U.S. patent application number 10/707499 was filed with the patent office on 2004-06-24 for ultra-thin surface modification system.
This patent application is currently assigned to JohnsonDiversey, Inc.. Invention is credited to Bober, Andrew M., Gaston, James H. II, Linden, Shwn-Meei Y..
Application Number | 20040121123 10/707499 |
Document ID | / |
Family ID | 32682051 |
Filed Date | 2004-06-24 |
United States Patent
Application |
20040121123 |
Kind Code |
A1 |
Bober, Andrew M. ; et
al. |
June 24, 2004 |
ULTRA-THIN SURFACE MODIFICATION SYSTEM
Abstract
This invention provides a thin laminate for modifying the
appearance of a surface. The laminate includes an indicia
containing layer disposed against the lower surface of a carrier
film. The laminate may optionally include a bonding coat or layer
for attaching the laminate to a surface, at least one removable
protective layer, and a release coating for facilitating the
transfer of the laminate on a surface. The invention also provides
methods and systems for modifying the appearance of a surface using
the laminate.
Inventors: |
Bober, Andrew M.; (Racine,
WI) ; Gaston, James H. II; (Racine, WI) ;
Linden, Shwn-Meei Y.; (Racine, WI) |
Correspondence
Address: |
S.C. JOHNSON COMMERCIAL MARKETS INC
8310 16TH STREET, M/S 510
PO BOX 902
STURTEVANT
WI
53177-0902
US
|
Assignee: |
JohnsonDiversey, Inc.
8310 16th Street P O Box 902
Racine
WI
|
Family ID: |
32682051 |
Appl. No.: |
10/707499 |
Filed: |
December 18, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60434499 |
Dec 18, 2002 |
|
|
|
Current U.S.
Class: |
428/138 |
Current CPC
Class: |
Y10T 428/31504 20150401;
B44C 1/1733 20130101; Y10T 428/24331 20150115; B41M 7/0027
20130101; B32B 7/06 20130101; Y10T 428/31855 20150401; Y10T
428/249953 20150401; B44C 1/16 20130101; Y10T 428/26 20150115; Y10T
428/31551 20150401; Y10T 428/14 20150115; B32B 27/08 20130101; B44C
1/105 20130101; B41M 5/508 20130101 |
Class at
Publication: |
428/138 |
International
Class: |
B32B 003/10 |
Claims
1. A surface modifying laminate comprising: (a) a carrier film
having an upper surface and a lower surface, the film at least
partially covering a surface to be modified; (b) an
indicia-containing layer disposed on at least a portion of the
lower surface of the carrier film; and (c) a cured top coat
disposed on at least a portion of the upper surface of the carrier
film.
2. The surface modifying laminate of claim 1, wherein the carrier
film is a transparent film, such that the indicia-containing layer
is visible through the carrier film.
3. The surface modifying laminate of claim 1, wherein the
indicia-containing layer is a substantially continuous layer
covering substantially the entire carrier film.
4. The surface modifying laminate of claim 1, wherein the
indicia-containing layer is printed onto the lower surface of the
carrier film.
5. The surface modifying laminate of claim 1, wherein the carrier
film is perforated.
6. The surface modifying laminate of claim 1, wherein the carrier
film comprises a film selected from the group consisting of
polypropylene films, polyacetal films, polyamide films,
polyanhydride films, polyester films, polyolefin films, polystyrene
films, polyvinylchloride films, polyvinylidene chloride films,
polyurethane films, and polyurea films.
7. The surface modifying laminate of claim 1, wherein the top coat
is not an alkali-soluble top coat.
8. The surface modifying laminate of claim 1, wherein the top coat
is a crosslinked top coat.
9. The surface modifying laminate of claim 1, wherein the top coat
is a permanent top coat.
10. The surface modifying laminate of claim 1, wherein the top coat
is selected from the group consisting of acrylic coatings,
polyurethane coatings, vinyl coatings and epoxy coatings.
11. The surface modifying laminate of claim 1, further comprising a
bonding layer disposed between the surface to be modified and the
indicia-containing layer.
12. A surface modifying laminate comprising: (a) a perforated
carrier film having an upper surface and a lower surface, the film
at least partially covering a surface to be modified; (b) an
indicia-containing layer disposed on at least a portion of the
lower surface of the carrier film.
