Adhesive-coated facestock and adhesive laminate, and method for production thereof

Abstract

The invention relates to an adhesive coated facestock, an adhesive laminate, a method for forming an adhesive laminate, and a method for forming an adhesive coated facestock. Various adhesive laminates are described, many of which perform functions such as liquid indication, degassing, liquid retention, electrical conduction, and sound channel. An adhesive region on the facestock is also described, wherein the region exhibits a specific dimensional proportion. Methods involving direct coating and transfer coating of the adhesive are also described. In a particular version, a roll-to-roll transfer coating method of sprayed pressure sensitive adhesive is described. Various adhesive films and laminates are also described, many of which can be produced using the method.

Description

[0001] This application is a divisional application of the patent application with application number 201980044813.1, application date May 3, 2019, and invention name “Adhesive laminate and method for manufacturing adhesive laminate”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 666,544, filed May 3, 2018, which is incorporated herein in its entirety. Technical Field

[0004] The present disclosure relates to the field of adhesives, and more particularly to adhesive-coated facestocks and adhesive laminates and methods of making and using the same. Background Art

[0005] Adhesive laminates are known in the art. These products are provided in a variety of forms, including, for example, tapes, sheets, and labels. While satisfactory in many respects, there remains a need for new types of laminates that provide one or more functions and can be produced in a cost-effective manner.

[0006] Various techniques for applying adhesives to face materials are well known. Methods of coating adhesives on secondary materials and then bonding them to the face material are also known. The adhesive layer can be continuous or discontinuous. Discontinuous adhesive layers typically include regular or uniform patterns or structures. Although such patterning can reduce the amount of adhesive used, regular or uniform patterns or structures can have limitations, such as uncoated / unglued edges of labels, resulting in poor dispensing, warping, poor print quality, and / or poor dye cutting. Although satisfactory in many respects, there is still a need for additional strategies for depositing adhesives on face materials in which specific properties and / or characteristics of the resulting structure can be maintained or improved. Summary of the invention

[0007] Described herein are adhesive-coated facestocks comprising a facestock defining a first side and an opposite second side. The term "facestock" includes one or more facestocks, one or more liners, and combinations thereof. The terms "facestock" and "liner" may also be used to refer to a specific facestock or facestocks and / or liners. The facestock comprises an adhesive disposed on a first side of the facestock. In some embodiments, the critical dimension ratio of the adhesive disposed on the facestock is less than about 50, less than about 40, less than about 35, less than about 30, less than about 25, or less than about 20. In some embodiments, the laminate comprises a patterned adhesive exhibiting the aforementioned critical dimension ratios. In some embodiments, the pattern is random. In some embodiments, the adhesive is applied in a random pattern, thereby forming adhesive fibers on the surface of the facestock. The formation of an irregular or random pattern of adhesive can overcome limitations associated with forming uniform or regular patterns, such as uncoated edges of labels, which can result in poor dispensing, warping, poor print quality, and / or poor dye cutting.

[0008] Also described herein are methods for forming adhesive laminates. In some embodiments, the method includes (1) providing a release liner defining a release surface and an outer, oppositely facing surface; (2) applying an adhesive to the release surface of the release liner to form an adhesive-containing release liner; (3) providing a face stock defining an inner surface and an outer, oppositely facing surface; and (4) simultaneously passing the adhesive-containing release liner and the face stock through a nip region defined between rollers of a roller assembly such that at least a portion of the adhesive contacts the inner surface of the face stock, thereby forming an adhesive laminate. In some embodiments, the method for forming an adhesive laminate is as described above, except that the adhesive is applied to the inner surface of the face stock rather than the release surface of the release liner.

[0009] Also described herein is a method for forming an adhesive-coated facestock. In some embodiments, the method includes (1) providing a release liner defining a release surface and an outer, oppositely directed surface; (2) applying an adhesive to the release surface of the release liner to form an adhesive-containing release liner; (3) providing a facestock defining an inner surface and an outer, oppositely directed surface; and (4) simultaneously passing the adhesive-containing release liner and the facestock through a nip region defined between rollers of a roller assembly such that at least a portion of the adhesive contacts the inner surface of the facestock. The method also includes separating the release liner from the facestock such that at least a portion of the adhesive remains with the facestock, thereby forming an adhesive-coated facestock. In some embodiments, the method for forming an adhesive-coated facestock is as described above, except that the adhesive is applied to the inner surface of the facestock, rather than the release surface of the release liner.

[0010] As will be realized, the subject matter described herein can be other and different embodiments, and several details thereof can be modified in various aspects, all without departing from the claimed subject matter. Accordingly, the drawings and description are to be regarded as illustrative or exemplary and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a schematic cross-sectional view of an adhesive area on a substrate according to the subject matter of the present invention.

[0012] Figure 2 is a schematic cross-sectional view of a plurality of adhesive areas on a substrate according to the subject matter of the present invention.

[0013] Figure 3 is a schematic cross-sectional view of a liquid indicator laminate according to the subject matter of the present invention.

[0014] Figure 4 is a schematic cross-sectional view of a degassing laminate according to the subject matter of the present invention.

[0015] Figure 5 is a schematic cross-sectional view of a water-absorbing laminate according to the subject matter of the present invention.

[0016] Figure 6 is a schematic cross-sectional view of a conductive laminate according to the subject matter of the present invention.

[0017] Figure 7 is a schematic cross-sectional view of a sound channel laminate according to the subject matter of the present invention.

[0018] Figure 8 is a schematic view of a system and method according to an embodiment of the subject matter of the present invention.

[0019] Figure 9 is a schematic cross-sectional view of an adhesive laminate according to the subject matter of the present invention.

[0020] Figure 10 is a schematic view of a system and method according to an embodiment of the subject matter of the present invention.

[0021] Figure 11 is a schematic cross-sectional view of an adhesive-coated facing material according to the subject matter of the present invention.

