ADHESIVE FILM FOR TINTING AUTOMOTIVE LENSES AND METHOD
20190376658 ยท 2019-12-12
Inventors
Cpc classification
F21S43/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C09J2301/20
CHEMISTRY; METALLURGY
C09J7/403
CHEMISTRY; METALLURGY
International classification
F21S41/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A tint wrap for an automotive lens comprises a tint film defining an inner face comprising a dry applied adhesive overlaying a back liner defining an embossed pattern formation of peaks and valleys. This formation forms in the adhesive contiguous air channels with flat areas interposed therebetween. The air channels are connected at intersections about the flat areas and respectively define a top wall, a bottom opening and spaced apart lateral walls therebetween. The height of the channel is defined between the top wall and the bottom opening and the width between the lateral walls. The air channel width is greater than the air channel height anywhere along the air channel height. When the tint film is removed from the back liner and is mounted to the automotive lens for wrapping thereof, the air channels provide for air between the tint film and the automotive lens to be released via the peripheral edges and wherein the air channels collapse for providing the top wall of the air channels to engage the automotive lens.
Claims
1. A tint wrap for an automotive lens comprising: a tint film for wrapping the automotive lens for tinting thereof, the tint film defining opposite outer and inner faces and being bounded by peripheral edges defining a surface area therebetween, the inner surface comprising a dry applied adhesive material for being adhesively mounted to the automotive lens; and a back liner supporting the tint film thereon, the back liner comprising an outer rear surface and an opposite inner support surface defining an embossed pattern formation thereon of peaks and valleys, the tint film overlaying the back liner with the inner face of the film engaging the support surface, the formation forming a corresponding pattern formation in the adhesive extending the surface area of the film between the peripheral edges and defining contiguous air channels with flat areas interposed therebetween, the air channels being connected at intersections about the flat areas, each air channel defining a top wall, a bottom opening defining a plane thereof and spaced apart lateral walls therebetween, the top wall and the bottom opening defining an air channel height therebetween, the spaced apart lateral walls defining an air channel width therebetween, wherein the air channel width is greater than the air channel height anywhere along the air channel height, wherein when the tint film being removed from the back liner and being mounted to the automotive lens for wrapping thereof, the air channels provide for air between the tint film and the automotive lens to be released via the peripheral edges and wherein the air channels collapse for providing the top wall of the air channels to engage the automotive lens.
2. A tint wrap according to claim 1, wherein the width to height ratio of the air channels is from about 10:1 to about 20:1.
3. A tint wrap according to claim 1, wherein the width to height ratio of the air channels is about 16:1.
4. A tint wrap according to claim 1, wherein the top wall comprises a generally domed configuration.
5. A tint wrap according to claim 1, wherein the top wall comprises a generally flat configuration.
6. A tint wrap according to claim 1, wherein the lateral walls are inwardly inclined from the bottom opening to the top wall.
7. A tint wrap according to claim 1, wherein the flat areas define respective widths separating a pair of the air channels.
8. A tint wrap according the claim 7, wherein the respective widths of the flat areas are about 1 mm in length.
9. A tint wrap according to claim 7, wherein the width to width ratio of the flat areas to the air channels is about 6:1 to about 13:1.
10. A tint wrap according to claim 9, wherein the width to width ratio of the flat areas to the air channels is about 10:1.
11. A tint wrap according to claim 1, wherein the intersections between a pair of laterally opposed peripheral edges are non-colinearly disposed along a contiguous pathway.
12. A tint wrap according to claim 11, wherein the contiguous pathway comprises a zig-zagging configuration.
13. A tint wrap according to claim 1, wherein the corresponding pattern in the adhesive comprises an orange peel texture.
