U.S. patent application number 10/763481 was filed with the patent office on 2005-07-28 for pressure sensitive adhesive repair product.
Invention is credited to Hoffmann, Dennis SR., Hubert, Ray.
Application Number | 20050161152 10/763481 |
Document ID | / |
Family ID | 34795046 |
Filed Date | 2005-07-28 |
United States Patent
Application |
20050161152 |
Kind Code |
A1 |
Hoffmann, Dennis SR. ; et
al. |
July 28, 2005 |
Pressure sensitive adhesive repair product
Abstract
A repair device which includes an intermittent coating of PSA on
a first side of a sheet of release paper. The cured PSA may be
easily transferred to a surface by pressing the release paper
against the surface thereby effectively transferring the
intermittent coating of PSA to the surface. The improved repair
device is useful for repairing delaminated or detached wallpaper,
holding wall patch repair devices in place during the application
of spackling or repair compound and holding door hinges in place
during the installation thereof.
Inventors: |
Hoffmann, Dennis SR.; (Fox
Lake, IL) ; Hubert, Ray; (Kankakee, IL) |
Correspondence
Address: |
MARSHALL, GERSTEIN & BORUN LLP
233 S. WACKER DRIVE, SUITE 6300
SEARS TOWER
CHICAGO
IL
60606
US
|
Family ID: |
34795046 |
Appl. No.: |
10/763481 |
Filed: |
January 23, 2004 |
Current U.S.
Class: |
156/249 ;
156/247; 156/539; 156/580 |
Current CPC
Class: |
Y10T 156/1702 20150115;
E04G 23/0207 20130101; E04G 23/0203 20130101; B44C 7/08
20130101 |
Class at
Publication: |
156/249 ;
156/247; 156/580; 156/539 |
International
Class: |
B32B 031/00; B30B
001/00 |
Claims
What is claimed is:
1. A repair device for applying pressure sensitive adhesive (PSA)
to a surface, the device comprising: a sheet of release paper
having a first side coated with first silicone and subsequently
coated intermittently with PSA that has been cured thereon, the
sheet also having a second side, wherein engagement of the first
side of the primary sheet and PSA against the surface and
imposition of a pressing force on the second side of the primary
sheet towards the surface thereby sandwiching the PSA between said
surface and the first side of the primary sheet resulting in
transfer of substantially all of the PSA to said surface.
2. The repair device of claim 1 wherein the PSA is applied to the
first side of the primary sheet in a swirl pattern.
3. The repair device of claim 1 wherein the PSA is applied to the
first side of the primary sheet in a dotted pattern.
4. The repair device of claim 1 wherein the second side is also
coated with silicone and the sheet is provided in roll form.
5. A method for re-adhering wallpaper that has become separated
from a wall surface, the method comprising: providing a repair
device comprising a sheet of release paper having a first side
first coated with silicone and subsequently coated intermittently
with PSA that has been cured thereon, the sheet also having a
second side, pressing the first side of the sheet against a back
side of the wallpaper that has become separated from the wall by
applying sandwiching pressure to the second side of the sheet and
the front side of the wallpaper thereby sandwiching the PSA between
the first side of the sheet and the back side of the wallpaper,
removing the sheet from the wallpaper thereby leaving the PSA
behind on the back side of the wallpaper, pressing the separated
wall paper back in place onto the wall surface.
6. The method of claim 5 wherein the PSA is applied to the first
side of the primary sheet in a swirl pattern.
7. The method of claim 5 wherein the PSA is applied to the first
side of the primary sheet in a dotted pattern.
8. A method for installing a door hinge on a door frame, the method
comprising: providing a repair device comprising a sheet of release
paper having a first side first coated with silicone and
subsequently coated intermittently with PSA that has been cured
thereon, the sheet also having a second side, pressing the first
side of the sheet against a surface of a door hinge by applying
pressure to the second side of the sheet thereby sandwiching the
PSA between the first side of the sheet and the surface of the door
hinge, removing the primary sheet from the surface of the door
hinge thereby leaving the PSA behind on the surface of the door
hinge, pressing the door hinge onto the surface of the door frame
with the PSA sandwiched therebetween, permanently attaching the
door hinge to the door frame.