13. The surface modifying laminate of claim 12, wherein the carrier
film is a transparent film, such that the indicia-containing layer
is visible through the carrier film.
14. The surface modifying laminate of claim 12, wherein the
indicia-containing layer is a substantially continuous layer
covering substantially the entire carrier film.
15. The surface modifying laminate of claim 12, wherein the
indicia-containing layer is printed onto the lower surface of the
carrier film.
16. The surface modifying laminate of claim 12, wherein the carrier
film comprises an average of at least 1 perforation per square
foot.
17. The surface modifying laminate of claim 12, wherein the carrier
film comprises an average of no more than about 200 perforations
per square foot.
18. The surface modifying laminate of claim 2, wherein the carrier
film comprise a film selected from the group consisting of
polypropylene films, polyacetal films, polyamide films,
polyanhydride films, polyester films, polyolefin films, polystyrene
films, polyvinylchloride films, polyvinylidene chloride films,
polyurethane films, and polyurea films.
19. The surface modifying laminate of claim 12, further comprising
a cured top coat disposed on at least a portion of the upper
surface of the carrier film.
20. A method for modifying a surface, the method comprising: (a)
applying a surface modifying laminate to the surface to be
modified, the laminate comprising a carrier film having an upper
surface and a lower surface and an indicia-containing layer
disposed on at least a portion of the lower surface of the carrier
film; (b) applying a curable composition over at least a portion of
the upper surface of the carrier film; and (c) curing the
composition to provide a cured polymer top coat.
21. The method of claim 20, further comprising applying a liquid
wetting agent having a surface tension equal to or less than the
surface tension of water to the surface to be finished, to the
lower surface of the carrier film, or to the indicia containing
layer prior to applying the laminate to the surface, such that the
liquid wetting agent is disposed between the indicia containing
layer and the surface to be finished after the laminate is applied
to the surface to be modified.
Description
BACKGROUND OF INVENTION
FIELD OF THE INVENTION
[0001] This invention provides a laminate for modifying the
appearance of a surface, surfaces modified with the laminate, and
methods for modifying the appearance of a surface with the
laminate.
[0002] Floor care programs today are primarily used to both protect
and enhance the appearance of a floor substrate. A variety of
materials including vinyl, marble, terrazzo, ceramic, linoleum,
wood, etc. are used as floor substrates. Floor care programs can
include many different types of products, but generally involve the
use of a sealer and/or finish applied to the surface of the floor
substrate. This finish is then maintained with the use of cleaners
and tools, which can include various buffing or burnishing
machines. Although these programs are very effective they are
considered a large expense to customers. Additionally, if a surface
becomes worn or unsatisfactory over time, it is necessary to
entirely remove the floor substrate, to provide a new fresher look
to the floor.
[0003] In retail locations it is commonplace to place advertising
and/or directions in locations readily visible to the customer or
client. Recently, several companies have begun producing floor
graphics to meet the needs of advertisers. These graphics consist
of a printed film covered with some kind of top laminate meant to
both protect the graphic and provide a non-slip surface.
Unfortunately, many of the floor stickers available today provide
for a slip, trip and fall hazard. These graphics, which are applied
over the floor finish, are very similar to a sticker in that a
backing is peeled off of the graphic, exposing an adhesive. The
sticker is then pressed down onto the floor finish. Such stickers
are utilized by a variety of end users, but are primarily found in
industrial and retail locations where informational data or
advertising play an important role in impulse purchasing.
[0004] There are many product defects or deficiencies which make
the presently available types of graphics less than desirable for
use in flooring or other surface applications. These include
distorted image, difficulty in application, wearing or tearing of
the sticker, difficult maintenance due to use of mechanical
equipment used in the floor care process which tend to tear up the
edges of the graphic, and thickness of the graphic. Most often
these deficiencies result in a poor appearance, low durability and
a trip, slip and fall hazard for individuals walking over or around
the graphic. Additionally, such graphics tend to accumulate dirt,
especially where damage to the graphics has occurred and adhesive
residue remains. Further, existing graphics are difficult to remove
and sometimes take several coats of the surface finish off during
removal thereby requiring that the entire surface be stripped and
recoated with a finish. None of these products addresses the
situation where it is desirable to change the appearance of the
entire surface or a large portion of the surface.