[0022] Figure 12 is a graph comparing the peel performance of patterned adhesive and uniformly coated adhesive.

[0023] Figure 13 is a graph comparing the peel performance of patterned adhesive and uniformly coated adhesive.

[0024] Figure 14It is a diagram for comparing the peel performance of patterned adhesives and uniformly coated adhesives.

[0025] Figure 15 It is a micrograph of a patterned adhesive sample according to an embodiment of the subject matter of the present invention. Detailed Embodiments

[0026] I. Adhesive Laminates / Adhesive-Coated Face Sheets

[0027] One or more adhesive regions and / or multiple adhesive structures disposed on a substrate are described herein. In some embodiments, the one or more adhesive regions and / or multiple adhesive structures exhibit specific dimensional ratios as described herein. In some embodiments, the adhesive is a pressure-sensitive adhesive (PSA). The PSA can be applied to a face sheet, such as a release liner or a fabric, using various techniques (e.g., spraying). Once applied, the PSA can be selectively cured and / or otherwise processed. In some embodiments, the release liner and the PSA disposed thereon are then contacted with a face sheet (e.g., label paper or a polymer film), thereby at least partially transferring the PSA to the face sheet. The release liner can be removed later to expose the PSA face and enable the user to adhere the face sheet to a substrate of interest. In other embodiments, a fabric (e.g., label paper or a polymer film) and the PSA disposed thereon are then contacted with a release liner. The release liner can be removed later to expose the PSA face and enable the user to adhere the face sheet to a substrate of interest.

[0028] By using these structures, components, and / or techniques, various PSA properties and deposition structures can now be obtained, which were not possible with conventional methods of depositing PSA on face sheets in the past.

[0029] If the adhesive is deposited and / or transferred to the face sheet as described herein such that the critical dimension ratios (CDR's) exhibited by the adhesive regions produced on the face sheet are less than about 50, less than about 45, less than about 40, less than about 35, or less than about 30, various useful features and beneficial properties of the adhesive laminate and the adhesive-coated face sheet can be obtained. Generally, the minimum CDR is about 1. In many embodiments, one or more adhesive regions exhibit a CDR of about 1 to about 10.

[0030] Adhesive laminates and / or adhesive-coated facers are also described, particularly those produced using the methods described herein, and more specifically by roll-to-roll coating of the adhesive onto the face layer of the laminate. Many of these laminates can be configured to provide one or more of the functions detailed herein. However, it should be understood that the subject matter of the present invention includes laminates as described herein, which may, however, be manufactured by techniques other than the unique methods described herein. Thus, the term "coating" as used herein includes a range of deposition and / or material transfer techniques other than transfer coating. For example, the term coating includes direct coating, spraying, brushing, dipping, and other methods. These and other aspects are described in more detail herein.

[0031] Figure 1 is a cross-sectional schematic view of an adhesive region on a substrate as described herein. Specifically, Figure 1 shows an assembly 1000, which includes an adhesive region 1010 disposed on face 1022 of a facer 1020 or other substrate. The adhesive region shows an average width distance AF W and an average thickness or height AF H . In many embodiments, the CDR of the adhesive region 1010 is in the range of 1 to 50.

[0032] The laminates or structures described herein may have adhesive regions of different sizes and proportions. For example, Figure 2 is a cross-sectional schematic view of a first adhesive region 1012 and a second adhesive region 1014 disposed on face 1022 of a facer 1020 or other substrate. The first adhesive region 1012 shows an average width distance AF W1 and an average thickness or height AF H1 . The second adhesive region 1014 shows an average width distance AF W2 and an average thickness or height AF H2 . These thicknesses may be different or the same, and these heights may be different or the same. In many embodiments, the CDR shown by the adhesive regions 1012 and / or 1014 is in the range of 1 to 50. The CDR of region 1012 may be the same as or different from the CDR of region 1014.

[0033] A. Adhesive

[0034] The laminate / structure described herein comprises one or more adhesives. The one or more adhesives can be PSA, non-pressure sensitive adhesives, hot melt adhesives, or combinations thereof. In some embodiments, the adhesive is PSA. The PSA can be any known PSA. In some embodiments, the PSA is a solvent-based adhesive, an emulsion-based adhesive, or a non-emulsion-based adhesive. In some embodiments, the PSA is an emulsion adhesive. A hot melt PSA can also be used. The adhesive can be acrylic or any other useful adhesive having the hardness and adhesive properties required for the laminate and / or the fabric coated with the adhesive. In certain embodiments, the hardness of the adhesive should be sufficient to prevent the adhesive from extruding from the laminate or the article during processing.

[0035] Exemplary PSAs can be found in (1) Encyclopedia of Polymer Science and Engineering, Vol. 13, Wiley-Interscience (New York, 1988); (2) Polymer Science and Technology, Vol. 1, Interscience Publishers (New York, 1964); (3) those described in U.S. Patent Nos. 5,164,444; 5,183,459; and 5,264,532, all assigned to Bernard, and U.S. Patent No. 5,385,965 assigned to Bernard et al.; and (4) combinations thereof. The PSA can be a solvent-based or a water-based adhesive. Conventional PSAs, including acrylic-based PSAs, rubber-based PSAs, and silicone-based PSAs, can be used for the laminate / structure described herein. In one embodiment, the pressure sensitive adhesive comprises an acrylic emulsion adhesive.

[0036] In some embodiments, the pressure sensitive adhesive is prepared by polymerizing an alkyl acrylate, a vinyl ester, a diester of a dicarboxylic acid, and an unsaturated acid. The alkyl acrylate typically contains about 2 to about 12, or about 4 to about 8 carbon atoms in the alkyl group. Examples of alkyl acrylates include, but are not limited to, ethyl acrylate, n-butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, and isooctyl acrylate, with 2-ethylhexyl acrylate being preferred. In one embodiment, the alkyl acrylate is present in an amount of at least about 35%. In some embodiments, the alkyl acrylate is present in an amount of from about 35 wt% to about 60 wt%.

