Abstract:
A pre-shaped adhesive and method are disclosed. The adhesive includes predetermined shaped single-sided adhesives adapted to cover and conform to the shape of corresponding adhesive element receiving areas. The predetermined shaped single-sided adhesives are removably stackable and dispensable in a number of disclosed methods.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     Embodiments of the present invention generally relate to adhesives. In particular, embodiments of the present invention relates to pre-shaped adhesives and methods.  
         [0002]     Many industrial, commercial and residential projects require repair, sealing, joining, and/or fastening of materials that have holes, gaps or openings. Some of these areas can be geometric shapes or irregular shapes.  
         [0003]     Currently, adhesives are sold as tape, which is available in rolls of about 2-4 inch widths. If areas needing an adhesive are large or not square or rectangular in shape, currently available adhesive tapes are inefficient in repairing, sealing, joining, and/or fastening these areas. Due to existing shape and size limitations of adhesive tape, multiple pieces or applications are required to cover these large areas of various shapes and sizes. Multiple applications are undesirable because of the added weight, bulk and multiple overlaps in areas prone to leakage, debris and sites for tearing.  
         [0004]     In addition, known adhesive tape does not offer aesthetically pleasing options. Generally, tape comes in a limited number of colors and textures. Some applications, such as areas needing repair in air ducts, are visible. When large areas need to be covered after performing work on visible applications, it is undesirable to have adhesive tape that contrasts in color and texture with the visible applications.  
         [0005]     Therefore, there is a need in the art for improved adhesives.  
       SUMMARY OF THE INVENTION 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]     So the manner in which the above recited features of the embodiments of the present invention can be understood in detail, a more particular description, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is noted; however, the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.  
         [0007]      FIG. 1A-1D  are top plan views showing a single-sided adhesive in various shapes in accordance with an embodiment of the present invention;  
         [0008]      FIG. 2  is a sectional view of the substrate of  FIG. 1  along edge a-a showing an adhesive side and corresponding non-adhesive side;  
         [0009]      FIG. 3A  is a plan view of an adhesive receiving area;  
         [0010]      FIG. 3B  is a plan view of the adhesive receiving of  FIG. 3A  area after a single-sided adhesive is applied;  
         [0011]      FIG. 3C  is a perspective view of another adhesive receiving area;  
         [0012]      FIG. 3D  is a perspective view of the adhesive receiving area of  FIG. 3C  after a single-sided adhesive is applied;  
         [0013]      FIG. 4  is a perspective view of an embodiment of the present invention showing a plurality of single-sided adhesives in a stack;  
         [0014]      FIG. 5  is a perspective view of an embodiment of the present invention showing a plurality of single-sided adhesives dispensable from a roll;  
         [0015]      FIG. 6  is a perspective view of an embodiment of the present invention showing a plurality of single-sided adhesives dispensable from a plurality of rolls in a single dispensing unit; and  
         [0016]      FIG. 7  is a perspective view of an embodiment of the present invention showing a plurality of single-sided adhesives dispensable as an individual unit having a non-adhesive backing. 
     
    
       [0017]     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0018]      FIG. 1A  depicts a top plan view of a single-sided adhesive element  10 . Element  10  includes a non-adhesive side  12  and an adhesive side  20  opposite the non-adhesive side  12 . Illustratively, one embodiment of the present invention includes a pre-cut geometric shape  14 , in particular, a parallelogram. This parallelogram can be a square, a rectangle or any other type of parallelogram and the like. Alternatively, embodiments of the present invention can include various shapes and sizes that correspond to an adhesive element receiving area.  
         [0019]      FIG. 1B  depicts a similar plan view as in  FIG. 1A , except that the single-sided adhesive element  10  is pre-cut into a different geometric shape  14 , namely, a circle. The geometric shape  14  can also be an ellipse, oval, triangle, trapezoid or polygon, and the like.  
         [0020]      FIG. 1C  depicts a similar plan view as in  FIG. 1A , except that the single-sided adhesive element  10  is pre-cut into a different irregular shape  16 , namely a rectangle with rounded corners. Irregular shape  16  can be a shape more complicated than geometric shape  14 . Irregular shape  16  can also be an irregular shape  18 , depicted in  FIG. 1D .  
