Method and system to provide a repositionable translucent cast vinyl film with an air-egress adhesive layer
Disclosed are a method, a device and/or a system of cast vinyl film and, more particularly, to a method and system to provide a repositionable translucent cast vinyl film with an air egress adhesive layer. In one aspect, a method includes mixing a solvent based polyvinyl chloride (PVC) organosol with a stabilizer and an additive to get a desired shade of pellucid tint of a translucent thermoplastic stretch wrap film. Further, the method includes casting the polyvinyl chloride (PVC) organosol onto a film carrier and moving the film carrier through a plurality of ovens at varying temperatures to care into a solid film. The cured solid film is laminated to an air-egress liner casted with a solvent-borne acrylic pressure-sensitive adhesive to provide ease of installation. The adhesive includes an air release patterning to allow escape of air from back of the film while repositioning the film around a complex shaped surface.
1 . A vinyl film for applying to a complex-shaped surface comprising:
(a) a polyvinyl chloride (PVC) portion including a PVC organosol layer formed by casting, using a casting process, a liquid organosol mixture on a film carrier, and wherein the film carrier is removable from the PVC organosol layer after casting; and
(b) an adhesive portion including an adhesive that is pressure-sensitive with air-egress channels that is on a removable liner;
(c) wherein the adhesive is directly coupled to the PVC organosol layer;
(d) wherein the vinyl film is adapted to be applied to a complex-shaped surface after removal of the removable liner by pressing the adhesive onto the complex-shaped surface and applying heat to the adhesive;
(e) wherein the casting process of the PVC organosol layer onto the film carrier enables three-dimensional stretchability to 130 percent and enables durability of the vinyl film and reduces shrinking back of the vinyl film when installed on the complex-shaped surface;
(f) wherein the casting process provides increased three-dimensional stretchability and durability of the vinyl film enabling stretching and repositioning of the vinyl film during installation of the vinyl film onto the complex-shaped surface; and
(g) wherein the pressure sensitive adhesive is semi-permanent and is adapted to enable long-term removal of the vinyl film from the complex-shaped surface.
2 . The vinyl film of claim 1 , wherein:
(i) the adhesive is a solvent-borne acrylic pressure-sensitive viscous material and the air-egress channels allow escape of air from a back of the vinyl film when installing onto the complex-shaped surface;
(ii) the vinyl film is repositionable by liquifying the adhesive with application of heat to allow appropriate stretchability for re-installation of the vinyl film; and
(iii) the adhesive is a semi-permanent adhesive adapted to allow for removability leaving 30% or less adhesive residue.
3 . The vinyl film of claim 2 , wherein the air-egress channels are interconnected.
4 . The vinyl film of claim 2 wherein the vinyl film is tinted and translucent.
5 . A vinyl film that is adapted for applying to a complex-shaped surface, comprising:
(a) a pre-application configuration, that is present prior to application of the vinyl film onto the complex-shaped surface, that includes layers of:
(i) a Poly Vinyl Chloride (PVC) organosol layer, which is a top layer, formed by casting, using a casting process, including a PVC organosol mixture on a carrier and curing the PVC organosol mixture while on the carrier to solidify the PVC organosol layer;
(ii) an adhesive that is pressure sensitive and includes air egress channels;
(iii) a removable liner; and
(b) a post application configuration after removal of the removable liner and application of the vinyl film onto the complex-shaped surface including directly adjacent layers of:
(i) the PVC organosol layer; and
(ii) the adhesive, wherein at least a substantial portion of the air egress channels of the adhesive becomes less visible after stretching of the film and application onto the complex-shaped surface;
wherein the casting process causes increased stretchability and durability of the vinyl film enabling stretchability and repositioning during installation of the vinyl film onto the complex-shaped surface; and
wherein the adhesive is adapted to enable removability of the vinyl film from the complex-shaped surface leaving minimal residue.
6 . The vinyl film of claim 5 , wherein the PVC organosol layer includes vinyl resin, a plasticizer, and a pigment.
7 . The vinyl film of claim 5 , wherein the PVC organosol layer includes vinyl resin, a plasticizer, a pigment and an active solvent.
8 . The vinyl film of claim 5 wherein the PVC organosol layer includes a vinyl resin, a plasticizer, an epoxidised plasticizer, pigment, a stabilizer and one or more desired fillers.
9 . The vinyl film of claim 5 wherein the adhesive is clear.
10 . The vinyl film of claim 5 wherein at least a substantial portion of the air-egress channels become invisible after application when stretched at least 10 percent during application.
11 . A tinted translucent vinyl film with a clear air-egress adhesive layer comprising:
a top layer of a cast Poly Vinyl Chloride (PVC) vinyl formed by casting a liquid organosol mixture blended with a plasticizer and a diluent, wherein the liquid organosol mixture includes a dispersed polyvinyl chloride resin mixed with a plasticizer and a diluent; and
a base layer of an acrylic pressure-sensitive adhesive with air-egress channels on a removable paper liner, the base layer formed using viscoelastic material to adhere to the top layer of the cast PVC vinyl upon application of light contact pressure and to allow repositioning of the tinted translucent vinyl film around a complex, bulbous shaped surface of an automotive light and a chrome;
wherein a casting process used to form the top layer causes an increased stretchability and/or durability of the vinyl film and reduces shrinking back of the vinyl film when installed on the complex, bulbous shaped surface; and
wherein the pressure sensitive adhesive is semi-permanent and is adapted to enable long-term removal of the vinyl film from the complex, bulbous shaped surface.