[0037] The vinyl ester typically has about 2 to about 12, or about 4 to about 8 carbon atoms in the alkyl group. Examples of vinyl esters include, but are not limited to, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl versatate, etc., with vinyl acetate being preferred. In some embodiments, the vinyl ester is present in an amount of from about 15 wt% to about 35 wt% or from about 20 wt% to about 25 wt%.

[0038] Diesters of dicarboxylic acids include alkyl esters of unsaturated dicarboxylic acids such as maleic acid or anhydride and fumaric acid. The alkyl group typically contains from about 2 to about 20, or from about 4 to about 16, or from about 6 to about 12 carbon atoms. Examples of diesters of dicarboxylic acids include but are not limited to dibutyl fumarate, dioctyl fumarate; dihexyl maleate, didecyl maleate; di-2-ethylhexyl maleate; dibutyl fumarate; and di-2-ethylhexyl fumarate and mixtures thereof. In some embodiments, the diester of dicarboxylic acid is present in an amount from about 20 wt% to about 35 wt%.

[0039] Unsaturated acids typically contain from about 2 to about 12, or from about 2 to about 6 carbon atoms. Examples of unsaturated acids include but are not limited to acrylic acid, methacrylic acid, itaconic acid, etc. In some embodiments, the unsaturated acid is present in an amount up to 5 wt% or from about 1 wt% to about 3 wt%.

[0040] In some embodiments, the thickness created by one or more adhesive regions on the face sheet ranges from about 0.1 μm to about 10,000 μm, from about 0.5 μm to about 5,000 μm, from about 1 μm to about 1,000 μm, from about 3 μm to about 500 μm, or from about 5 μm to about 250 μm.

[0041] In certain embodiments, the adhesive is deposited on the face sheet to form raised regions or features having specific dimensional ratios. These dimensional ratios can be quantified and are represented herein as the critical dimension ratio (CDR) defined in formula (I):

[0042]

[0043] As used herein, "adhesive feature width" refers to the average width distance of the adhesive region disposed on the face sheet and measured in a direction transverse to the processing direction of the face sheet. "Adhesive feature height" as used herein refers to the average thickness of the same adhesive region disposed on the face sheet and measured in a direction across the plane of the face sheet.

[0044] In some embodiments, the adhesive is deposited or formed in a patterned layer or region or a non-uniform layer or region. In some embodiments, the adhesive is in the form of multiple adhesive regions separated from each other along the face of the face sheet, fabric or substrate. When such a patterned adhesive layer or region is incorporated into a laminate as described in more detail herein, the voids or spaces between the adhesive regions are in some respects similar to pores or hollow voids. These pores or voids can be used in multi-layer functional laminates described in more detail herein. The terms "patterned" and "discontinuous" are used interchangeably and both terms are used to denote an adhesive that covers less than 100% of the fabric coated with the adhesive.

[0045] In some embodiments, the CDR of one or more adhesive layers or regions is less than about 50, less than about 45, less than about 40, less than about 35, or less than about 30. In some embodiments, the minimum CDR of one or more adhesive layers or regions is about 1. In some embodiments, one or more adhesive layers or regions exhibit a CDR of about 1 to about 10.

[0046] B. Release Liner

[0047] In some embodiments, the laminates described herein may include one or more release liners. The liner can be any useful liner that provides the necessary support and release properties. The liner can be made of a variety of materials, including but not limited to paper or polymer film. In one embodiment, the paper web thickness is sufficient to die-cut the resulting laminate or article. For example, for a PET liner, the liner thickness can range from about 18 mm to about 23 mm. In one embodiment, the liner has a flat-laying property. In some embodiments, the liner has a machine glaze or finish. In some embodiments, the liner has a silicone barrier layer. The barrier layer provides adhesion between the release coating and the release liner. The silicone barrier layer also prevents the silicone release coating from penetrating into the liner.

[0048] In some embodiments, the release liner includes a liner having a release coating. The release coating of the release liner provides peelable adhesion to the PSA or other adhesives. The release coating can be any composition that provides the desired peelable adhesion strength.

[0049] In one embodiment, the release coating is a silicone release coating. The release coating can be prepared by curing a silicone silicone polymer in the presence of a controlled release agent. In some embodiments, the controlled release agent is a monofunctional silicone unit of the formula R3SiO 1 / 2 and a copolymer of a tetrafunctional silicone unit of SiO 4 / 2 wherein R is an alkyl or alkenyl group. In one embodiment, the alkyl or alkenyl group contains about 1 to about 12, or about 1 to about 6 carbon atoms. Non-limiting examples of alkyl and alkenyl groups include methyl, ethyl, propyl, butyl, hexyl, vinyl, propenyl, butenyl, and hexenyl groups.

[0050] Release agents are typically reactive with polysiloxanes. The polysiloxane can be any polysiloxane useful for forming a release coating. Examples of useful polysiloxanes include, but are not limited to, vinyl-terminated, hydroxyl-terminated, and epoxy-terminated polysiloxanes. In one embodiment, the polysiloxane is a functional polydialkylsiloxane, where the alkyl groups contain from about 1 to about 6 carbon atoms. The alkyl groups independently include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl groups, or mixtures thereof. In one embodiment, the alkyl or alkenyl groups contain from 1 to about 12, or from about 1 to about 6 carbon atoms. The polysiloxane typically has a viscosity-average molecular weight greater than 300,000 centipoise (cps). In another embodiment, the polysiloxane has a viscosity molecular weight of from about 300,000 to about 1,000,000 or greater. The polysiloxane can be represented by formula (II):

[0051] RO((Si(R)2O) x )-Si)-R(II)

[0052] where each R is independently defined as above and x is an integer.

