Patent Description:
Automotive manufacturers use functional and decorative films for large format car body applications. The target applications areas can include the whole roof area, roof side, or the entire vehicle. Especially useful types of film are paint film and blackout film, which have potential to replace application of liquid paint in many applications. Use of these films can save significant time when compared with multiple applications of paint while avoiding emissions of volatile organic compounds. Other useful films include paint protection films that are applied over previously painted surfaces. All of these surfacing films can provide both functional and decorative benefits.

<CIT> discloses methods of applying an adhesive-backed film to the surface of a vehicle and cutting the film to fit the surface using a separate cutting tool guide structure.

Providing a consistent and high-quality result in film application can be assisted with a jig, but conventional jigs continue to present significant technical challenges. First, the exterior surface of automobiles have complex contours, which vary significantly amongst vehicle models, thus requiring different jigs for different models. Second, the application of films using conventional jigs tends to be very technique-sensitive, resulting in inconsistent wet-out of the film. Third, use of a blade to cut the film generally requires additional structure opposing the blade to guide the cut to avoid <NUM>) risk of injury to the user and <NUM>) potentially damaging the surface of the vehicle.

Provided herein is a trimming and application device to apply tape or film on a three-dimensional surface. This application device is a jig that includes a thin metal shim received into an elongated and flexible body capable of contouring to the 3D surface. To trim the film, a tool is pressed against the film, pressing the film into a corner of the metal shim. Advantageously, the applied pressure cuts the film without need for a sharp cutting blade. Once the film is trimmed in this manner, wet-out near the trimmed edge can proceed with help of the device's angled shelves. The angled shelves reduce tenting on the film edges by allowing sequential geometry radii to be wet-out in the proper order, limiting variability of the operator and reducing the chance of trapping air under the film during application.

Optionally, the custom cut profiles can accommodate already installed roof-ditch clips with a pocket design. The said device quickly snaps into place with its flexible design and magnetic surfaces but is not limited to such. This trimming application is not limited to roof ditch and could be used in other trim areas that do not have an exposed edge. The provided jig and method provides for an easy application with limited operator skill, reduces safety concern as there are no sharp objects, and adds repeatability as the film cutting location is fixed. This solution also reduces film trim and final wet-out time while reducing the level of skill needed by the operator.

In a first aspect, a method of applying a film to a first panel of a vehicle is provided, the first panel being connected to a second panel of the vehicle by a joint area containing a ditch portion that is recessed relative to the first panel. The method comprises: placing into the ditch portion an elongated jig that comprises a shim extending continuously along the length of the ditch portion, the shim protruding above a height of the first panel; applying the film to the first and second panels such that the film extends over the elongated jig; using a tool to apply pressure against the film and toward a cutting edge of the shim along the length of the shim to trim the film along a peripheral edge; removing the elongated jig from the ditch portion; and adhering the peripheral edge of the film to the ditch portion.

In a second aspect, a jig is provided for applying a film to a first panel of a vehicle that is connected to a second panel of the vehicle by a joint area containing a ditch portion that is recessed relative to the first panel, the jig comprising: an elongated body having a convex bottom surface complemental to the ditch portion, the elongated body having a plurality of discontinuous segments; and a shim extending continuously along the length of the elongated body, wherein the shim has a cutting edge facing away from the elongated body and having a convergence angle of from <NUM> degrees to <NUM> degrees.

Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the disclosure. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope of the principles of the disclosure as defined by the appended claims. The figures may not be drawn to scale.

As used herein, the terms "preferred" and "preferably" refer to embodiments described herein that can afford certain benefits, under certain circumstances.

Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the invention as defined by the appended claims.

As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" or "the" component may include one or more of the components and equivalents thereof known to those skilled in the art. Further, the term "and/or" means one or all of the listed elements or a combination of any two or more of the listed elements.

It is noted that the term "comprises", and variations thereof do not have a limiting meaning where these terms appear in the accompanying description. Moreover, "a," "an," "the," "at least one," and "one or more" are used interchangeably herein. Relative terms such as left, right, forward, rearward, top, bottom, side, upper, lower, horizontal, vertical, and the like may be used herein and if so, are from the perspective observed in the particular drawing. These terms are used only to simplify the description, however, and not to limit the scope of the invention in any way.

Reference throughout this specification to "one embodiment," "certain embodiments," "one or more embodiments" or "an embodiment" means that a particular feature, structure, material, or characteristic described relating to the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrases such as "in one or more embodiments," "in certain embodiments," "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Where applicable, trade designations are set out in all uppercase letters.