9. The method of claim 8 wherein the PSA is applied to the first
side of the primary sheet in a swirl pattern.
10. The method of claim 8 wherein the PSA is applied to the first
side of the primary sheet in a dotted pattern.
11. A method for installing repair patch onto a wall area in need
of repair, the method comprising: providing a repair device
comprising a sheet of release paper having a first side first
coated with silicone and subsequently coated intermittently with
PSA that has been cured thereon, the sheet also having a second
side, pressing the first side of the sheet against a surface of a
repair patch by applying pressure to the second side of the sheet
thereby sandwiching the PSA between the first side of the sheet and
the surface of the repair patch, removing the sheet from the repair
patch thereby leaving the PSA behind on the surface of the repair
patch, pressing the repair patch onto the area of the wall in need
of repair where the PSA is disposed, permanently attaching repair
patch over the area of the wall in need of repair.
12. The method of claim 10 wherein wherein the PSA is applied to
the first side of the sheet in a swirl pattern.
13. The method of claim 10 wherein the PSA is applied to the first
side of the sheet in a dotted pattern.
14. A method of manufacturing a repair device comprising: providing
a piece of release paper having a first side coated with silicone;
intermittently coating pressure sensitive adhesive (PSA) on said
first side of said release paper; curing the PSA.
15. The method of claim 14 wherein wherein the PSA is applied to
the first side of the sheet in a swirl pattern.
16. The method of claim 14 wherein the PSA is applied to the first
side of the sheet in a dotted pattern.
Description
TECHNICAL FIELD
[0001] An improved system for applying pressure sensitive adhesive
to a surface or substrate as disclosed. More specifically, pressure
sensitive adhesive is applied intermittently, such as in a swirl
pattern, dot pattern, checkerboard pattern, etc. is deposited on a
first side of a release paper or release sheet. The pressure
sensitive adhesive is then allowed to cure. The adhesive is applied
to a surface such as the back side of a detached piece of wallpaper
or the surface of an item such as a piece of hardware that needs to
be installed by simply pressing the release paper against the
surface with the cured pressure sensitive adhesive sandwiched
therebetween which will then result in a pressure sensitive
adhesive being transferred from the release paper to the back side
of the detached wallpaper or the hardware item. A cover sheet of
release paper may also be used and applied over the cured pressure
sensitive adhesive and first side of the primary release paper or
sheet. The pressure sensitive adhesive may be of the permanent or
temporary types.
DESCRIPTION OF THE RELATED ART
[0002] One of the problems facing consumers who have installed
wallpaper in their homes, offices or other buildings is the
tendency of some portions of the wallpaper to become delaminated
from the wall or surface to which it was originally adhered.
Wallpaper glue can crack and become brittle with age and the
lamination between the wallpaper and the wall can be lost. As a
result, portions of the wallpaper, particularly corners of a piece
of wallpaper can become separated from the wall or surface to which
it is intended to be adhered or laminated. Consumers are then
forced to use commercially available glue to re-adhere the
wallpaper in place. If too much glue is used, the glue can seep out
from beneath the wallpaper over other sections of the wallpaper
thereby making the repair job easily visible to even untrained
eyes. Liquid glue can also coat the user's hands and other
fixtures, such as plate covers for electrical outlets and light
switches thereby causing aggravation and frustration.
[0003] Thus, there is a need for an improved method and system for
permanently reattaching wallpaper that has become delaminated from
the wall surface.
[0004] Another problem faced by consumers during home repairs is
the need to temporarily install a device on a vertical surface
which will then be permanently attached using plaster, patching
compound or fasteners such as screws, nails or bolts. Specifically,
perforated metal repair patches are used to repair a piece of
broken drywall. Some of these patches are sold with a layer of
pressure sensitive adhesive on one side to secure the patch in
place during the application of patching compounds over the
perforated metal sheet.
[0005] However, in manufacturing these products, it is very
difficult to apply the coating of pressure sensitive adhesive.