[0053] In some embodiments, the release coating is prepared from a crosslinking agent. In some embodiments, the crosslinking agent is a reactive polysiloxane, such as a polydialkyl or polyhydroxyalkylsiloxane. The alkyl groups are the same as those described above.

[0054] The release coating can be applied in solvent, solventless, or emulsion form. The release coating can be cured by any known curing process, such as thermal curing, radiation curing, etc., to form a release coating. The curing can be catalyzed by a silicone-soluble complex compound of a Group VIII transition metal, such as platinum.

[0055] Commercially available release agents include, but are not limited to, GE SS-4335, a silicone release agent in an inert solvent. Commercially available polysiloxanes include, but are not limited to, GE SS-4331, a vinyl-terminated polydimethylsiloxane. Commercially available crosslinking agents include, but are not limited to, GESS-4300C, a polymethylvinylsiloxane. Exemplary catalysts include, but are not limited to, the SS-8010 catalyst in toluene. These materials are commercially available from the Silicone Products Division of General Electric Company. Similar silicone products are available from Dow Corning under the trade name Syl-off.

[0056] It should be understood that the subject matter of the present invention is not limited to any of the described release coatings or release agents, but includes almost any release coating or release agent suitable for the intended end-use application. Further, although the subject matter of the present invention has been described in connection with a release liner, it should be understood that a suitably configured carrier film and other components can be used in place of the release liner.

[0057] C. Face Sheet

[0058] Suitable facestock includes, but is not limited to, synthetic paper such as polyolefin type and polystyrene type; various plastic films or sheets such as polyolefin, polyvinyl chloride, polyethylene terephthalate, polystyrene, polyurethane, polymethacrylate, and polycarbonate. Other examples of suitable facestock include paper and paperboard. The facestock may be or may include a multi-layer polymer sheet. The multi-layers may be co-extruded, or the multi-layers may be laminated together. In one embodiment, the facestock includes co-extruded multi-layers and laminated multi-layers. Additionally, a white opaque film may be formed by adding a white pigment to one or more of the above synthetic resins and used as the facestock. In one embodiment, a foamed film is used as the sheet. The foamed film may be formed by conventional foaming operations. In another embodiment, the facestock may be a laminate formed by combining a plurality of single-layer sheets made of the above materials. Examples of such laminates may include a combination of cellulose fiber paper and synthetic paper, and a laminate of combined cellulose fiber paper and plastic film or sheet. In another suitable embodiment, the facestock includes coated paper and uncoated paper, metallic paper, aluminum foil, laminated paper, and paper with a polymer material extruded on the paper surface. In certain versions, the facestock may be coated with a liquid-absorbing material. The selected facestock may be porous or semi-porous. The facestock may exhibit certain visibility characteristics such as opacity, color, and / or brightness. The facestock may include water or other liquid-absorbing properties. The facestock may be conductive and / or include a conductive coating or region. Various commercial facestocks may be used, for example, those materials named TESLIN.

[0059] Depending on the specific criteria of the application, the thickness of the facestock may be optionally determined. Such criteria may include the desired end use. In one embodiment, the sheet thickness is in the range of about 10 μm to about 300 μm. In another embodiment, the sheet thickness is in the range of about 20 μm to about 200 μm. In yet another embodiment, the sheet thickness is in the range of about 30 μm to about 150 μm. Optionally, a primer treatment, corona discharge treatment, or plasma treatment may be used on the facestock to increase the adhesion strength between the facestock and the dry topcoat composition that will be formed on the surface of the facestock.

[0060] In certain embodiments described herein, the facestock exhibits one or more functions or functional characteristics. For example, the facestock may be selected to achieve or facilitate an indication (such as a visual indication of a liquid), degassing (such as guiding or allowing air or gas to flow through the thickness of the facestock), retention of water or liquid within the facestock, discharge or conductivity of the facestock, chemical transfer through the thickness of the facestock, sound passing through the thickness of the facestock, and / or a combination of these functions or characteristics.

[0061] D. Optional Layers

[0062] The adhesive-coated facing material and / or laminate described herein may include one or more additional layers or components. Non-limiting examples of such layers include protective layers, adhesive coatings, transparent layers, colored layers, white layers, reflective layers, fluid transmission layers, strength promoting layers, topcoats, print receiving layers, print containing layers, marker layers, functional layers, and the like.

[0063] E. Laminate Properties

[0064] The laminates described herein may have specific, useful properties or functions. In some embodiments, the techniques described herein are capable of forming laminates in which the transfer, propagation, and / or migration of liquids, gases, sound waves, electric currents, and / or other reagents or elements can occur and be controlled in the Z-direction through or across the laminate. The "Z-direction" as referred to herein is the direction through the thickness dimension of the laminate or a portion thereof. Thus, the "X-direction" and / or "Y-direction" as referred to are directions perpendicular to the Z-direction and correspond to the width and length dimensions of the laminate.

[0065] Non-limiting representative examples of laminates with specific functions provided by the subject matter of the present invention include liquid indicator laminates, degassing laminates, water-absorbing laminates, sound channel laminates, conductive laminates, and laminates having combinations of these functions and / or laminates having combinations of one or more of these functions and additional functions.

[0066] For example, a liquid indicator laminate can be produced such that the rate of change of the indicator color is associated with the fabric selection and the properties of the porous adhesive. A discontinuous structure, such as formed by pores in the adhesive layer or region, for example, can allow liquid to flow from one side of the adhesive to the other through the discontinuous adhesive, and when a dye or other reagent in the functional coating in the laminate dissolves, a permanent color change occurs. Details of the laminate are described in conjunction with Figure 3 to describe.

[0067] Figure 3 An embodiment of a liquid indicator laminate 200 is schematically described. The laminate 200 generally includes a functional fabric or facing material 210, a patterned layer or region of adhesive 220, a layer or region of a functional agent sensitive to liquids or other media or one or more components passing through the laminate in the Z-direction 230, a carrier layer 240 that provides support and stability to the laminate, an optional second adhesive layer 250 for bonding or otherwise attaching the laminate to a substrate or surface of interest, and an optional release liner 260. Figure 3 The arrow A in shows the flow of the medium in the Z-direction of the laminate 200.