[0005] In summary, a considerable number of deficiencies exist in
the art relating to appearance modification and enhancing systems
related to indoor and outdoor surfaces, such as floor surfaces,
wall surfaces, ceilings, windows, vehicle surfaces, driveways,
sidewalks, patios, and the like. While prior art stickers provide a
means for advertising and including a graphic on a sticker, the
poor print quality, difficult application, difficult maintenance,
thickness, poor adhesion and/or wearing and tearing, low durability
and labor intensive and expensive removal and recoating process
make them less than desirable, expensive and time consuming
options. Additionally, the danger posed by the worn or lifted edges
of such stickers creates a safety hazard. Further, the appearance
of such stickers is not very professional and is oftentimes dull or
less than crisp. Additionally, when it is desirable to modify the
appearance of the entire surface or large portions thereof, few
options other than the expensive removal and replacement of the
substrate exist.
[0006] Thus, there is an ongoing search for an appearance
modification system which would enable a surface to be altered
partially or in its entirety, which can be quickly and easily
applied yet is readily removable and protected from scratches,
scuffs, gouges and other damage by maintenance equipment and
general wear and tear. In particular, there is a need for an
improved appearance modification system which overcomes the
shortcomings of the stickers of the prior art.
SUMMARY OF INVENTION
[0007] One aspect of the invention provides a surface modifying
laminate structure containing a thin indicia containing layer
disposed on a carrier film. The carrier film serves to facilitate
the removal of the laminate from a surface by peeling the laminate
away without the need for any stripping agents or other chemicals.
Other optional layers in the laminate include a bonding coat or
layer for attaching the carrier film and indicia containing layer
to a surface, at least one removable protective layer for
protecting the carrier film, the indicia containing layer and/or
any bonding layer prior to the application of the laminate to a
surface, and a release coating between the indicia containing
layer, the carrier film, or the bonding coat and the removable
protective layer. The bonding coat may be selected to attach the
indicia containing layer in a removable or repositionable
manner.
[0008] Another aspect of the invention provides a surface
modification system which includes an indicia containing layer
disposed on a carrier film and a surface onto which the system is
to be applied. Optionally, the system may also include at least one
top coat applied over at least a portion of the laminate and over
at least a portion of the surface adjacent the laminate. The system
may additionally include at least one base coat applied to the
surface prior to application of the laminate to the surface. The
combination of the carrier film and the indicia containing layer in
such a system should be sufficiently thin to provide a minimal
difference between the height of the surface without the laminate
and the height of the surface having the laminate applied thereon.
In some embodiments, the laminate is disposed on at least a portion
of the surface whereby the remaining portion of the surface is
devoid of laminate. In other embodiments the laminate is applied
over the entire surface.
[0009] The inventive system also optionally includes a surface
cleaner for cleaning a surface to which an indicia containing layer
has been applied. Such cleaners include neutral cleaners, alkaline
cleaners, acidic cleaners, cleaner/maintainers and maintainers,
including polymeric type cleaners. During surface cleaning the
indicia containing layer remains intact and is not degraded or
damaged by the cleaning material or process.
[0010] In practice, application of the surface modifying laminate
to a surface comprises the following steps. It is advisable, but
not required, that the surface be properly cleaned prior to the
application of the laminate to remove dirt or debris which may
adversely affect the overall appearance of the laminate covered
surface. The next step involves positioning or disposing the
laminate, indicia containing layer side down, on at least a portion
of the surface. After such positioning, a top coat may be applied
over at least a portion of the laminate and the surface. In some
embodiments a base coat layer may be applied to the surface after
the cleaning step but prior to positioning the laminate on the
surface.
[0011] In certain constructions, the surface modifying laminate is
strong enough that it may be readily removed from the surface
simply by peeling the carrier film away from the surface. In a
process for removing the laminate from an enhanced surface wherein
at least a portion of the laminate is disposed below a top coat,
conventional means may be employed to remove the top coat prior to
the removal of the laminate.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a cross-sectional view illustrating an exemplary
surface modifying laminate according to the present invention.
[0013] FIG. 2 is a cross-sectional view of a surface to which the
surface modifying laminate of the present invention has been
applied. Although the laminate structure is depicted as a single
block in FIG. 2, it should be understood that the laminate actually
includes multiple layers, as shown in FIG. 1.
