Source: https://patents.google.com/patent/WO2003095238A1/en
Timestamp: 2018-07-19 02:23:50
Document Index: 372781447

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'art.\n1']

WO2003095238A1 - Articles and methods for applying color on surfaces - Google Patents
WO2003095238A1
WO2003095238A1 PCT/US2003/015043 US0315043W WO2003095238A1 WO 2003095238 A1 WO2003095238 A1 WO 2003095238A1 US 0315043 W US0315043 W US 0315043W WO 2003095238 A1 WO2003095238 A1 WO 2003095238A1
PCT/US2003/015043
WO2003095238A9 (en )
Articles (10) for applying color on a surface that includes a sheet (12) of dry color component having a margin, a front sheet surface, and a rear sheet surface opposite the front sheet surface, and an adhesive (25) on the rear sheet surface for bonding the sheet to the surface. Either the margin of the sheet or the entire sheet is adapted for reducing or eliminating the visual perceptibility of the seam created when the margin is positioned in an overlapping, abutting, or spaced apart relationship with a margin of a juxtaposed second article. The reduction or elimination of the visual perceptibility of the seam may be promoted by a physical mechanism, a chemical mechanism, an optical mechanism, or a combination of these mechanisms.
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; 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.
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 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.
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 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. Examples of articles 10 are disclosed in U.S. Provisional Application No. 60/343,146, entitled "Articles and Methods for Applying Color on Surfaces" and filed on December 20, 2001 as Attorney Docket No. 8817P, U.S. Provisional Application No. 60/380,225, entitled "Articles and Methods for Applying Color on Surfaces" and filed on May 13, 2002 as Attorney Docket No. 8817P2, and U.S. Provisional Application No. 60/380,205, entitled "Articles and Methods for Applying Color on Surfaces" and filed on May 13, 2002 as Attorney Docket No. 8817P3. Each of these applications is hereby incorporated by reference herein in its entirety. 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.
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 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 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. 9 A, 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 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.
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 10 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 workabihty 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.
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.
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- 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).
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, 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.
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.
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.
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.
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. 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 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. 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 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, 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 Dm 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.
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 Dm to about 100 Dm. 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.
The surface features 74 may be aperiodic or amorphous or may be added as an 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.
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.), which is hereby incorporated by reference herein in its entirety. At the point of apphcation, 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.
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. 10 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).
Various methods of forming article 10 are disclosed in U.S. Provisional Application No. 60/343,146, entitled "Articles and Methods for Applying Color on Surfaces" and filed on December 20, 2001 as Attorney Docket No. 8817P, U.S. Provisional Application No. 60/380,225, entitled "Articles and Methods for Applying Color on Surfaces" and filed on May 13, 2002 as Attorney Docket No. 8817P2, and U.S. Provisional Application No. 60/380,205, entitled "Articles and Methods for Applying Color on Surfaces" and filed on May 13, 2002 as Attorney Docket No. 8817P3, each of which is incorporated by reference herein. 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.
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 apphcation 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.
1. 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.
2. The article of claim 1, wherien said sheet is characterized by comprising a rheology- modifying additive operative to selectively coalesce the dry colorant material forming said margin; optionally wherein said rheology-modifying additive is confined spatially to said margin; optionally wherein said rheology-modifying additive is selected from the group consisting of a plasticizer, a liquid-sensitive chemical agent, thermally-activated chemical agent and combinations thereof; optionally, wherein said rheology-modifying additive is responsive to the application of a compressive pressure to said margin for coalescing said margin; optionally, wherein said rheology-modifying additive is a solvent applied to the margin after the article is applied to the surface; optionally, wherein said rheology-modifying additive is a plasticizer selected from the group consisting of propylene glycol, ethylene glycol, dibutyl phthalate, tricyresyl phosphate, benzyl phthalate and combinations thereof; optionally, wherein said article is stored in a controlled environment after manufacture to preserve the activation of the rheology-modifying additive until said article is applied to the surface; and optionally, wherein said rheology-modifying additive is microencapsulated for delayed activation.