[0068] In one embodiment, a liquid indicator laminate is provided. The speed or rate of the indicator color change is related to the properties of the fabric, such as the liquid absorption rate and the porosity of the adhesives patterned in the Z direction. The indication is typically irreversible and can be measured by color change or a simple visual comparison.

[0069] Typically, the liquid indicator 200 provides a visual indication of the presence of liquid on the surface in contact with the patterned adhesive or the bottom surface of the laminate (e.g., the exposed bottom surface of the second adhesive layer 250). The layer or region 230 of the functional agent is sensitive to the liquid passing through the laminate because the functional agent may undergo a significant and perceptible change when exposed to the liquid, and can be carried or transported with the liquid or both when the liquid travels in the Z direction through the laminate. In some versions, the layer 230 of the functional agent may include one or more dyes, one or more colorants, and / or one or more components that migrate or are transported in the Z direction through the layer or region 220 of the patterned adhesive to the functional fabric 210. The laminate also includes one or more dyes, one or more colorants, and / or one or more components that migrate or transfer in the opposite direction, such as from the functional fabric 210 to the layer or region 230 of the functional agent.

[0070] The color change of the surface or region of the laminate can be measured and quantified by optical changes, such as by CIE Lab or a simple visual comparison. The color change can be permanent or non-permanent. The color change may also be temporary and return to the initial state after a period of time. In some embodiments, the period of time is pre-determined.

[0071] This transmission phenomenon through the discontinuity of the adhesive in the Z direction can be implemented in other label applications, especially pressure-sensitive adhesive labels, for example, for the following labels: degassing the substrate through an air channel in the Z direction, marking a wet substrate through a liquid channel in the Z direction, discharging in the Z direction, transferring a chemical substance from one layer to another in the Z direction, and / or a sound channel in the Z direction. This phenomenon enables the medium or reagent to be transferred, transported, and / or migrated from one side of the adhesive region of the laminate to the other side of the adhesive region. Although it is noted that the penetration or transmission of the medium is in the Z direction, it should be understood that the subject matter of the present invention is not limited thereto and may also include penetration / transmission in the X direction and / or the Y direction.

[0072] In some embodiments, the laminates described herein include a layer or region of a second adhesive. The second adhesive is typically used to attach the laminate to a substrate of interest. The second adhesive can comprise one or more adhesives that are the same as or different from the adhesive of the patterned or porous adhesive. Descriptions of representative examples of the second adhesive are provided herein. In such an adhesive configuration, the first adhesive can be coated onto the face sheet, and the second adhesive can be coated onto the release liner. The coated adhesives and the release liner can be laminated together such that the first adhesive and the second adhesive are in direct contact with each other. Alternatively, or additionally, both the first adhesive and the second adhesive can be coated on the face sheet or the release liner and then laminated together. It is contemplated that the layering of the first and second adhesives with respect to the face sheet and the release liner can be face sheet, first adhesive, second adhesive, and release liner or face sheet, second adhesive, first adhesive, release liner. Regardless of the order of the first and second adhesives, considering that other adhesives can be continuous, it is contemplated that at least one of the first and second adhesives is patterned.

[0073] Figure 4 An embodiment of a degassing laminate 300 is schematically depicted. The degassing laminate 300 generally includes a functional face sheet or face material 310 (having the function that air, gas, or other mediums can pass through the face material 310 in the Z direction), a layer or region 320 of a patterned adhesive having pores or other voids oriented in the Z direction, and an optional release liner 340.

[0074] When the laminate 300 is applied as a pressure-sensitive adhesive label to a substrate, gas or air can pass from the substrate in the Z direction through the adhesive 320 to the functional face material 310. If the functional face material allows one or more desired components to pass through the adhesive in the direction of the substrate, reverse migration or transport can also be achieved. Laminates or label assemblies having a degassing function are useful for applications where degassing problems of the substrate can cause label blistering. Typical applications include applications to one or more surfaces of in-mold plastics or painted surfaces.

[0075] Figure 5 An embodiment of a water-absorbing laminate 400 is schematically shown. The water-absorbing laminate 400 generally includes a functional face sheet or face material 410 having water-absorbing properties, a layer or region 420 of a patterned adhesive having pores or other voids oriented in the Z direction, and an optional release liner 440.

[0076] For example, a laminate such as the laminate 400, in which a patterned adhesive is used to direct liquid from the substrate through the porous adhesive to the functional face material for water retention, can reduce adhesive attachment problems under wet or sensitive marking conditions. The liquid absorption rate can be measured as the weight gain of the functional face material.

[0077] When the laminate 400 is applied as a pressure-sensitive adhesive label to a moist substrate, moisture or water will pass from the substrate through the adhesive 420 in the Z-direction to the functional fabric 410. Reverse migration or transport can also occur if the functional fabric permits one or more of the desired components to pass through the discontinuous adhesive in the direction of the substrate.

[0078] Figure 6 An embodiment of a conductive laminate 500 is schematically shown. The laminate 500 generally includes a conductive functional fabric or facestock 510, a layer or region 520 of a patterned adhesive having pores or voids oriented in the Z-direction, and an optional release liner 540.

[0079] When the conductive fabric is applied as a pressure-sensitive adhesive label with a thin patterned adhesive coating to a conductive substrate, the adhesive will permit current to pass from the substrate through the adhesive in the Z-direction to the functional fabric. Reverse current can also occur.

[0080] Figure 7 An embodiment of a sound channel laminate 600 is schematically shown. The laminate 600 generally includes a functional fabric or facestock 610. In many versions, the fabric 610 comprises polyurethane. The laminate 600 also includes a layer or region 620 of a patterned adhesive having pores or voids oriented in the Z-direction and an optional release liner 640.

