Adhesive laminates and method for making adhesive laminates

Patent metadata

Field	Value
Publication number	US-11479693-B2
Application number	US-201917052612-A
Country	US
Kind code	B2
Filing date	May 3, 2019
Priority date	May 3, 2018
Publication date	Oct 25, 2022
Grant date	Oct 25, 2022

Abstract

A variety of adhesive laminates are described, many of which perform functions such as liquid indication, outgassing, liquid retention, electrical conducting, and sound channeling. Also described are adhesive regions on face materials in which the regions exhibit particular dimensional proportions. Methods involving direct and transfer coating of adhesives are also described. In a particular version, a method of roll to roll transfer coating of sprayed pressure sensitive adhesives is described. Also described are various adhesive films and laminates many of which can be produced using the methods.

First claim

What is claimed is:

1. An adhesive coated face material comprising:
a face material defining a first face and an oppositely directed second face;
a patterned adhesive disposed on the first face of the face material;
wherein a critical dimensional ratio (CDR) of the patterned adhesive disposed on the face material is less than 50,
wherein the CDR is defined in formula (I):

Adhesive

Feature

Width

Adhesive

Feature

Height

,

(
I
)

wherein “Adhesive Feature Width (AF W )” is the average width distance of an adhesive region disposed on a face material and measured in a cross direction relative to the direction of processing of the face material and “Adhesive Feature Height (AF H )” is the average thickness of the same adhesive region disposed on a face material and measured in a direction transverse to the plane of the face material,
wherein the adhesive pattern is irregular and/or random, and
wherein the adhesive pattern is discontinuous.

2. The adhesive coated face material of claim 1 wherein the critical dimensional ratio is less than 40.

3. The adhesive coated face material of claim 2 wherein the critical dimensional ratio is less than 30.

4. The adhesive coated face material of claim 1 wherein the coverage of adhesive on the face material is less than about 100% to about 5%.

5. The adhesive coated face material of claim 1 wherein the coverage of adhesive on the face material is less than about 75%.

6. The adhesive coated face material of claim 5 wherein the coverage of adhesive on the face material is from about 35% to about 70%.

7. The adhesive coated face material of claim 6 wherein the coverage of adhesive on the face material is from about 40% to about 65%.

8. The adhesive coated face material of claim 1 wherein the thickness of the adhesive on the face material is within a range of from 0.1 μm to 10,000 μm.

9. The adhesive coated face material of claim 8 wherein the adhesive is a pressure sensitive adhesive.

10. The adhesive coated face material of claim 1 further comprising a release liner at least partially contacting the adhesive.

11. The adhesive coated face material of claim 10 wherein the release liner defines a release face and the release liner includes a release agent on the release face.

12. The adhesive of claim 1 wherein the face material visually indicates presence of a liquid contacting the patterned adhesive.

13. The adhesive of claim 1 wherein the face material enables passage of a gas through the patterned adhesive and through the face material.

14. The adhesive of claim 1 wherein the face material absorbs liquid from a surface, through the patterned adhesive.

15. The adhesive of claim 1 wherein the face material conducts electricity through a thickness of the face material.

16. The adhesive of claim 1 wherein the face material conducts sound through a thickness of the face material.

17. The adhesive of claim 1 , wherein adhesive is in the form of fibers.

18. The adhesive coated face material of claim 1 wherein the pattern is irregular and random.

19. The adhesive coated face material of claim 1 wherein the pattern is random.

20. The adhesive coated face material of claim 1 wherein the pattern is irregular.

21. The adhesive coated face material of claim 1 wherein the pattern is formable by spraying the adhesive onto the first face of the face material.

22. The adhesive coated face material of claim 21 wherein the spraying is a spraying technique selected from the group consisting of ink jetting, electrospinning, airless spraying, air guided nozzle spraying, and combinations thereof.

23. A laminate comprising:
the adhesive coated face materials of claim 1 and one or more additional films or layers.

24. The laminate of claim 23 wherein the one or more additional layers comprise at least one of a layer or region of a functional agent that is sensitive to liquid passing through the laminate, the patterned adhesive and the at least one layer or region of the functional agent.

25. The laminate of claim 23 wherein the functional agent undergoes a visibly perceptible change upon exposure to liquid.

26. The laminate of claim 23 wherein the functional agent is transported by liquid flowing through the laminate.

27. The laminate of claim 23 wherein the laminate enables passage of a gas through the patterned adhesive and through the functional facestock.

28. The laminate of claim 23 wherein the laminate absorbs liquid from a surface, through the patterned adhesive.

29. The laminate of claim 23 wherein the laminate conducts electricity through a thickness of the laminate.

30. The laminate of claim 23 wherein the laminate conducts sound through a thickness of the laminate.

31. The laminate of claim 23 further comprising a carrier layer, wherein the at least one layer or region of the functional agent is disposed between the patterned adhesive and the carrier layer.

32. A process for forming an adhesive laminate, the process comprising:
providing a release liner defining a release face and an oppositely directed outer face;
applying adhesive in a pattern to the release face of the release liner to form an adhesive containing release liner;
providing a face material defining an inner face and an oppositely directed outer face;
concurrently passing both the adhesive containing release liner and the face material through a nip region defined between rollers of a roller assembly,
such that at least a portion of the adhesive is contacted with the inner face of the face material, to thereby form an adhesive laminate,
wherein a critical dimensional ratio (CDR) of the patterned adhesive disposed on the face material is less than 50,
wherein the CDR is defined in formula (I):

Adhesive

Assignees

• Avery Dennison Corp

Inventors

• Bartholomew Eric L
• Dhopatkar Nishad
• Ghoussoub Yara
• Janko Pavel
• Klittich Mena R
• Kohler Christopher E
• Miller Brandon S
• O'Donnell Kerry L
• Whitman David W

Classifications

• C09J2301/302

  the adhesive being pressure-sensitive, i.e. tacky at temperatures inferior to 30°C · CPC title

• C09J2301/16

  by the structure of the carrier layer · CPC title

• C09J7/38 Primary

  Pressure-sensitive adhesives [PSA] · CPC title

• C09J7/29 Primary

  Laminated material (metallised plastics C09J7/22) · CPC title

• C09J2301/12

  by the arrangement of layers · CPC title