14. A tint wrap according to claim 1, wherein the tint film has a thickness of about 3 mils.
15. A tint wrap according to claim 1, wherein the adhesive comprises acrylate.
16. A tint film for wrapping the automotive lens for tinting thereof, the tint film defining opposite outer and inner faces and being bounded by peripheral edges defining a surface area therebetween, the inner surface comprising dry applied adhesive for being adhesively mounted to the automotive lens; a pattern formed in the adhesive extending the surface area of the film between the peripheral edges and defining contiguous air channels with flat areas interposed therebetween, the air channels being connected at intersections about the flat areas, each air channel defining a top wall, a bottom opening defining a plane thereof and spaced apart lateral walls therebetween, the top wall and the bottom opening defining an air channel height therebetween, the spaced apart lateral walls defining an air channel width therebetween, wherein the air channel width is greater than the air channel height anywhere along the air channel height, wherein when the tint film being mounted to the automotive lens for wrapping thereof, the air channels provide for air between the tint film and the automotive lens to be released via the peripheral edges and wherein the air channels collapse for providing the top wall of the air channels to engage the automotive lens.
17. (canceled)
18. A method of tinting an automotive lens, the method comprising: providing a tint film for wrapping the automotive lens for tinting thereof, the tint film defining opposite outer and inner faces and being bounded by peripheral edges defining a surface area therebetween, coating the inner surface of the tint film with a dry adhesive for being adhesively mounted to the automotive lens with the film; and forming a pattern formation in the adhesive extending the surface area of the film between the peripheral edges and defining contiguous air channels with flat areas interposed therebetween, the air channels being connected at intersections about the flat areas, each air channel defining a top wall, a bottom opening defining a plane thereof and spaced apart lateral walls therebetween, the top wall and the bottom opening defining an air channel height therebetween, the spaced apart lateral walls defining an air channel width therebetween, wherein the air channel width is greater than the air channel height anywhere along the air channel height; and mounting the tint film with the adhesive to the automotive lens for wrapping thereof, wherein the air channels provide for air between the tint film and the automotive lens to be released via the peripheral edges and wherein the air channels collapse for providing the top wall of the air channels to engage the automotive lens.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] In the appended drawings:
[0032]
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DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0050] Generally stated and in accordance with an aspect of the present disclosure, there is provided a tint wrap for an automotive lens comprising a tint film for wrapping the automotive lens for tinting thereof. The tint film defines opposite outer and inner faces and is bounded by peripheral edges defining a surface area therebetween. The inner surface comprises a dry applied adhesive for being adhesively mounted to the automotive lens. A back liner supports the tint film thereon. The back liner comprises an outer rear surface and an opposite inner support surface defining an embossed pattern formation thereon of peaks and valleys. The tint film overlays the back liner with the inner face of the film engages the support surface. The formation forms a corresponding pattern formation in the adhesive extending the surface area of the film between the peripheral edges and defines contiguous air channels with flat areas interposed therebetween. The air channels are connected at intersections about the flat areas. Each air channel defines a top wall, a bottom opening defining a plane thereof and spaced apart lateral walls therebetween. The top wall and the bottom opening define an air channel height therebetween. The spaced apart lateral walls define an air channel width therebetween. The air channel width is greater than the air channel height anywhere along the air channel height. When the tint film is removed from the back liner and is mounted to the automotive lens for wrapping thereof, the air channels provide for air between the tint film and the automotive lens to be released via the peripheral edges and wherein the air channels collapse for providing the top wall of the air channels to engage the automotive lens.
[0051] Turning now to
[0052]
[0053]
[0054] The back liner 106 defines the outer rear surface 108 and an opposite support surface 112 for receiving the adhesive layer 110 thereon. The support surface defines a pattern formation for imprinting a complementary pattern within the adhesive 110. The back liner 106 comprises a paper liner 114 coated on one face 116 thereof with a layer 118 in the form of silicone or another suitable substance defining the surface 112. The paper liner 114 is coated on its opposite face 120 with a layer 122 in the form of silicone or another suitable substance defining the outer surface 108. The pattern forming surface 112 is embossed in order to define peaks 124 and valleys 126.