[0081] When the laminate 600 is applied as a pressure-sensitive adhesive label with a discontinuous adhesive, sound passes from the substrate in the Z-direction to the functional fabric 610. Reverse transmission of sound is also contemplated.

[0082] In some embodiments, a different arrangement of layers and components may be used. In some embodiments using a patterned adhesive, such as a layer of discontinuous adhesive, the layer is disposed between the functional fabric and the liner or functional layer. And, in a liquid indicator laminate, the patterned adhesive may be disposed between the functional fabric and a layer or region of an adhesive sensitive to liquids passing through the laminate. And, in a liquid indicator laminate, a layer or region of a functional agent may be disposed between the patterned adhesive and the carrier layer.

[0083] Figure 8 System 1 for forming an adhesive laminate according to embodiments described herein is schematically illustrated. It should be understood that the systems and methods described herein may also be used to produce laminates and coated facestock materials different from the embodiments described herein. System 1 and related methods include providing Figure 8The supply of the release liner 10 shown, for example, is provided in the form of a roll. As will be understood, the release liner 10 includes a release surface 12 and an outer surface 14 in the opposite direction. The release surface 12 contains a release material, a release coating, and / or a release agent, as described herein. The release liner 10 is oriented to the system 40, where the adhesive composition 20 is applied to the release surface 12 of the release liner 10. Generally, in many embodiments, the adhesive 20 is applied to the release liner 10 by spraying. However, other or specific spraying techniques may also be used, such as but not limited to inkjet, electrospinning, airless spraying, air-guided nozzle spraying, etc. or combinations thereof.

[0084] After receiving an effective amount of the adhesive deposited on the release surface 12 of the release liner 10, the release liner containing the adhesive optionally undergoes Figure 8 one or more curing operations shown, i.e., the curing station 50. Through the optional curing station 50, the adhesive can be partially or fully cured, crosslinked, or otherwise modified. The curing station 50 may emit heat, radiation, and / or remove one or more solvents from the deposited adhesive. In many cases, curing results in an increase in the viscosity of the adhesive.

[0085] Then, the release liner 10 containing the adhesive is oriented to a roller assembly that includes a pair of rollers 60, 65, which are positioned and oriented for contacting and transferring the adhesive. The rollers 60, 65 define a "pinch area" 68 between the outer peripheral surfaces of the closely positioned rollers. The pinch area is an area that extends along the width or span of the rollers and includes the interface area between the rollers. Figure 8 The pinch area 68 associated with the rollers 60, 65 is illustrated. The release liner 10 is oriented to the first roller 60 and towards the pinch area 68.

[0086] The system 1 also includes a supply Figure 8 of the facing material 30 shown, which is typically supplied in the form of a roll. The facing material 30 includes an inner surface 34 and an outer surface 32 in the opposite direction. The facing material 30 is oriented to the roller assembly and specifically oriented to the second roller 65 and towards the pinch area 68.

[0087] The release liner 10 containing the adhesive and the facing material 30 simultaneously pass between the rollers 60, 65 and within the pinch area 68, such that the adhesive 20 disposed on the release surface 12 of the release liner 10 at least partially contacts the inner surface 34 of the facing material 30. The rollers 60, 65 are positioned and oriented relative to each other such that at least a portion of the adhesive 20 contacts the inner surface 34 of the facing material 30. Then, the resulting laminate 100 exiting the rollers 60, 65 is oriented to a collection station (not shown), which, for example, winds the laminate in a roll. It is also contemplated that the laminate undergoes one or other processing operations, such as topcoating with one or more protective films, die-cutting to form or create perforations, and / or receiving additional layers or components.

[0088] Figure 9 Schematically shows a cross-section of the laminate 100 described herein. The laminate 100 includes a face sheet 30 defining an inner face 34 and an outer face 32 in the opposite direction. The laminate also includes a release liner 10 defining an inner face 12 and generally including a release coating and an outer face 14 in the opposite direction. The laminate 100 also includes an adhesive 20 disposed between the face sheet 30 and the release liner 10.

[0089] The described adhesive-coated face sheet can also be formed by a transfer technique. In some embodiments, after the transfer, the release liner that initially carried the adhesive for transfer to the face sheet is removed or otherwise separated. The release liner can be reused or subsequently reattached or bonded to the adhesive-coated face sheet. Figure 10 Schematically shows a system and method for producing an adhesive-containing face sheet without a release liner. System 1 is the same as or similar to Figure 8 the system, but after the liner 10, adhesive 20, and face sheet 30 pass through rollers 60, 65, the release liner 10 is separated from the face sheet 30 to produce an adhesive-containing face sheet 150. As previously described, the liner 10 can be redirected to the source roller 10, redirected for further processing, and / or reattached to the adhesive-containing face sheet 150.

[0090] Figure 11 is a schematic cross-sectional view of the adhesive-containing face sheet 150. The adhesive-containing face sheet 150 includes the aforementioned face sheet 30 and a layer or region of the aforementioned adhesive 20 disposed on the face sheet.

[0091] Adhesive laminates and / or adhesive-coated face sheets having fluid / air management features, controlled removability, and / or unique thermal and / or electrical conductivity can be produced using the techniques and features described herein. Additionally, the use of these techniques and features can reduce materials, such as adhesives, thereby saving costs. However, it should be understood that the subject matter of the present invention includes adhesive-coated face sheets and laminates described herein formed by other methods than those described herein.

[0092] The methods of the subject matter of the present invention can be carried out in a batch, continuous, or semi-continuous manner. For a continuous process, typical processing speeds are between about 100 m / min and 1000 m / min. However, it should be understood that the subject matter of the present invention is not limited to these speeds and includes processing speeds less than 100 m / min and / or speeds greater than 1000 m / min.