A jig according to one exemplary embodiment is shown in <FIG> and hereinafter referred to be the numeral <NUM>. The jig <NUM> has an elongated shape and is shown on top of an automotive roof panel <NUM> for size comparison. As depicted, the jig <NUM> is comprised of a continuous shim <NUM> (or wire) extending along the length of the jig <NUM> and a plurality of discontinuous segments <NUM> coupled to the shim <NUM> and distributed along its length. In a preferred embodiment, the segments <NUM> are joined to each other only by the shim <NUM>. Alternatively, however, the segments <NUM> could also include mechanical hinges allowing adjacent segments <NUM> to couple to each other. Broadly, the segments <NUM> can be made modular in nature to accommodate different panel sizes and shapes.

While the provided embodiments are directed to the roof panel of an automobile, these could easily be applied to other panels as well. The provided jigs and methods could generally be used to facilitate the trimming of film near the roof ditch, front windshield, rear windshield, and moonroof of a vehicle. These jigs and methods also need not be limited to vehicular applications, and could be adapted for use on other large assemblies in which two or more exterior-facing panels come together along a seam that defines a registration surface.

The discontinuous nature of the segments <NUM> enables the relatively thin shim <NUM> to flexibly trace along a recessed ditch portion <NUM> defining a perimeter of the roof panel <NUM>, even if the segments <NUM> themselves are relatively inflexible. The ditch portion <NUM>, which will be described later in more detail, defines the boundaries of the area over which a film is to be applied. In some cases, but not necessarily all cases, the ditch portion <NUM> defines a boundary between contiguous panels.

For durability and strength, the shim <NUM> can be made from a metal, such as steel, aluminum, nitinol, copper, or alloy thereof. Preferably the metal is highly elastic and resists permanent deformation when flexed, for example, around a corner portion of a panel. The material of the shim <NUM> is not necessarily limited to metals, however, and can also be made from a flexible polymer or ceramic material. Optionally, the segments <NUM> are also at least somewhat flexible, being made from a pliable material such as a polymer, allowing flexibility and potentially lateral expansion or contraction of the material along the segments <NUM>. Such properties can also help the segments <NUM> better conform to the ditch portion <NUM> and potentially aid in securement.

If the shim <NUM> is pliable, it can be possible for the shim <NUM> to elongate along its longitudinal axis to further assist in conforming the jig <NUM> to the boundaries of the roof panel <NUM>. In some embodiments, the shim <NUM> can be fashioned into a continuous loop that extends along the entire perimeter of the roof panel <NUM>. Such a shim could include one or more joints that enable segments to be reversibly attached to each other. In these embodiments, the shim itself may be segmented to enable customization in the length of the jig <NUM>.

To assist in fitting the jig <NUM> to a particular panel at hand, it can be made possible for the segments <NUM> to be slidably movable along the shim <NUM> to accommodate sharper bends that might be encountered near corners of the film. The shim <NUM> can be made as thin as needed along its transverse direction to provide a suitable degree of flexibility. In some embodiments, the jig <NUM> is capable of being resiliently deflected along a bending radius down to <NUM> centimeters, down to <NUM> centimeters, or down to <NUM> centimeters without permanent deformation.

The segments <NUM> can represent any suitable portion of the overall length of the jig <NUM>, such as from <NUM> percent to <NUM> percent, from <NUM> percent to <NUM> percent, from <NUM> percent to <NUM> percent, or in some embodiments, less than, equal to, or greater than <NUM> percent, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> percent of the overall length of the jig <NUM>.

<FIG> shows an enlarged view of the jig <NUM> showing its profile along its longitudinal axis. In this example, the shim <NUM> has a generally rectangular cross-sectional shape, where the cross-section is defined perpendicular to a longitudinal axis of the shim <NUM>.

The shim <NUM> is partially embedded in each segment <NUM> such that one of the narrow faces of the shim <NUM> faces upward (i.e., away from the vehicle panel when installed) and is fully exposed along the entire length of the jig <NUM>. It is preferable for the shim <NUM> to protrude above the top surface of the segments <NUM> by a certain amount. As an example, at least <NUM> percent, at least <NUM> percent, or at least <NUM> percent of the shim <NUM> can protrude above the segments <NUM>.

The vertical dimension of the shim <NUM> is far greater than the transverse dimension, thus allowing for a high degree of flexibility along transverse directions. Non-rectangular shapes are also possible, so long as the cross-section of the shim has at least one upward-facing corner that protrudes above the segments <NUM>, thereby providing a continuous cutting edge for the film. In one example, the upward-facing portion of the shim <NUM> can have a generally "D"-shaped cross-section. The cross-section of the shim <NUM> may or may not be uniform along its length. In some instances, the shim <NUM> includes one or more notches along its bottom-facing surface to facilitate bending of the shim along the plane of the roof panel <NUM>.