Providing the metal mesh or perforated sheet with pressure
sensitive adhesive drives up the manufacturing costs and packaging
costs. Thus, if there was a way to quickly and easily temporarily
hold such a metal perforated repair patch in place on a vertical
surface while the user is preparing to install or apply patching
compound over the perforated sheet, manufacturers could sell the
sheets without the pressure sensitive adhesive and the associate
manufacturing difficulties. As a result, less expensive repair
patches could be provided.
[0006] Further, other home repairs require fixtures to be
temporarily suspended or held in place on a wall while permanent
fasteners are prepared and installed. One such example is during
the installation of hanging door hinges. Specifically, it would be
very convenient to provide a means for temporarily securing a door
hinge in place while the holes are drilled for the wood screws that
eventually are used to permanently attach the door hinge to the
frame and/or the edge of the door. Consumers must hold the hinge in
place, mark the hole pattern, remove the hinge and then drill the
holes. Currently, no such "temporary" attachment mechanism is
available other than quick-dry adhesives and glues which would
eliminate the holding, marking and removing steps. This solution is
not preferred due to the problems of using liquid adhesives which
can be messy and soil nearby surfaces if too much liquid adhesive
is applied and allowed to seep outward once the door hinge is
pressed into place. Liquid adhesives can also block or plug the
holes through which the screws or fasteners must pass to
permanently attach the hinge to the door frame.
[0007] Therefore, in addition to a need for an improved method of
preparing wallpaper, there is also a general need for a product
which can quickly and easily attach and fixture or mechanical
device to a vertical surface temporarily while the user is
preparing to permanently attach the fixture or device in place.
[0008] Also, it is often necessary to permanently attach a fixture
in place during remodeling or construction. On such example is a
nail guard which is used to protect pipes and electrical conduits
behind drywall or wall board. These fixtures need to be installed
permanently and it would be much easier to do so if there was a
convenient way to make them self-adhesive.
SUMMARY OF THE DISCLOSURE
[0009] In satisfaction of the aforenoted needs, an improved repair
device is disclosed. In an embodiment, a repair device comprises a
sheet, section, or roll of release paper having a first side and a
second side. On the first side, pressure sensitive adhesive (PSA)
is applied intermittently to the first side of the release paper.
The PSA is then allowed to cure. The PSA may be of the temporary or
permanent type.
[0010] The release paper may then be used as a repair device as
follows. For a section of wallpaper that has become delaminated
from a wall, the first side of the release paper may be applied
against the back side of the detached portion of the wallpaper.
Pressure may be applied to the second opposing side of the release
sheet which results in a transferal of the pressure sensitive
adhesive to the back side of the wallpaper. The wall paper then may
be reattached to the wall surface by simply pressing the wallpaper
against the wall surface with the transferred PSA sandwiched
therebetween.
[0011] Similarly, to temporarily or permanently hang a mechanical
device, repair mesh or other device to a vertical surface, the
first side of the release paper may be pressed against the back
side of the device that will engage the vertical surface and
pressure applied to the second opposing side of the release paper
results in transferal of the PSA to the device. Then, the repair
patch, door hinge or other device is pressed against the vertical
wall surface with PSA sandwiched therebetween to temporarily or
permanently attach the repair patch, door hinge or other device to
the vertical wall surface. One advantage of the disclosed repair
device is that the PSA will not plug or block the holes of the door
hinge, repair mesh or other fixture. Further, use of the disclosed
repair device can render a fixture such as a door hinge, nail guard
or other fixture "self-adhering" thereby eliminating the need for
liquid adhesive and its disadvantages as disclosed above.
[0012] In a refinement, the release paper is silicone coated on
both sides and rolled up so the side of the release paper without
cured adhesive thereon serves as a protective cover for the cured
PSA.