[0055] When tint wrapping a surface 130 such as an automotive lens surface (headlights or taillights), the combination of the tint film 102 with the adhesive is removed from the back liner 106 and the adhesive has a pattern 132 (see
[0056] With reference to
[0057] With reference to
[0058] With reference to
[0059] With respect to
[0060] As previously mentioned, the air channels 140 are spaced about 1 mm apart (which is the usual width of the flat area 148 defined between adjacent air channels 140), whereas in the prior art the air release or air egress channels are on average spaced about every mm making air channels 4-5 times more concentrated on the prior art film.
[0061] There are a variety of issues relating to using air egress or air channels on headlights or taillights. The design/configuration of the air channels may greatly affect the transmission of light. By spacing the air channels 140 further apart all this allows more room for the flat areas 148 thereby providing more transmission of light in comparing to air egress patters with very small geometrical patterns that are highly concentrated resulting in less transmission of light.
[0062] Turning now to
[0063] With particular reference to
[0064] The foregoing solves the problem of tint films with air channels that do not collapse. With the heat projected from the headlight, air trapped in the film expands further creating even more distortion and failure in the film.
[0065]
[0066]
[0067]
[0068] The air channels 140 are contiguous but meet at intersections 150 that are not colinear from along the length and width of the tint film in comparison to prior art films. The adhesive 110 provides for a plurality of openings 160 (see
[0069] Thus, the air channels 140 provide an air-release between the film 102 and the lens 130 with the air escaping via the openings at the peripheral edges 128. Moreover, the air channels 140 provide for the tint film 102 to be repositionable, easier to smooth out on the lens surface 130 and avoid the air bubbles 170 of standard tinting films 172 (see
[0070] As such, the tinting film 102 is repositionable on the lens 130 and can be applied without liquid solution. Liquid based tints (wet application) are difficult to install, they require training and need to be applied on flat and slightly curved surfaces. The film 102 can thus be applied on highly curved, jagged and otherwise too difficult to wrap surfaces. Indeed, headlights and taillights are being manufactured with more intricate designs and shapes that provide challenges for standard tint films 170. Since the film 102 is repositionable it is much easier to handle.
[0071] Transparent tints on headlights are usually wet applied. Wet application basically refers to using lubricants to allow the film not to stick for repositionability purposes. Wet application is extremely difficult if not impossible on certain shapes that we commonly see in the automotive industry In the prior art, wet applying film provided optimal clarity for visual light transmission. It is a method commonly used as air pockets and distortion caused by air channels reduce visibility greatly.
[0072] In the present tint wrap 100, the air release or air egress channels 140 and collapsing channel walls 144A and 144B greatly improve visibility compared to standard methods. The present tint wrap 100 uses dry application and as such ensures the adhesive 110 is working at its full potential which is necessary when stretching and curving to complex shapes such as a headlight installation on complex surfaces. The low distortion achieved by the pattern 132 of adhesive 110 during repositionability allows easier and more reliable installation of product on complex surfaces 130. Conventionally, other adhesives and materials get marred or blurred when being applied and repositioned.
[0073] On average, a trained installer would take approximately 75 minutes to install two front headlights and require a dry period of 6 to 12 hours to seal edges with wet application. In an embodiment, the present tinting film 102 takes on average take 20-30 minutes to install without a drying or sealing period. As such, the film 102 provides for air-release which allows the film 102 to be dry applied thereby drastically reducing installation time.
[0074] Conventionally, softer, high-tack solvent-based adhesives are used on wet-apply films which makes the adhesive non-repositionable thus the reason a liquid solution is used in order to allow some movement and reduce bond on surface. If the material is lifted and repositioned, the wet apply film may be irreversibly damaged. In contrast, the film 102 is repositionable and can be lifted and reapplied with negligible damage thereto and to the adhesive.