Since the cross-section of the shim <NUM> is rectangular, each of the two cutting edges protruding above the segments <NUM> has by definition a convergence angle of <NUM> degrees, the convergence angle being defined as the angle at which the adjacent sides of the shim come together. In alternative embodiments, the one or more cutting edges can have convergence angles that deviate from <NUM> degrees. For instance, a given cutting edge can have a convergence angle of from <NUM> degrees to <NUM> degrees, from <NUM> degrees to <NUM> degrees, from <NUM> degrees to <NUM> degrees, or in some embodiments, less than, equal to, or greater than <NUM> degrees, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> degrees. At least one cutting edge of the shim <NUM> preferably has a corner edge suitable to cut through a film, such as a corner radius of up to <NUM> micrometers, up to <NUM> micrometers, up to <NUM> micrometers, or up to <NUM> micrometers.

While not restricted, the transverse thickness of the shim <NUM> can be from <NUM> micrometers to <NUM> micrometers, from <NUM> micrometers to <NUM> micrometers, from <NUM> micrometers to <NUM> micrometers, or in some embodiments, less than, equal to, or greater than <NUM> micrometers, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> micrometers. Further, the aspect ratio (i.e., height/width) of the cross-section of the shim <NUM> can be from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, or in some embodiments, less than, equal to, or greater than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>.

<FIG> show opposing bottom and top sides of a customized segment <NUM> that can optionally be used in combination with the shim <NUM>. The customized segment <NUM> contains a pocket <NUM> that provides space to accommodate any obstructions in the ditch portion <NUM> that would normally interfere with a segment, such as roof ditch clip <NUM> shown in <FIG> shows the upward-facing major surface of the customized segment <NUM>, revealing a groove <NUM> for seating a shim (not shown in <FIG>). Use of the customized segment <NUM> can also be advantageous in guiding the shim <NUM> along particularly sharp bends, such as along corner portions of the vehicle panel. While not shown here, it is possible for the customized segment <NUM> to have a configuration in which it mechanically attaches to the clip <NUM> to provide a datum point for positioning the jig <NUM> relative to the roof panel <NUM>.

<FIG> shows, in more detail, an engagement between the jig <NUM>, including the shim <NUM> and segments <NUM>, and the ditch portion <NUM> of the roof panel <NUM>. While not explicitly shown, the ditch portion can extend along the boundary between two adjacent vehicle panels, for example between a roof panel and a side panel of the vehicle. In these cases, the ditch portion preferably includes surfaces that are recessed relative to both panels. The ditch portion <NUM>, as shown, includes both concave and convex surface regions represented by a double radius. These surface regions can be complemental to mating surfaces of the segment <NUM>.

Optionally and as further shown in <FIG>, the mating surfaces extend along at least two adjacent sides of each segment <NUM>. These adjacent sides are generally bottom and side surfaces of the segment <NUM>. The mating engagement between the segments <NUM> and the ditch portion <NUM> can significantly improve registration between the jig <NUM> and the roof panel <NUM>. This in turn can provide a high degree of precision in the cut lines obtained using the jig <NUM> relative to those obtained by conventional methods.

Advantageously, each segment <NUM> includes an angled shelf <NUM> disposed between the shim <NUM> and the roof panel <NUM>. After the film is cut, the angled shelf <NUM> can help reduce tenting on the edges of the film by allowing sequential geometry radii to be wet-out in the proper order. This reduces the chance of trapping air under the film during application. By providing for a more consistent transfer of an adhesive-backed film from the segment <NUM> to the roof panel <NUM>, the angled shelf <NUM> can help limit variability in the quality of film application attributable to differences in operator technique.

<FIG> shows a schematic that illustrates a process of using the jig <NUM> to cut a film that is disposed on a roof panel <NUM>. In this process, the jig <NUM> is placed in the ditch portion <NUM> of the roof panel <NUM> as described above. When the jig <NUM> is properly seated, the upward-facing surface of the shim <NUM> should be protruding above the height of the roof panel <NUM>. In some embodiments, the jig <NUM> extends continuously along some or all of the length of the ditch portion <NUM>. While not necessary, it is possible to use a tape or temporary adhesive to secure the jig <NUM> to the ditch portion <NUM>, where the tape or adhesive is later removed.