DETAILED DESCRIPTION
[0014] The present invention is directed to surface modification
laminates used to modify or enhance a surface and to surface
modification systems that include the laminates. Such laminates and
systems enable modification or enhancement of a surface with visual
images and/or text disposed on at least a portion of the surface.
Alternatively, the entire appearance or color of the surface can be
modified.
[0015] The present invention has potential applications on any
surface where visual images, text, color, graphics and/or designs
can be applied to provide a modified visual appearance of the
surface. Such surfaces may be found both indoors and outdoors on
such objects as architectural structures, vehicles and consumer
products. As used herein, the term architectural structure includes
building structures, such as floors, walls, ceilings, windows,
roofs, patios, shelves, and stairs, and ground cover structures,
such as roads, driveways, and sidewalks. Examples of vehicles to
which the surface modifying laminates may be applied include,
automobiles, aircraft, watercraft, trucks, motorcycles, and
bicycles. Toys and appliances are only two of many consumer
products to which the surface modifying laminates may be applied.
The surface to be modified may be made from a vast variety of
materials, including, but not limited to, vinyl, marble, terrazzo,
ceramic, linoleum, wood, metal, plastic, rubber, gypsum board,
plaster, concrete, stone, vinyl composition tile, and glass.
[0016] FIGS. 1 and 2 show exemplary embodiments of the invention.
As shown in FIG. 1, the laminate structure 18 includes a carrier
film 20 and an indicia containing layer 22 disposed on the lower
surface of the carrier film 20. In the structure exemplified in
FIG. 2, the surface 24 to be modified is at least partially covered
by the carrier film 20 onto which the indicia containing layer 22
has been disposed. The surface modifying laminate of FIG. 1 and the
surface modifying system of FIG. 2 further include, a bonding coat
26 disposed against the lower surface of the carrier film 20, and a
top coat 34 applied over the top of the laminate structure. A base
coat 28 is also shown in FIG. 2, sandwiched between the surface to
be modified 24 and the bonding coat 26. Additionally, the present
invention can include removable protective layers 30 and 32. Upper
removable layer 30 is designed to protect the upper surface of the
carrier film 20 and lower removable layer 32 is designed to protect
the indicia containing layer 22 and/or any bonding coat 26 applied
thereto and/or any portion of the lower surface of the carrier film
20 not having any indicia containing layer or bonding coat disposed
thereon, if any. Although not shown in the figures, the laminate
may also include a release coat between the upper removable layer
and the carrier film and/or between the lower removable layer and
the exposed lower surface of the carrier film or any bonding coat
applied thereto.
[0017] The carrier film facilitates the transfer of the indicia
containing layer to the surface to be modified and removal of the
laminate from the surface. The inventors have surprising and
unexpectedly discovered that the carrier film is selected and
designed such that the carrier film, along with the indicia
containing layer disposed thereon, may be readily removed by
peeling the laminate layer away from the surface, either in a
single sheet or in smaller pieces. This eliminates the need for
conventional stripping agents and makes the removal process, less
expensive, less energy intensive, and less time consuming. It also
eliminates the need for stripping chemicals which pose a hazard to
both the user and the environment.
[0018] The carrier film should be thin so that the thickness of the
seam between the surface and the laminate is minimized. In some
embodiments the carrier film has a thickness of 8 mils or less.
This includes embodiments where the carrier film has a thickness of
6 mils or less, embodiments where the carrier film has a thickness
of 4 mils or less, and embodiments where the carrier film has a
thickness of 2 mils or less, and embodiments where the film has a
thickness of 0.5 mils or less, where a "mil" is defined as one
one-thousandth of an inch. The choice of film thickness will
depend, at least in part, on the intended application and location
of the laminate. Additionally, the type of film will impact the
film strength. Thus, it may be possible to utilize films of
particular materials in a thinner dimension while maintaining
sufficient strength to be peeled away from the surface without
tearing or with only minor amounts of tearing. A thinner film might
be more desirable where it is imperative that the transition from
the surface to the laminate is nearly imperceptible. Alternatively,
a thicker film might be used to smooth out an underlying surface
that is uneven, rough, or damaged.
