively, an intermediate layer  10  is inserted between the upper layer  2  and the lower layer  6  suitable to determine prevalently both the thickness and the hardness or softness of the label  1 . 
     The intermediate layer  10  comprises in fact a plurality of overlapping soft laminas  11 . 
     Said soft laminas  11  are in synthetic foam or synthetic sponge. 
     In detail, the soft laminas  11  are preferably in a number comprised between two and four and are in polyurethane foam. 
     In addition the thicknesses of the soft laminas  11  are similar or equal to each other and constitute a total thickness preferably between about two and about five millimetres when the laminas are superposed on each other. This thickness is also that of a possible single soft lamina  11  defining the intermediate layer  10 . 
     Different thicknesses are however possible, in particular greater thicknesses. 
     In a presently preferred embodiment, shown in  FIG. 3 , three soft laminas  11  are provided and each has a thickness of about 1.2 millimetres. 
     Advantageously, the intermediate layer  10  is glue-free and in particular the laminas  11  are superposed with each other without any glue or adhesive material (hereinafter referred to solely as adhesive material). Consequently, the soft laminas  11 , being devoid of adhesive material interposed between them, are not integrally constrained to each other. Innovatively, they are thus able to slide reciprocally, simulating specific and/or highly valued materials. 
     Additionally or alternatively, the intermediate layer  10  may be facing the upper layers  2  and lower layers  6  without the interposition of adhesive material between each layer  2  or  6  and the intermediate layer  10  so that the laminas  11  are able to slide with respect to the upper  2  and lower  6  layers. 
     It is in fact provided that the intermediate layer  10  is clamped between the upper  2  and lower layers  6  directly connected to each other and connected in particular by high frequency ultrasound welding and cutting. 
     It is to be noted how the constraint of the upper  2  to the lower layer  6  does not substantially interfere with the reciprocal mobility of the soft laminas  11  which are thus able to reciprocally slide even after the constraint of the upper layer  2  to the lower one  6 . 
     NEW METHOD 
     The invention teaches a new method for the manufacture of an adhesive unit for decoration and protection from wear. 
     The method is provided for a label  1  of the type having a lower layer  6  with an adhesive film  8  and an upper layer  2  provided with a visible leaf  3 . 
     It consists of inserting between said upper  2  and lower layers  6  an intermediate layer  10  suitable to determine prevalently both the thickness and the hardness or softness of the label  1  and defined by a plurality of soft laminas  11  in synthetic foam. 
     Appropriately, the soft laminas  11  are in polyurethane foam, simply stacked on top of each other, in the absence of adhesive material so as to be able to reciprocally slide innovatively simulating specific and/or highly valued materials. It is to be noted how, as a result, the intermediate layer  10  is free of adhesive material. 
     A particular implementation of the joining of the various elements making up the label is then provided for which allows the laminas  11  to reciprocally slide. 
     In fact, in the upper layer  2  and in the lower layer  6  an upper sheet  4  in PVC and a base sheet  7  also made of PVC are respectively arranged. 
     The upper  2  and lower layer  6  can be arranged on the intermediate layer  10  without interposing adhesive material between each layer  2  and  6  and the intermediate layer  10  so that the laminas  11  are able to slide with respect to the upper  2  and lower layers  6 . 
     Thanks to this identity of materials an effective and rapid high-frequency ultrasonic welding is performed between the sheets  4  and  7  and consequently between the top layer  2  and the lower layer  6 . 
     A mould known per se is used in appropriately shaped brass with sharp edges which combined with the ultrasound, welds and cuts the various superposed elements, shaping the label  1 . 
     As is known, ultrasonic welding is particularly effective between plastic materials of the same type and is particularly suitable for PVC, while it is not suitable for polystyrene foam. 
     In this situation the intermediate layer  10  made of polystyrene foam is hardly affected by the welding operation and only affected by the cutting operation. 
     As a result, advantageously, the soft laminas  11  remain mainly free inside the sandwich defined by the upper layer  2  and the lower layer  6 . 
     The effect of not blocking or partial blocking of the soft laminas  11  is then incremented by the presence—in the preferred embodiment—of a plurality of soft sheets  11  simply superposed on each other and therefore substantially free and sliding with each other. 
     The visible leaf  3  is also made of PVC in the preferred case shown, but may be in any suitable material capable of being cut in that a bonding by gluing between said visible leaf  3  and the upper sheet  4 , thanks to a film of glue  5  which—as mentioned—may be provided already joined to the leaf  3 , is advantageously provided for. 
     A similar procedure occurs for the removable protective element  9 , which is joined to the base sheet  7  by an adhesive film. 
     The invention achieves the proposed objectives and permits important advantages. 
     In fact an adhesive unit or label has been devised able to efficiently simulate specific or valuable materials. 
     This advantage has been innovatively achieved by making an intermediate layer  10  which, comprising several soft laminas  11  not rigidly constrained to one another by adhesive material or otherwise, is able to exploit the mutual sliding between the soft laminas  11  to simulate the deformations of a label composed of a valuable material. 
     Moreover, the mobility of the soft laminas  11  can be increased by arranging the layers  2  and  6  on the intermediate layer  10  without interposing adhesive material. 
     The label  1  is also able to blend in with the materials which it is applied to and also, if necessary, may be provided with a similarly matt finish. 
     For example, it can be inserted in full view for example on the tank of a motorcycle and blend in with the same to avoid scratches and abrasions. 
     The label produced is then reliable in terms of resistance to stress, to transverse tensions and to opening thanks to its manufacturing process. 
     The fact that the label is suitable to present an adequate thickness, soft and substantially regular and uniform as to thickness, even in cases of a highly irregular shape, is also fundamental. 
     This is thanks to its original structure which provides an intermediate layer sensitive to cutting but insensitive to ultrasonic welding at high frequency and therefore substantially free and preferably formed of a plurality of soft laminas which can slide in relation to one another, not being mutually engaged. 
     In practice, even in narrow areas  1   a  of the adhesive unit or label  1  depressions and irregularities of thickness are substantially avoided. 
     Variations may be made to the invention without departing from the scope of the inventive concept defined in the independent claims and by their technical equivalents. 
     All details may be replaced with equivalent elements and the materials, shapes and dimensions may be any within the scope of protection defined by the independent claims and by the technical equivalents.