         [0021]      FIG. 2  depicts a sectional view of  FIG. 1A  cut along line a-a showing the adhesive side  20  and corresponding non-adhesive side  12 . The non-adhesive side  12  of any one of the above shapes and sizes can be any backing used in the adhesive industry such as, but not limited to, bi-axially-oriented polypropylene backing (BOPP), cloth, crepe paper, fiber filled, fiberglass cloth, flatback paper, foil, foil/tri-directional/paper, or glass fiber—BOPP, and the like. The adhesive side  20  can be any adhesive used in the industry such as, but not limited to, acrylic, rubber, polyurethane, silicone or urethane, and the like. The rubber used for adhesive can be any rubber used in the adhesives industry such as, but not limited to, butyl rubber, flame retardant rubber, hot melt rubber, natural and synthetic rubber, natural rubber, synthetic rubber, or reclaim rubber, and the like.  
         [0022]      FIGS. 3A and 3B  depict a plan view of an adhesive element receiving area  30  before and after a single-sided adhesive element  10  is applied.  FIG. 3A  illustrates an adhesive element receiving area  30  with an irregular shape  18 . It should be noted that, although an irregular shape  18  is depicted, any of the other aforementioned shapes (i.e., geometric and irregular shapes) could be substituted interchangeably for this irregular shape  18 . The adhesive element receiving area  30  is depicted here as a hole in material  32  having a texture  34  and color  36 . However, it should be noted that the adhesive element receiving area  30  could be a gap or any other opening or area of repair.  
         [0023]      FIG. 3B  illustrates the adhesive element receiving area  30  after the single-sided adhesive element  10  is applied. The size and shape of the single-sided adhesive element  10  is chosen to substantially correspond to the size and shape of the adhesive element receiving area  30 . In one embodiment, the single-sided adhesive element  10  is chosen to substantially correspond to the texture  34  and/or color  36  of the material  32 . Based on the sizes and shapes of the adhesive element receiving area  30  or texture  34  and color  36  of the material  32 , the single-sided adhesive element  10  can be manufactured in the corresponding sizes, shapes, textures and colors. As such, the single-sided adhesive element  10  is applied in a single application that corresponds substantially to the adhesive element receiving area  30 .  
         [0024]      FIGS. 3C and 3D  depict perspective views of an adhesive element receiving area  30  of another embodiment before and after a single-sided adhesive element  10  is applied. Specifically,  FIG. 3C  illustrates an adhesive element receiving area  30  with a geometric shape  14  as found in an air duct system. The adhesive element receiving area  30  is depicted here as a round aperture in the material  32  having a texture  34  and color  36 . The aperture may be made when the air ducts are being cleaned and the apertures are needed in the ducts to accommodate cleaning equipment such as vacuum hoses and cabling.  
         [0025]      FIG. 3D  illustrates the adhesive element receiving area  30  after the single-sided adhesive element  10  is applied. The size and shape of the single-sided adhesive element  10  is chosen to cover and substantially correspond to the size and shape of the adhesive element receiving area  30 . Moreover, the single-sided adhesive element  10  can be chosen to substantially correspond to the texture  34  and color  36  of material  32 . For example, the air duct could have a shiny metallic texture and a silver color. Alternative textures and colors are also contemplated and within the scope of the present invention. The adhesive element receiving area  30  may be a round area left after working on the air duct. Based on this, the single-sided adhesive element  10  is applied in a single application that covers and substantially corresponds to the adhesive element receiving area  30 .  
         [0026]     Applying the single-sided adhesive element  10  in a single application that corresponds substantially to the adhesive element receiving area  30  has many benefits. A single application will have less weight and bulk than applying multiple layers of narrow tape. Moreover, a single application is prone to leakage, collecting debris, or potential sites for tearing than multiple applications with narrow or ill-fitting tape. Also, a single application eliminates the need to manually alter the tape to substantially correspond with the adhesive element receiving area  30 . This saves time and prevents waste of excess material, therefore, reducing costs.  
         [0027]     In addition to the technical benefits realized by a single application of the single-sided adhesive element  10 , there are also aesthetic benefits. Generally, a uniform, maintained appearance is preferred over a non-uniform, shoddy appearance. The single-sided adhesive element  10  can be manufactured in various textures and colors to match the texture  34  and color  36  of the material  32 .  FIG. 3B  illustrates the single-sided adhesive element  10  having the same texture  34  and color  36  as the material  32 . For example, as depicted in  FIGS. 3C and 3D , one type of texture  34  could be a metallic, shiny appearance of air ducts and one type of color  36  could be silver. By having the same texture  34  and color  36  as the material  32 , the single-sided adhesive element  10  is camouflaged.  