3. The article according to any one of the preceding claims, characterized in that said dry colorant forming said sheet is textured with a three-dimensional topography having multiple projections and multiple depressions, adjacent ones of said projections being separated by a corresponding one of said multiple depressions; optionally, wherein said article includes a plurality of particulates, said particulates being dimensioned and distributed within either said adhesive or said sheet for providing said dry colorant with the three-dimensional topography; optionally, wherein said projections have a spatial distribution free of perceptible organization; optionally, wherien said sheet incorporates a rheology-modifying additive operative to selectively coalesce the dry colorant material forming said margin; and optionally, wherein said rheology-modifying additive is a thermally -activated chemical agent.
4. The article according to any one of the preceding claims, characterized in that said dry colorant forming said margin has a lesser thickness than the dry colorant forming other portions of said sheet; optionally, wherein said margin and the overlapped margin of the juxtaposed sheet collectively have an average thickness less than 6 mils and an opacity of between 0.93 and 1; optionally, wherein the thickness of said margin tapers outwardly toward said peripheral edge; optionally, wherein said peripheral edge is contoured with a non-linear pattern of repeat elements; optionally, wherein said peripheral edge is rounded; optionally, wherein said sheet is adapted to either transmit incident visible light or diffusely reflect incident visible light; optionally, wherein at least one of said sheet of dry colorant and said adhesive includes a structural component adapted to at least partially collapse upon the application of a compressive pressure directed generally inwardly toward the surface; and optionally, wherein said dry colorant forming said sheet is textured with a three-dimensional topography having multiple projections and multiple depressions, adjacent ones of said projections being separated by a corresponding one of said multiple depressions.
5. The article according to any one of the preceding claims, characterized in that either the dry colorant or said adhesive includes a structural component adapted to at least partially collapse upon the application of a compressive pressure directed generally inwardly toward the surface; optionally, wherein said structural component is confined spatially to said margin; and optionally, wherein said structural component is selected from the group consisting of a plurality of gas-filled microparticles, a plurality of open cells, a plurality of projections extending outwardly from said rear sheet surface and combinations thereof.
6. The article according to any one of the preceding claims, characterized in that said peripheral edge is contoured with a non-linear pattern of repeat elements; optionally, wherein the transitions between adjacent pairs of said repeat elements are smoothly curved.
7. The article according to any one of the preceding claims, characterized in that said printed pattern is formed from a plurality of pixels.
8. The article according to any one of the preceding claims, characterized in that said dry colorant forming said margin is transparent.
9. The article according to any one of the preceding claims, characterized in that said sheet is adapted to diffusely reflect incident visible light.
10. The article according to any one of the preceding claims, characterized in that said sheet includes a pearlescent material having a particle size distribution capable of producing a pearlescent-type reflective visual effect; optionally, wherein said pearlescent material is confined spatially to said margin.
11. The article according to any one of the preceding claims, characterized in that said peripheral edge is rounded.
12. 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; optionally, wherein said filler is a spreadable grout material that is capable of being disposed in said gap, said grout material having visual characteristics substantially similar to the visual characteristics of said first and second sheets of dry colorant; and optionally, wherein said filler is a strip positioned in a bridging relationship relative to said gap, said strip having a portion that is insertable into said gap.
13. 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.
14. The kit of claim 13, characterized in that said margin incorporates a rheology- modifying additive operative to selectively coalesce the dry colorant material forming said margin; optionally, wherein said rheology-modifying additive is a liquid-sensitive chemical agent operative to coalesce the dry colorant material forming said margin, and said initiator is an activation liquid operative to activate the compound; optionally, wherein said rheology-modifying additive is a thermally-activated chemical agent operative to coalesce the dry colorant material forming said margin, and said initiator is a heat source for supplying heat sufficient to activate the thermally-activated chemical agent in the margin; and optionally, wherein said rheology-modifying additive is a solvent.
15. A method of 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.
16. The method according to claim 15, characterized in that at least the margin of at least one of the sheets of the first and second articles includes a rheology-modifying additive operative to selectively coalesce the dry colorant forming the margin when exposed to an initiator; and the reducing step further comprises using the initiator to the margin of the at least one of the first and second sheets to activate the rheology-modifying additive for coalescing the dry colorant material forming the margin; optionally, wherein the rheology-modifying additive is a liquid-sensitive chemical agent and the initiator is an activation liquid operative to chemically activate the liquid-sensitive agent; optionally, wherein said rheology-modifying additive is a thermally-activated chemical agent and the initiator is a heat source for supplying heat sufficient to activate the thermally-activated chemical agent; and optionally, wherein said chemical agent is a rheology-modifying chemical agent and said activator is a compressive pressure directed inwardly toward the surface to which the first and second articles are applied.