[0013] In another refinement, various methods of making home
repairs utilizing the above repair device are also disclosed. For
example, an improved method of repairing a detached section of
wallpaper is disclosed. An improved method of installing a door
hinge is also disclosed. Further, an improved method of utilizing a
perforated metal patch to repair a section of drywall or automobile
body is also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The disclosed embodiments and methods are described more or
less diagrammatically in the accompanying drawings wherein:
[0015] FIG. 1 is a front plan view of a sheet of release paper with
an intermittent coating of PSA thereon;
[0016] FIG. 1A is an end view of the release paper with
intermittent PSA coating thereon as shown in FIG. 1 but in a roll
form;
[0017] FIG. 2 is a front plan view of an alternative embodiment
whereas instead of the swirling pattern disposed in FIG. 1, the PSA
is applied in an intermittent stock pattern as shown;
[0018] FIGS. 3A-3D illustrate, schematically, a disclosed method
for repairing a detached piece of wallpaper in accordance with the
disclosed methods;
[0019] FIGS. 4A-4C illustrate, schematically, a disclosed method
for repairing a hole in a piece of drywall or other vertical
surface such as an automobile exterior panel; and
[0020] FIGS. 5A-5C illustrate an improved method for installing a
door hinge in accordance with the disclosed methods.
[0021] The drawings are not necessarily to scale and the
embodiments are only described as fragmentary views and
diagrammatic representations. It should be understood, that this
disclosure is not necessarily limited to the particular embodiments
illustrated herein.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
[0022] FIG. 1 is a plan view illustrating a repair device 10 that
includes a sheet 11 of release paper having a first side 12 which
is intermittently coated with PSA 13. The sheet 11 of release paper
also includes a second side 14 which is opposite the first side 12.
The release substrate or paper 11 typically includes a silicone
coating (not shown) applied to at least one surface 12. Other
coated films, such as polyesters and polypropylenes could also be
used to coat the release sheet 11. Further, other polyolefins could
be used that have inherent release characteristics.
[0023] The PSA is preferably an aqueous emulsion polymer
composition or an organic solution polymer composition having
pressure sensitive adhesives for (PSA) properties. Suitable PSA
polymer compositions that have an adhesive characteristic include
polyethylene terephthalate. Other suitable PSA compositions can
comprise a polymer or a copolymer of at least one ethylenically
unsaturated monomer, such as acrylic monomers.
[0024] Exemplary acrylic monomers include esters of acrylic acid
with an alkyl group having from 1 to 18 carbon atoms, including
methyl, ethyl, n-butyl, sec-butyl, the various isomeric pentyl,
hexyl, heptyl, and octyl (especially 2-ethylhexyl), lauryl, cetyl,
stearyl, and like groups; and alkyl esters of methacrylic acid with
an alkyl group having from 4 to about 18 carbon atoms, including
n-butyl, n-hexyl, 2-ethylhexyl, n-octyl, lauryl, cetyl, stearyl and
like groups. Polymers derived from styrene and butadiene or styrene
and isoprene are also suitable. The above polymer compositions may
also contain other modifying monomers such as acrylic and
methacrylic acid and their esters, vinyl acetate, ethylene,
acrylonitrile, and styrene. In addition, tackifying resins can
optionally be part of the compositions; for example, rosin and
rosin derivatives such as rosin esters and hydrogenated rosin, tall
oil and derivatives, or hydrocarbon resins well known in the PSA
art. Wetting agents, defoamers, and possibly thickeners can also be
added to the PSA polymer compositions to render them suitable for
the coating process.
[0025] Pressure-sensitive adhesives can be formulated to fit
specific performance requirements, including sufficient shear, peel
adhesion, and tack or quickstick, at various temperatures and on a
variety of substrates. Depending on the choice of facestock to
which they are laminated, and the substrates to which they are
applied, PSAs may be classified as more or less "permanent" or
"temporary." When a permanent PSA tape or label is adhered to a
substrate, the adhesive bond to the substrate grows over time, and
the backing material cannot be removed without damaging the backing
and/or the substrate, or without leaving an adhesive residue on the
substrate. In contrast, temporary PSAs can be removed from a
substrate by application of a relatively small peel force, even
after an extended period of time, because adhesion to the substrate
remains constant, or grows only slightly over time.