[0093] II. Method of Manufacturing an Adhesive Laminate

[0094] Adhesive laminates and / or adhesive-coated face materials as described herein can be prepared or manufactured by using direct coating on the face material and / or the technology of transfer coating of the adhesive from the release liner to the face material. In one embodiment, the method comprises depositing the adhesive material on the release liner, optionally curing or otherwise modifying the deposited adhesive, and then simultaneously passing the adhesive-coated release liner and the face material through a plurality of rollers. When the adhesive on the release material contacts the face or area of the face material, at least a portion of the adhesive is transferred to the face material. In many embodiments, the laminate produced by the face material, adhesive and release liner is collected and / or further processed. However, the subject matter of the present invention is also included in a method in which the release liner is separated from the face material and / or removed by the face material after passing through a plurality of rollers. Typically, at least a portion of the adhesive remains on the face material. In other embodiments, the adhesive can be directly coated on the face material. In other embodiments, at least a portion of the adhesive may be applied to individually cut labels or a series of labels as an alternative to applying the adhesive to a roll of facestock by direct coating or transfer coating prior to forming the individual labels.

[0095] The methods described herein also include applying or depositing the adhesive on the release liner or fabric in a specific pattern and / or using specific techniques as described herein. In certain embodiments, the adhesive can be applied by spraying in a regular or orderly pattern on the release liner. Alternatively, in other embodiments, the adhesive can be applied by spraying in an irregular or random pattern. "Irregular" or "random" refers to uneven or unbalanced changes in shape, arrangement, or pattern direction, and non-repeating unevenness. Irregular or random patterns or graphics can overcome limitations or problems associated with regular or uniform patterns or graphics, including the edges of the label not being glued, resulting in poor distribution, warping, poor print quality, and / or poor dye cutting. Combinations of these techniques can also be used. In certain configurations, multiple adhesives can be deposited simultaneously, sequentially, or in combination thereof. For example, a first adhesive can be deposited from a first adhesive source, and a second, different adhesive can be deposited from a second adhesive source to form a pattern of two adhesives interwoven together. Alternatively, or in addition, a first patterned adhesive can be deposited directly onto the substrate, followed by a second, different adhesive deposited on top of the first deposited adhesive. In other configurations, the first adhesive can be deposited in multiple lanes, and the second, different adhesive can be deposited in parallel lanes between the multiple lanes of the first adhesive. Of course, other configurations are also contemplated in which the first and second adhesives are deposited on different areas of the substrate.

[0096] In some embodiments, the adhesive is disposed on a release liner or a facing sheet such that the release surface of the release liner or one or more regions of the facing sheet remain uncovered or exposed. In some embodiments, the coverage rate of the adhesive on the release surface or the facing sheet is less than 100%, less than 95%, less than 90%, less than 85%, less than 80%, less than 75%, less than 70%, less than 60%, less than 50%, less than 40% and less than 30%. In some embodiments, the coverage rate of the adhesive is at least 5%, at least 10%, and in specific embodiments at least 20%. In many embodiments, the coverage rate of the adhesive on the release liner or the facing sheet ranges from less than about 100% to about 5%, more particularly from about 95% to about 20%, more particularly from about 60% to about 10%. In other embodiments, the coverage percentage ranges from about 35% to about 70% or from about 40% to about 65%.

[0097] In some embodiments, when such a release liner containing an adhesive is guided to a roller assembly where the adhesive contacts the facing sheet, the degree of coverage of the adhesive on the facing sheet is the same as or substantially the same as the coverage rate on the release surface. For example, for a release liner containing an adhesive where the coverage rate of the adhesive on the release surface is 70%, after roll-to-roll transfer to the facing sheet, the coverage rate of the adhesive on the facing sheet is also 70% or approximately 70%. In some embodiments, the coverage rate of the adhesive on the facing sheet is within ±10% of the coverage rate of the adhesive on the release liner, preferably within ±5%. Non-limiting representative examples of the coverage rate of the adhesive on the facing sheet include less than about 100% to about 5%, typically in the range of about 95% to about 20%. However, it should be understood that the subject matter of the present invention includes facing sheets having specific percentage coverage rates of about 75%, about 50% or about 25%.

[0098] The subject matter of the present invention also includes adhesive laminates and / or adhesively coated facing sheets that exhibit combinations of these aspects. In some embodiments, one or more adhesive regions exhibit a thickness in the range of about 20 mm to about 70 mm, a CDR in the range of about 1 to about 10, and a coverage rate on the substrate in the range of about 60% to about 10%.

[0099] In other embodiments, an adhesive showing special rheological characteristics is used. In some embodiments, the adhesive shows a viscosity in the range of about 500 cPs to about 100,000 cPs at 150 °C. In one embodiment, it has been found that an adhesive that has a viscosity of less than about 10,000 cPs when heated to a temperature of 170 °C and does not flow at a pressure of 120 psi at ambient temperature can form a patterned adhesive. In some embodiments, if a hot melt adhesive is used, the adhesive shows a viscosity in the range of about 10,000 cPs to about 100,000 cPs at 150 °C, preferably about 30,000 cPs to about 50,000 cPs at 150 °C. However, it should be understood that the subject matter of the present invention includes other adhesives showing viscosities outside of these ranges.

[0100] In some embodiments, the adhesive does not contain a filler. In other embodiments, the adhesive may contain a filler. In some embodiments, a filler is a particulate additive that can be added to the adhesive to increase the volume of the adhesive and / or improve properties. Fillers are commonly used in adhesive formulations to: (1) reduce cost (e.g., by adding calcium carbonate, clay, or talc); (2) color the adhesive, e.g., by adding titanium dioxide, colored toners, and security labels; and (3) improve performance, e.g., increase stiffness and tensile strength, reduce cold flow, reduce edge flow, improve cutting, etc. The filler particles can be inert non-reinforcing fillers or active reinforcing fillers. An inert non-reinforcing filler or compatibilizer refers to a filler that does not strongly interact with the adhesive polymer resin. Examples include, but are not limited to, untreated clay, talc, calcium carbonate, and titanium dioxide. They are typically included in the adhesive to increase the volume of the adhesive, reduce cost, or alter the appearance or chemical resistance of the adhesive. Such fillers also improve the processability of the polymer resin mixture. An active reinforcing filler is a filler that interacts with the adhesive polymer resin, e.g., by promoting additional crosslinking or filler-polymer interfacial interactions. Examples of such fillers include, but are not limited to, surface-treated clay, zinc oxide, fine-grained silica, and carbon black. Reinforcement is generally defined as an increase in mechanical properties (such as tensile strength or modulus), and occasionally also includes adhesive properties.