[0019] The carrier film may be made from any material onto which
the indicia containing layer may be applied or printed. Examples of
suitable materials for the carrier film include, but are not
limited to, fabrics, foils, polymeric sheeting, and paper. Specific
examples of suitable polymeric sheeting materials include, but are
not limited to, polypropylene films, polyacetal films, polyamide
films, polyanhydride films, polyester films, polyolefin films,
polystyrene films, polyvinyl chloride films, polyvinylidene
chloride films, polyurethane films, polyurea films, and the like.
In some embodiments the carrier film is transparent, such that the
indicia containing layer in visible through the carrier film.
[0020] The indicia containing layer may comprise a design, picture,
graphic, text, or the like and may exist as a continuous or
discontinuous layer on the carrier film. In some embodiments the
indicia containing layer may be a substantially continuous layer
covering substantially the entire carrier film. The indicia
containing layer is made from an ink, pigment, or dye formulation
which may contain any suitable ink, dye, or pigment that is capable
of being applied, for example by dry transfer or printing, to the
lower surface of the carrier film. In some embodiments the graphic
provided by the indicia containing layer gives the appearance of a
painted graphic or even a photograph. In some embodiments, the ink,
pigments, or dyes are readily dissolvable in water or common
organic solvents, are readily removable, and do not migrate or
diffuse into the adjacent carrier layer, base coat or top coat of
the system. Suitable inks include UV cured inks, water based inks,
or solvent based inks. The indicia containing layer may be a
multi-colored layer and the inks, dyes, and/or pigments that make
up the layer may be contained in a single stratum or multiple
strata within the indicia containing layer. In some embodiments the
ink formulation is a 100% active formulation.
[0021] As noted above, the present invention may optionally include
a bonding coat on the lower surface of the indicia containing layer
or any portion of the lower surface of the carrier film devoid of
the indicia containing layer as shown in FIG. 1, where the lower
surface is the surface that will be face down with respect to the
surface once the laminate is applied. Such a bonding coat can be
made from an adhesive which serves to adhere the indicia containing
layer and carrier film to the surface. The tackiness of the
adhesive may vary over a broad range depending on the intended
application of the laminate. As used herein, the term "tack" refers
to the rate at which an adhesive bond forms between two surfaces.
As one of skill in the art will recognize, the tack of certain
adhesive may be influenced by the thickness of the adhesive layer.
In embodiments where it is desirable to provide a surface
modification system wherein the laminate is readily removed from
the surface, the adhesive should be selected such that it bonds
preferentially to the carrier film, rather than the surface to be
modified. In certain embodiments the tack of the adhesive will
range from 50 to 2000 grams per square centimeter. This includes
embodiments where the tack of the adhesive ranges from 100 to 1500
grams per square centimeter, and further includes embodiments where
the tack of the adhesive ranges from 150 to 1000 grams per square
centimeter.
[0022] The bonding coat or layer should be thin in order to
minimize the combined thickness of the bonding layer, the indicia
containing layer, and the carrier film. In various embodiments the
combined thickness of these three components is 8 mils or less, 6
mils or less, 5 mils or less, 4 mils or less and even 2 mils or
less. Suitable adhesives for use in the bonding coat or layer
include pressure sensitive adhesives. In some embodiments, the
pressure sensitive adhesives are non-curing adhesives or adhesives
that do not require curing after application, because such
adhesives may be more easily removed from some surfaces. For
example, in some embodiments, curable epoxies are avoided. Other
suitable adhesives include temperature sensitive adhesives,
repositionable adhesives, or any other suitable adhesive known to
one of ordinary skill in the art. Examples of suitable pressure
sensitive adhesives include, but are not limited to those disclosed
in U.S. Pat. Nos. 4,845,149; 4,879,333; and 4,923,919, which are
incorporated herein by reference. In some embodiments the bonding
coat can include a supported adhesive.
[0023] The bonding coat may be applied directly to the lower
surface of the indicia containing layer or any exposed portion of
the lower surface of the carrier film or may first be applied to
the surface of a protective removable layer, of the type described
below, which is then disposed adjacent to the lower surface of the
indicia containing layer or exposed lower surface of the carrier
film, sandwiching the adhesive coating between the indicia
containing layer and the removable protective layer. In this
embodiment it is advantageous if the adhesive bonds preferentially
to the indicia containing layer and/or any exposed portion of the
lower surface of the carrier film such that it is transferred along
with the indicia containing layer and carrier film onto the surface
to be modified. The bonding coat may be applied to the surface of
the indicia containing layer, any exposed portion of the lower
surface of the carrier film or the protective layer by any
conventional means. For example, the adhesive may be spray coated,
rolled or printed onto the indicia containing layer and carrier
film or protective layer. In some embodiments the bonding coat
dissolves readily in mild detergents. Alternatively, the bonding
may be applied directly to the surface to be modified, or a portion
thereof, and the indicia containing layer and carrier film may
subsequently be adhered to the adhesive.