         [0028]     The single-sided adhesive element  10  can be commercialized to be dispensed in many ways, all of which are embodiments contemplated by, and within the scope of, the present invention.  FIG. 4  depicts a perspective view of one embodiment of the present invention showing a plurality of single-sided adhesive elements  10  dispensable from a stack  40 . The adhesive side  20  of one of the plurality of single-sided adhesive elements  10  removably contacts the non-adhesive side  12  of another one of the plurality of single-sided adhesive elements  10 . The stack  40  is formed in this manner until the desired number of single-sided adhesive elements  10  is reached. The stack  40  is finished by removably contacting the adhesive side  20  of the bottom most single-sided adhesive element  10  with a non-adhesive backing  42 .  
         [0029]     In another embodiment of the present invention, the single-sided adhesive element  10  can be dispensed in a roll  50  as depicted in  FIG. 5 . A plurality of single-sided adhesive elements  10  is dispensed. Roll  50  comprises a plurality of single-sided adhesive elements  10  placed adjacent each other on a non-adhesive backing  42 . Although  FIG. 5  illustrates an example of a roll  50  with the same irregular shape  16 , roll  50  is not limited to a plurality of single-sided adhesive elements  10  with the same shape, but can also comprise a plurality of single-sided adhesive elements  10  with different shapes.  
         [0030]      FIG. 6  depicts a perspective view of another embodiment of the present invention showing the single-sided adhesive element  10  dispensed in a plurality of rolls  50 , which are contained in a single dispensing unit  60 . The single dispensing unit  60  comprises a plurality of integrated rolls  50 . Each roll  50  in single dispensing unit  60  is the same as roll  50  depicted in  FIG. 5 . Again, although  FIG. 6  illustrates an example roll  50  with the same shapes, roll  50  is not limited to a plurality of single-sided adhesive elements  10  with the same shape, but can also comprise a plurality of single-sided adhesive elements  10  having different shapes.  
         [0031]      FIG. 7  depicts a perspective view of one embodiment of the present invention showing the single-sided adhesive element  10  dispensed as an individual unit  70 . The adhesive side  20  is removably contacted with a non-adhesive backing  42 . The single-sided adhesive element  10  can be packaged and sold as a plurality of individual units  70 . The package of individual units  70  can all be the same shape or a mixture of different shapes.  
         [0032]     In operation, a user may apply a single-sided adhesive element  10  to repair, seal, join, or fasten an adhesive element receiving area  30 . Referring to  FIG. 3A-3D , a user will determine the shape of the adhesive element receiving area  30 , the texture  34  and color  36  of material  32 . For example, a user may work on an air duct that has a shiny metallic texture and a silver color. While working, the user may need to create a large circular opening in the air duct. After the user finishes work on the air duct, the user will determine that he needs a circular-shaped single-sided adhesive element large enough to cover the opening. He may also determine that the adhesive element needs to have a shiny metallic texture and a silver color to match the receiving area.  
         [0033]     Based on this information, the user removes the appropriate single-sided adhesive element  10  dispensed from a stack  40 , roll  50 , or a plurality of rolls  50  in a single dispensing unit  60 . Then, the single-sided adhesive element  10  is applied. The single-sided adhesive element will substantially cover and conform to the shape of the corresponding adhesive element receiving area  30 , the texture  34  and color  36  of material  32 .  
         [0034]     Finally, the single-sided adhesive element  10  can be included in a kit of components for repairing, sealing, joining or fastening for various applications. The kit of components comprises at least two single-sided adhesive elements  10 . Referring to  FIG. 3A - FIG. 3D , a user working on the adhesive element receiving area  30  on material  32  can utilize the kit of components to choose a single-sided adhesive element  10  that substantially corresponds to the shape and size of adhesive element receiving area  30  and the texture  34  and color  36  of material  32 . The kit of components may comprise a plurality of single-sided adhesive elements  10  dispensed in a method or any combination of methods as described previously.  
         [0035]     While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.