12 . A tinted translucent vinyl film with an air-egress adhesive layer comprising:
a top layer of a cast Poly Vinyl Chloride (PVC) vinyl formed by casting a liquid organosol mixture blended with a plasticizer and a diluent, wherein the liquid organosol mixture includes a dispersed polyvinyl chloride resin mixed with the plasticizer and the diluent; and
a base layer of a pressure-sensitive adhesive with air-egress channels on a removable liner, the base layer formed using viscoelastic material that adheres to the top layer of the cast PVC vinyl upon application of light contact pressure;
wherein the base layer can be applied to a complex shaped surface using heat application; and
wherein the base layer enables application of and repositioning of the tinted translucent vinyl film around said surface.
13 . A vinyl film comprising:
a) a top vinyl layer adapted to be softened and stretchable with heat application;
b) an adhesive layer that is pressure sensitive and includes air egress channels; the adhesive layer adapted to at least partially liquefy with heat application;
c) wherein the adhesive layer is directly adhered to the top vinyl layer;
d) wherein the adhesive layer, while coupled to the top vinyl layer, is adapted to be applied to a complex-shaped surface;
e) wherein application of heat during installation of the top vinyl layer and adhesive layer on the complex-shaped surface enables stretching, lifting up, and/or repositioning as needed during installation;
f) wherein the adhesive layer is semi-permanent enabling clean, long-term removability from the complex-shaped surface with an ability to leave no to minimal residue after use for a plurality of years; and
g) wherein there is no to minimal shrinking back of the top vinyl layer coupled to the adhesive layer after installation onto the complex-shaped surface.
14 . A vinyl film comprising:
a) a top vinyl layer adapted to be softened and stretchable with heat application;
b) an adhesive layer that is pressure sensitive and includes air egress channels; the adhesive layer adapted to at least partially liquefy with heat application;
c) wherein the adhesive layer is directly adhered to the top vinyl layer;
d) wherein the adhesive layer, while coupled to the top vinyl layer is adapted to be applied to a complex-shaped surface; and
e) wherein application of heat during installation of the top vinyl layer and adhesive layer on the complex-shaped surface enables stretching, lifting up, and/or repositioning as needed during installation; and
f) wherein there is no to minimal shrinking back of the top vinyl layer coupled to the adhesive layer after installation onto the complex-shaped surface.
15 . The vinyl film of claim 14 wherein the adhesive layer is clear.
16 . The vinyl film of claim 14 wherein at least a substantial portion of the air egress channels become invisible after application.
17 . A method of manufacturing a vinyl wrap that is stretchable and repositionable and that is for adhering to a complex-shaped surface, the method comprising the steps of:
a) mixing a liquid organosol with a polyvinyl chloride (PVC) resin to form a PVC organosol mixture;
b) casting, using a casting process, the PVC organosol mixture onto a film carrier;
c) moving the film carrier after step (b) through an oven to cure the PVC organosol mixture and form a cast vinyl film; and
d) laminating the cast vinyl film to an adhesive that is pressure sensitive and semi-permanent and that is cast on a liner; wherein the cast vinyl film is the top layer;
wherein the film carrier and the liner are removable from the cast vinyl film and the adhesive prior to application of the vinyl wrap on the complex-shaped surface;
wherein the casting process of step (b) causes an increased three-dimensional stretchability and durability of the cast vinyl film;
wherein the adhesive allows repositioning of the cast vinyl film while installing onto the complex-shaped surface wherein the adhesive can be lifted up and re-applied to the complex-shaped surface; and
wherein the adhesive is semi-permanent enabling removability from the complex-shaped surface.
18 . The method of claim 17 wherein the organosol mixture includes a plasticizer, a diluent and a pigment.
19 . The method of claim 17 wherein the casting process of step (b) is a reverse roll coating process that enables up to 130% stretchability of the vinyl wrap during installation of the vinyl wrap.
20 . The method of claim 19 wherein the reverse roll coating process enables the cast vinyl film to be installed on the complex-shaped surface with no to minimal shrinking back of the cast vinyl film.
21 . The method of claim 17 wherein the adhesive is adapted to remain removable from the complex-shaped surface after installation for at least 3 years using heat and/or chemicals.
22 . The method of claim 17 wherein the adhesive includes an air release patterning with air egress channels that allow air to escape when installing the cast vinyl film onto the complex-shaped surface eliminating or lessening the presence of air bubbles during installation.
23 . The method of claim 17 wherein the adhesive is adapted to enable clean removability allowing the vinyl wrap to be removed leaving less than 30% of adhesive residue on the complex-shaped surface.