[0024] In some embodiments, the bonding coat may be omitted. For
example, an external source may be utilized to maintain the
position of the indicia containing layer and carrier film on the
surface to be modified during application of a top coat over at
least a portion of the laminate such that the top coat secures the
laminate to the surface.
[0025] As noted above, the indicia containing layer may optionally
include a removable protective layer disposed below the indicia
containing layer and/or above the carrier film. The lower removable
protective layer, namely the protective layer below the indicia
containing layer, protects the indicia containing layer from damage
during handling. A release coating may be included between the
lower removable protective layer and the indicia containing layer
in order to facilitate the transfer of the indicia containing layer
to the surface to be modified. In some embodiments the laminate
includes an upper removable protective layer disposed next to the
upper surface of the carrier film. In such embodiments, a bonding
coat as described above, may be included between the removable
protective layer and the indicia containing layer. In this
construction the removable protective layer serves to prevent
debris from collecting in the adhesive and to prevent the adhesive
from attaching to a surface prematurely.
[0026] The upper and lower removable protective layers may be made
from the same or different materials. Suitable materials include,
but are not limited to, plastics, such as polyester, polypropylene,
or polyethylene. The removable protective layer or layers may
optionally be transparent materials. In some embodiments the
removable protective layer or layers are made from paper which may
optionally be coated paper. This has the advantage of significantly
lowering the cost of production of the surface modifying laminates.
In addition, because the paper may be readily recycled, this
embodiment saves energy and reduces waste.
[0027] Suitable materials for use in release coats are well known
and include, but are not limited to, polyvinyl chloride and
acrylics designed to facilitate the release of the removable layer
or layers from the carrier film, the indicia containing layer or
the bonding coat. The release coat may be designed to remain
substantially adhered to the removable protective layer after the
transfer of the remainder of the laminate to the surface to be
modified. Alternatively, the release coat may be designed to remain
substantially adhered to the indicia containing layer, the bonding
coat, or the carrier film after the transfer. In the latter design,
the release coat is referred to as a breakaway coating. The
breakaway coating should be selected and designed such that it does
not substantially affect the thickness of the applied laminate and
assimilates with the indicia containing layer without negatively
affecting the appearance of that layer. In other embodiments the
release coat is split between the indicia containing layer or the
carrier film and the removable protective layer upon the removal of
the latter. In various embodiments, the combined thickness of the
carrier film, the indicia containing layer, any bonding coat and
any release coating is 8 mils or less, 6 mils or less, 5 mils or
less, 4 mils or less, or even 2 mils or less.
[0028] After the application of the surface modifying laminates to
the surface to be modified, at least one top coat may be disposed
over at least a portion of the laminate and over at least a portion
of the surface adjacent the laminate. The top coat may be any
conventional sealant or finish and may be applied as a solid or a
liquid top coat. Such top coats are well known and commercially
available and are generally used to impart shine, dirt resistance,
water resistance, and/or scratch/wear resistance to the surface.
The top coat may help adhere the laminate to the surface to be
modified and to further smooth out the already extremely narrow
edges of the laminate. Another advantage provided by the top coat
is that it provides a surface having a single coefficient of
friction which helps prevent trips, slips and falls. However, the
top coat is not required.
[0029] For many applications, such as floor applications, it is
desirable for a surface finish to provide a slip-resistant surface
or a surface having a single coefficient of friction which helps
prevent trips, slips and falls. In some instances, the flexible
film may provide a sufficiently slip-resistant surface, however,
when it is desirable to increase the slip-resistance of the film, a
top coat which provides a coefficient of friction higher than that
of the film may be applied over at least a portion of the film. In
some embodiments the top coat may provide a non-slip surface. As
used herein, a "non-slip" surface is a surface having a coefficient
of friction of at least 0.5 as measured by ASTM D 2047, a standard
test method for determining the static coefficient of friction of
polish-coated floor surfaces as measured by the James Machine. This
includes embodiments where the top coat provides a surface having a
coefficient of friction of at least 0.55, further includes
embodiments where the top coat provides a surface having a
coefficient of friction of at least 0.6, still further includes
embodiments where the top coat provides a surface having a
coefficient of friction of at least 0.65, yet further includes
embodiments where the top coat provides a surface having a
coefficient of friction of at least 0.7, and even further includes
embodiments where the top coat provides a surface having a
coefficient of friction of at least 0.75.