[0075] In an embodiment, the material of the film 102 comprises transparent or translucent polymeric PVC for tinting automotive lenses (e.g. Cast PVC, Polymeric PVC and Calendered PVC). In an embodiment, the film material has a thickness of about 3 mils to 10 mils. In an embodiment, the film 102 is from about 3 mils to about 7 mils thick depending on color and finish. In embodiment, the thickness of the film 102 can be about 3 mils. In an embodiment, the material thickness is dependent on its type and color. The film material comes in different shades and colors. Of course, the material is not opaque as it is meant to diffuse light. In an embodiment, the material offers some protection against the elements. Moreover, the material is thermoformed to curved surfaces.
[0076] In an embodiment, the film 102 comprises a material that is thicker than standard films 10 or 172. A thicker material provides greater resiliency to heat expelling from the light source in headlight/taillight. This thickness also makes air channels 140 less visible giving a higher gloss finish which in turn also improves visual light transmission from the light and of course greater light transmission translates into improved safety. A thicker material on the automotive lenses also acts as a protective barrier from the elements. The thickness of the film 102, the less distortion created from air channels 140 in addition to the air channels 140 causing a more subtle lift 154 in the film outer surface 104 as well as collapsing over time due to their configuration in conjunction to the thickness of the film 102. The thickness of the film 102 also adds thermal protection as the material can take more heat from the lights. The thicker film 102 creates a more resistant barrier from elements.
[0077] A variety of suitable adhesive materials can be used. In an embodiment, the adhesive material is a pressure sensitive adhesive that is non-permanent, peelable or removable and repositionable. In a non-limiting example, the adhesive comprises acrylate or is acrylic based. Rubbers offer good shear strength, flexibility and adhesion, work well in long- and short-term applications, and are low cost. They are also prone to yellowing, do not do well with high temperatures, and require additives to sustain tack and adhesion. Acrylates offer UV-, solvent- and hydrolosis-resistance, as well as shear strength and an ability to function at temperatures between 45 and 121 degrees Celsius (C). They tend to be more expensive, and some have low creep resistance. Silicones can function within a wider temperature range, between 73 and 260 degrees C., and feature high chemical and solvent resistance. They are more expensive than acrylates.
[0078] In an embodiment, the adhesive 110 comprises: a solvent-based acrylate pressure sensitive adhesive (transparent); with the following characteristic: viscosity (centipoise) 5,500; a solid content (%) 43.0; solvent system (%); Ethyl acetate 36; Heptane 35; Isopropanol 18, Ethanol 11.
[0079] A stiffer adhesive for increased visibility and repositionability and decreases deformities by coating film with 45% less adhesive in thickness. By thinning the adhesive and lengthening curing dwell times during the coating process, adhesive that has less initial tack and a stiffer construction is achieved. As an effect of thinning the adhesive, the air channels 140 cannot penetrate as deeply through the adhesive which gives the channel 140 better chances of completely sealing itself. The adhesive 110 has a higher than average solid content and a high-range viscosity which helps in this process as well.
[0080] In an embodiment, the backing 106 comprises backing paper 114 made of silicone embossed release line. The silicone 118 embossing creates the air-channels 140 in the adhesive 110 which allows for trapped air to escape beneath the film 102. The results are a paint-like, bubble free finish (see
[0081] The backing paper 104 is also plasticized or coated (122) on its exterior side 108 to create a water and humidity-proof barrier. Uncoated backing paper can expand or shrink when absorbing humidity or drying out, this creates an uneven finish on the paper, translating to the adhesive and ultimately the surface of the film as it takes the form of the adhesive texture. This is also a safety feature as less texture on the surface lessens light diffusion and improves light transmission and focus.
[0082] The various features described herein can be combined in a variety of ways within the context of the present disclosure so as to provide still other embodiments. As such, the embodiments are not mutually exclusive. Moreover, the embodiments discussed herein need not include all of the features and elements illustrated and/or described and thus partial combinations of features can also be contemplated. Furthermore, embodiments with less features than those described can also be contemplated. It is to be understood that the present disclosure is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The disclosure is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation. Hence, although the present disclosure has been provided hereinabove by way of non-restrictive illustrative embodiments thereof, it can be modified, without departing from the scope, spirit and nature thereof and of the appended claims.