17. The method according to any one of the preceding claims, characterized in that at least the margin of at least one of the sheets of the first and second articles includes a collapsible structure selectively susceptible to collapse when a compressive pressure of a sufficient magnitude is applied in a direction generally toward the surface; and the reducing step further comprises applying a compressive pressure to the overlapping margins directed generally toward the surface so that the collapsible structure at least partially collapses; optionally, wherein the collapsible structure comprises a structure selected from the group consisting of a plurality of gas-filled microparticles, a plurality of projections extending toward the surface, a plurality of individual cells and combinations thereof; optionally, wherein said method is further characterized by comprising the step of cutting an outer peripheral edge of the margin of at least one of the sheets of the first and second articles to provide a plurality of repeat elements contoured in a manner operative for reducing the visual perceptibility of the seam; optionally, wherein the step of reducing is further characterized by comprising the step of impressing a three-dimensional texture in the sheets of the first and second articles, the texture having surface features extending above and/or below a plane containing the first and second sheets, the texture being operative to reduce the visual perceptibility of the seam; optionally, wherein said texture is impressed after the steps of applying; and optionally, wherein said texture is impressed at the point of apphcation before the steps of applying.
18. 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.
19. The method of manufacturing according to claim 18, characterized in that the step of modifying includes impressing the sheet with a three-dimensional texture having surface features extending above and below a plane containing the sheet, the texture adapted to reduce the visual perceptibility of the seam; optionally, wherein said surface features have a spatial distribution free of perceptible organization; optionally, wherein the step of modifying includes cutting an outer peripheral edge of the margin of the sheet to provide a plurality of repeat elements contoured in a manner operative for reducing the visual perceptibility of the seam; optionally, wherein the step of modifying includes supplying a rheology-modifying additive, during the step of fabricating, operative to coalesce the dry colorant when selectively exposed to an initiator; optionally, wherein the step of modifying includes providing the sheet, during the step of fabricating, with a collapsible structure operative to selectively susceptible to collapse when a compressive pressure of a sufficient magnitude is exerted in a direction generally toward the surface to which the sheet is applied; optionally, wherein the step of modifying includes thinning the dry colorant forming the margin to a lesser thickness than the dry colorant forming other portions of the sheet.
PCT/US2003/015043 2002-05-13 2003-05-13 Articles and methods for applying color on surfaces WO2003095238A9 (en)
US60/380,224 2002-05-13
KR20047018260A KR100648020B1 (en) 2002-05-13 2003-05-13 Articles and methods for applying color on surfaces
EP20030734021 EP1506097A1 (en) 2002-05-13 2003-05-13 Articles and methods for applying color on surfaces
JP2004503290A JP4002272B2 (en) 2002-05-13 2003-05-13 Articles and methods for applying color on a surface
CN 03812224 CN1655955B (en) 2002-05-13 2003-05-13 Articles and methods for applying color on surfaces
CA 2485281 CA2485281C (en) 2002-05-13 2003-05-13 Articles and methods for applying color on surfaces
WO2003095238A1 true true WO2003095238A1 (en) 2003-11-20
WO2003095238A9 true WO2003095238A9 (en) 2004-03-18
ID=29420611
PCT/US2003/015043 WO2003095238A9 (en) 2002-05-13 2003-05-13 Articles and methods for applying color on surfaces
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KR (1) KR100648020B1 (en)
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EP0623477A2 (en) * 1993-05-07 1994-11-09 Minnesota Mining And Manufacturing Company Process for the manufacture of multi-color donor elements for thermal transfer systems
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Free format text: APRESENTE DOCUMENTOS COMPROBATORIOS QUE EXPLIQUEM A DIVERGENCIA NO NOME DE UM DOS INVENTORES (ANNEKE MARGARET KAMINSKI) QUE CONSTA NA PUBLICACAO INTERNACIONAL WO 2003/095238 DE 20/11/2003 E O CONSTANTE DA PETICAO INICIAL NO 020040008386 DE 10/11/2004.