[0030] Examples of suitable top coats include, but are not limited
to, polymeric top coats, such as acrylic finishes. Specific
examples of such top coats include styrene acrylics, urethane
acrylics, urethanes, including polyurethanes, vinyls, epoxys, and
the like. Such top coats may or may not be alkali-soluble top
coats. Such top coats can be cured or uncured, permanent or
non-permanent. As used herein, a "cured" coating includes coatings
that are formed by the evaporation of a solvent and the coalescence
of the solid film without crosslinking (i.e.
"evaporatively-cured"coatings) and coatings that are formed by
crosslinking reactions. Suitable, commercially floor finishes for
use as top coat herein include SIGNATURE floor finish, VECTRA floor
finish, PREMIA floor finish, JON-WOOD Waterborne wood floor finish,
all of which are available from JohnsonDiversey, Inc. In various
embodiments, the combined thickness of the laminate and any top
coat is 8 mils or less, 6 mils or less, 5 mils or less, 4 mils or
less, or even 2 mils or less. However, it is not imperative that
the top coat be particularly thin.
[0031] Suitable commercially available cured floor finishes for use
with the floor finish systems provided herein include Signature, a
metal interlock styrene-acrylic finish that cures at ambient
temperatures, available from JohnsonDiversey, Inc. (Racine Wis.).
Suitable commercially available evaporatively-cured floor finishes
include ZF-175, Linobase, and JX-4000, available from
JohnsonDiversey, Inc. (Racine, Wis.). Conventional floor finishes
mixed with crosslinking hardeners may also be employed. For
example, Signature may be mixed with about 1% polyaziridine to
provide a more durable crosslinked finish.
[0032] As noted above, at least one base coat may be disposed
between the surface to be modified and the carrier film of the
laminate. Suitable base coats are well known and commercially
available. The base coat can be of similar or identical composition
to the top coat, as previously discussed, or a different
composition.
[0033] Further embodiments of the present invention allow for a
first surface modifying laminate to be applied to a surface,
followed by the application of a top coat over at least a portion
of the first surface modifying laminate, and the subsequent
application of a second surface modifying laminate disposed on top
of the top coat, optionally followed by an additional top coating.
Further, alternating layers of laminate and top coats can be
utilized to achieve a desired effect. In such an embodiment, as in
previous embodiments, a base coating layer can be disposed on top
of the surface prior to application of the first surface modifying
laminate. In these multi-layered constructions, the uppermost
laminate may be made from a series of individual portions or
patches of laminate. This embodiment is useful because monitoring
the degree of disappearance of the uppermost laminate allows the
user to determine when the surface requires reapplication of a top
coat over the lower laminates. The ability to provide multiple
layers of laminates is also advantageous because it allows the
lower laminates to be patched in order to fix holes or cover
damage. Further, it provides for optional layering of laminates to
easily modify the appearance of a surface, for example, to match
seasonal decor or displays.