[0026] A liquid or wet PSA polymer composition is applied to the
surface 12 of the release paper 11 in an intermittent fashion, such
as the swirling pattern shown at 13 in FIG. 1. Equipment used for
such as swirled pattern as shown in FIG. 1 is known in the art and
simply includes a nozzle connected to a PSA polymer composition
reservoir under pressure.
[0027] After deposition of the PSA on the first side 12 of the
release substrate or paper 11, the PSA coating 13 is allowed to dry
or cure. Drying can be performed by passing the paper 12 through a
dryer or oven that is suitable temperature and airflow to reduce
the moisture level below 5% by weight to achieve a cured state.
[0028] The thickness of the cured PSA material can vary widely and
range from about 1 to 2 mils to about 10 mils. The cured PSA
material 13, after coating on the first side 12 of the release
substrate 11, can then be laminated onto a vertical wall surface by
simply pressing the first side 12 of the release paper 11 to the
vertical wall surface and effectively transferring the PSA 13 to
the vertical wall surface by applying pressure to the back or
second side 14 of the release paper 11. Of course, the protective
release paper layer 15 has been removed in advance if such a
protective release paper layer 15 is provided after curing of PSA
13. Then, as shown in FIG. 1A, the sheet may be rolled up using the
second side 14 as a protective cover for the adhesive 13. In this
case, the second side 14 should be coated with silicone as
well.
[0029] An alternative embodiment of a repair device 10a is shown in
FIG. 2 wherein the first side 12a of the release sheet 11a is
coated with PSA material 13a in a dot pattern.
[0030] FIGS. 3A-3D illustrate a disclosed method for repairing a
piece of wallpaper 21 that has become detached from a vertical wall
surface 22. A piece of properly laminated wallpaper 23 is also
shown. As shown in FIG. 3B, the detached wallpaper 21 is pulled
upward or away from the vertical wall surface 22 under repair. A
release device 10 is shown as it is being moved into position with
the cured PSA 13 facing the back side 25 of the detached wallpaper
21. As shown in FIG. 3C, pressure is applied to the rear side 14 of
the release paper and the front side 26 of the wallpaper 21 thereby
causing transfer of the PSA 13 from the first side 12 to the back
side 25 of the wallpaper 21. The release paper of the device 10 has
been removed thereby leaving the PSA 13 against the wallpaper
surface 25 which is then ready to be pressed back into place
against the wall surface 22 as shown in FIG. 3D. Use of a permanent
PSA 13 renders the repair permanent.
[0031] In FIGS. 4A-4C, a vertical wall surface has been damaged by
causing a hole 31. As shown in FIG. 4B, the device 10 as discussed
above can be applied to a repair mesh 32 to leave an intermittent
coating of PSA 13 on one side of the repair mesh 32. Then, as shown
in FIG. 4C, the repair mesh 32 and may be temporarily (or
permanently) installed on the wall surface 30, thereby covering the
hole 31 and the mesh or sheet 32 will stay in place while the user
is applying spackling or repair compounds (not shown). The same
techniques may be used to permanently mount a nail guard in place
that is, a device 10 with permanent PSA 13 can be pressed against a
nail guard to render it self adhering and then the nail guard may
be pressed into place at the desired location.
[0032] Turning to FIGS. 5A-5B, a door jam 41 is shown with inner
and outer frame components 41, 42 and a jam 43 disposed
therebetween. A recess 44 is cut into the frame member 41 and ready
to receive a door hinge 45. As shown in FIG. 5B, to facilitate this
process, PSA 13 is applied to the surface 46 of the hinge 45
without blocking or plugging the screw holes (now shown in FIG. 5B)
using the repairs devices 10, 10a described above and then the
hinge 45 may be temporarily installed in the recess 44 as shown in
FIG. 5C. Then holes 47 may be drilled through the screw holes 48
with the hinge 45 in place as shown in FIG. 5C and screws (not
shown) are installed.
[0033] Although only certain embodiments have been shown and
described, alternative embodiments will be apparent to those
skilled in the art. These and other alternatives are considered
equivalents and within the spirit and scope of this disclosure,
which is intended to be limited only by the appended claims.
* * * * *