A film <NUM> is then placed over both the roof panel <NUM> and the jig <NUM>. It is common for the film <NUM> to be an adhesive-backed film, in which case the film <NUM> can be adhesively bonded to the roof panel <NUM> upon such placement. Optionally, the film <NUM> extends across the entirety of the roof panel <NUM>, although this need not be required. A tool <NUM> can then pressed against the film <NUM> and translated along the shim <NUM>, applying pressure to compress the film <NUM> between the tool <NUM> and the shim <NUM> to cut the film along a cutting edge of the shim <NUM>. The tool <NUM> is typically pressed against the film <NUM> manually by a human operator but this operation could also be carried out in an automated manner, such as using a robotic arm controlled by a computer. Where a computer is used, the jig <NUM> could be detected using fiducial markers on the jig <NUM> that assist in locating its position. This cutting step can take place along a continuous loop along the perimeter of the roof panel <NUM> as defined by the ditch portion <NUM>. It is also possible for the ditch portion <NUM> to only extend along a portion of the perimeter of the roof panel <NUM>, in which case more than one cutting step might be required to separate the portion of the film <NUM> disposed on the roof panel <NUM> from portions of the film <NUM> extending beyond the roof panel <NUM>.

Optionally and as shown, the tool <NUM> has a recess <NUM> that has a shape that is complemental to the shape of the cutting edge of the shim <NUM>. This can prevent slippage and help ensure pressure is directed to the proper portions of the film to achieve a cleaner cut line. To facilitate cutting, the tool <NUM> is generally made from a slightly pliable material, relative to that of the shim <NUM>. Such a material can be an engineering polymer such as polyoxymethylene, provided under the trade designation DELRIN by Dupont de Nemours, Inc. , Wilmington, DE. In a preferred embodiment, the tool can have engagement surface with a Shore D hardness of up to 70D.

A significant technical benefit of this technique is that the cutting edge of the shim <NUM> does not operate like a sharp blade in the traditional sense. In various embodiments, it has a <NUM> degree edge that cuts the film <NUM> using a scissoring action or compression-based mechanism, making the operation safer for a human operator. In some embodiments, and depending on the composition of the film being trimmed, the shim <NUM> can be pre-heated to facilitate cutting of the film.

Further refinements are also possible in relation to the shim <NUM>. For example, the shim <NUM> could be withheld inside a carrier (such as the segments <NUM>) until the jig <NUM> is placed into the ditch portion <NUM> of the roof panel <NUM>. The shim <NUM> could then be slidably urged out of the carrier when the jig <NUM> is fully seated into the ditch portion <NUM>. A benefit of this configuration is that it can help avoid scratching any painted surfaces on the roof panel <NUM> while the jig <NUM> is being applied.

After the film <NUM> has been fully trimmed using the steps above, the jig can be removed from the ditch portion <NUM> of the roof panel <NUM>. The remaining edge portion of the newly trimmed film <NUM> on the roof panel <NUM> can then adhered, as appropriate, to the portion of the ditch portion <NUM> where the jig <NUM> was vacated. The excess portion of the film <NUM>, sometimes referred to as the "weed" portion, can then be discarded or repurposed.

Objects and advantages of this disclosure are further illustrated by the following non-limiting example, but the particular materials and configurations thereof recited in this example, as well as other conditions and details, should not be construed to unduly limit this disclosure.

A jig as shown in <FIG> and <FIG> was inserted into a roof ditch of a Toyota Corolla vehicle. A piece of a <NUM> Paint Protection Film PUL2008 obtained from <NUM> Company of St. having a sufficient length was positioned to cover the roof ditch (containing the jig) and adhered to a first panel and second panel of the vehicle roof. The release liner was removed from the PUL2008 film prior to film's application to the panels. Then, a polyoxymethylene plastic block (obtained from DUPONT of Wilmington, DE under the trade designation DELRIN) with a recess was used to press the film into the shim of the jig which cut the film. The height of the recess was equal to the height of the exposed shim embedded in the jig. The width of the recess was designed such that it was less or equal to five times the width of the shim.

Claim 1:
A method of applying a film to a first panel (<NUM>) of a vehicle wherein the first panel (<NUM>) is connected to a second panel of the vehicle by a joint area containing a ditch portion (<NUM>) that is recessed relative to the first panel (<NUM>), the method comprising:
placing into the ditch portion (<NUM>) an elongated jig (<NUM>) that comprises a shim (<NUM>) extending continuously along the length of the ditch portion (<NUM>), the shim (<NUM>) protruding above a height of the first panel (<NUM>);
applying the film to the first and second panels such that the film extends over the elongated jig (<NUM>);
using a tool to apply pressure against the film and toward a cutting edge of the shim (<NUM>) along the length of the shim (<NUM>) to trim the film along a peripheral edge;
removing the elongated jig (<NUM>) from the ditch portion (<NUM>); and
adhering the peripheral edge of the film to the ditch portion (<NUM>).