[0034] In readying the surface for application of a surface
modifying laminate, it is recommended, but not required, that the
surface initially be cleaned or stripped to remove dirt, debris or
similar waste, as well as any inferior coatings applied on the
surface. Conventional cleaners including neutral cleaners, alkaline
cleaners, acidic cleaners, cleaners/maintainers, or maintainers
including polymeric cleaners, may be utilized for this purpose. One
such cleaner is JWP UHS Cleaner available from JohnsonDiversey,
Inc. Dust mopping, or similar light cleaning may be utilized to
remove the majority of the dust and dirt. After cleaning and
stripping, the laminate is positioned on the surface. The film may
be applied beginning at one edge by adhering an edge of the film to
the surface, using any adhesive coated on the lower surface of the
film or a strip of tape, and spreading (e.g. rolling) the film
outwardly from that edge, pressing it onto the surface as it
spreads. A tool having a flat edge may be utilized to uniformly
apply the film to the surface and remove any bubbles, wrinkles,
etc. Such tools include, rubbing sticks, rigid blades, flat-bladed
squeegees, T-bars, including weighted T-bars and rollers, including
heated and/or weighted rollers. Any bubbles remaining in the film
after application may be removed by pricking the bubbles with a pin
or similar object to release trapped air or liquid. If the laminate
is packaged with one or more removable protective layers, those
layers are removed, exposing the indicia containing layer or the
bonding coat, if present, and applying the laminate to the surface,
typically by applying light pressure. A rubbing stick, squeegee or
roller may be utilized to uniformly apply the laminate to the
surface and remove any bubbles, wrinkles, etc. After the laminate
is suitably placed and positioned on the surface to be modified,
any removable layers may be peeled away. Next, a top coat may be
disposed over at least a portion of the laminate. Multiple layers
of the top coat may be applied.
[0035] Alternatively, a water release or water slide technique can
be utilized to position the laminate on the surface whereby the
laminate is positioned above the surface and moisture is applied to
slide the indicia containing layer and carrier film off of a
removable protective layer and onto the surface.
[0036] The inventors have surprisingly and unexpectedly discovered
that bubbles in the film may be reduced or eliminated by first
applying a thin layer or mist of a liquid wetting agent having a
surface tension, equal to or less than the surface tension of water
to the surface to be finished, or to the lower surface of the
indicia containing layer prior to the application of the indicia
containing layer and film to the surface such that the liquid
wetting agent is disposed between the indicia containing layer and
the surface to be finished or modified, after the laminate is
applied to such surface. Suitable liquid wetting agents include
water, conventional cleaning solutions including alcohol-containing
cleaners, acidic cleaners, alkaline cleaners, maintainers, and
floor finishes similar to those used herein as a top coat.
[0037] Bubbles may also be reduced by using an air or liquid
permeable film or by using a film that has one or more perforations
to allow any liquid or air trapped below the film to escape as the
film is flattened onto the surface. The perforations may include
holes of various shapes, however narrow slits or pin holes are
preferred because they allow air and liquid to escape without
significantly reducing the smoothness of the film. This is
desirable because a rough surface may wear out faster as dirt
collects in rough areas and edges become frayed. Thus, the number
of perforation is desirably sufficient to reduce the number of
bubbles without unnecessarily roughening the surface of the film or
weakening the film. In some embodiments, the films have an average
of at least 1 perforation per square foot. This includes
embodiments where the films have an average of at least 10
perforations per square foot. In some embodiments, the films have
an average of no more than about five hundred perforations per
square foot. This includes embodiment where the films have an
average of no more than about two hundred perforations per square
foot, further includes embodiments where the films have an average
of no more than about one hundred perforations per square foot and
still further includes embodiments where the films have an average
of no more than about fifty perforations per square foot.
[0038] The flexible films may be provided in sheets or rolls and
may be applied as a single sheet or in multiple smaller film
segments. The film segments may take on a variety of shapes, but
desirably include one or more straight edges. Suitable shapes
include rectangles and squares. When multiple film segments are
laid down they are desirably disposed adjacent each other with
edges in contact, but not overlapping. This process may be
facilitated using a laser-guided chalk line to help establish
straight rows and clean butt joints.
[0039] Maintenance of a laminate-modified surface according to the
present invention, may be handled by utilization of commonly used
cleaners, including neutral cleaners, alkaline cleaners, acidic
cleaners, polymeric cleaners and polymeric maintainers. Commonly
available products such as JWP Stride Cleaner available from
JohnsonDiversey, Inc. can be utilized. After the cleaner is applied
to the surface, an agitating force sufficient to remove dirt from
the laminate without damaging the laminate may be applied. This may
be accomplished with commonly used mechanical tools such as
auto-scrubbers and buffers.
[0040] It should be noted that the layer thicknesses depicted in
the figures, is for illustration purposes only and is in no way
meant to reflect the actual thickness of each layer or its relative
thickness with respect to any other layer.
[0041] These embodiments represent a few possibilities for the
inventive appearance enhancement and modification system of the
present invention. While the principles of this invention have been
described in connection with specific embodiments, it should be
understood clearly that these descriptions are made only by a way
of example and are not intended to limit the scope of the
invention.
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