[0101] Examples

[0102] Example 1. Patterned Hot Melt Adhesive

[0103] The hot melt adhesive was applied to the fabric using two different methods (Samples A and B). Sample A contained an adhesive that was used to form a patterned adhesive area on the fabric using a transfer coating spraying technique. Sample B contained an adhesive that was applied to the same fabric using a conventional ink-over coating method. As Figure 12As shown, the 90° peel measurements of the samples were plotted as a function of the adhesive coating weight. The 90° peel measurements were conducted according to ASTM D6862. A decrease in the amount or coverage of the surface area of the adhesive in Sample A, compared to the adhesive in Sample B, resulted in an adhesive with a greater thickness. The increased adhesive thickness in Sample A performed well on challenging rough surfaces such as cardboard. Figure 12 It is shown that the peel value of the patterned adhesive applied according to the subject matter of the present invention is greater than the peel value of an equal amount of adhesive applied using conventional techniques.

[0104] A hot melt adhesive with a viscosity of 5030 cPs at 150 °C was applied to the fabric using two different methods (Samples A and B). Sample A contained an adhesive using a transfer coating spray technique for forming a patterned adhesive area on the fabric, with a coverage of 35% ± 2% and a CDR of 8.9. Sample B contained an adhesive applied to the same fabric using a conventional ink coating (100% coverage) method. As Figure 12 shown, the 90° peel measurements of the samples were plotted as a function of the adhesive coating weight. Sample A required a 30% reduction in the adhesive to match the peel performance of the evenly coated Sample B.

[0105] A hot melt adhesive with a viscosity of 48,500 cPs at 150 °C was applied to the fabric using two different methods (Samples C and D). Sample C contained an adhesive using a transfer coating spray technique for forming a patterned adhesive area on the fabric, with a coverage of 62% ± 3% and a CDR of 2. Sample D contained an adhesive applied to the same fabric using a conventional ink coating method known in the art. As Figure 13 shown, the 90° peel measurements of the samples were plotted as a function of the adhesive coating weight. The 90° peel measurements were conducted according to ASTM D6862. Sample C required a 30% reduction in the adhesive to match the peel performance of the evenly coated Sample D.

[0106] A hot melt adhesive with a viscosity of 35,000 cPs at 150 °C was applied to the fabric using two different methods (Samples E and F). Sample E contained an adhesive using a transfer coating spray technique for forming a patterned adhesive area on the fabric, with a coverage of 57% ± 4% and a CDR of 3.5. Sample F contained an adhesive applied to the same fabric using a conventional ink coating (100% coverage) method. As Figure 14 shown, the 90° peel measurements of the samples were plotted as a function of the adhesive coating weight. Sample E required a 30% reduction in the adhesive to match the peel performance of the evenly coated Sample F.

[0107] As Figure 15As shown, an adhesive is applied to a fabric material, and this figure is a micrograph of a patterned adhesive sample according to the subject matter of the present invention. Figure 15 The pattern showing the adhesive area may be irregular and / or random.

[0108] When attached to the same rough surface, a patterned adhesive layer applied to a rough surface may have an advantage over a uniform adhesive coating. If two samples have the same volume of adhesive, but one sample has a uniformly applied adhesive while the other sample has the adhesive concentrated in a smaller percentage area, the second sample has a higher local thickness (and correspondingly lower CDR) in that area. The high local thickness can enable the sample to adapt to the roughness. This can improve the adhesion compared to a sample with a uniform application on the same rough surface. The uniformity and thickness of the uniformly applied sample are limited. If the amplitude of the waves describing the original roughness is much larger than the local thickness of the patterned adhesive, this advantage may be diminished.

[0109] Then, the coverage and thickness of the pattern can be customized for a specific surface roughness. For example, for a uniformly applied sample with a thickness of 10 microns, a surface with 30 - micron - high features may be challenging. The same adhesive, when patterned, can have a thickness of 30 microns, matching the feature size of the surface roughness and improving the adhesion.

[0110] All adhesive - coated facings, laminates, labels, and other structures can be provided in various forms. In some embodiments, these forms include self - winding tapes. However, it should be understood that the subject matter of this aspect is not limited to wound tapes and includes sheets in stacked, folded, or continuous forms.

[0111] Without a doubt, with the future application and development of this technology, many other benefits will become apparent.

[0112] All patents, applications, standards, and terms described herein are hereby incorporated by reference in their entirety.

[0113] The subject matter of this aspect includes all operable combinations of the features and aspects described herein. Thus, for example, if one feature is described in connection with one embodiment and another feature is described in connection with another embodiment, it should be understood that the subject matter of this aspect includes embodiments having combinations of these features.

[0114] As described above, the subject matter of this aspect addresses many problems associated with prior strategies, systems, and / or devices. However, it should be understood that, for example, for the purpose of explaining the nature of the subject matter of this aspect, various variations in the details, materials, and arrangements of the components and / or layers within the laminate described and illustrated herein as acetonitrile can be made by those skilled in the art without departing from the principles and scope of the subject matter protected by the appended claims.

Claims

1. An adhesive-coated facing material, the facing material comprising: A facing material defining a first side and a second side in an opposite direction; Patterned adhesive disposed on the first side of the facing material; Wherein the critical dimension ratio of the patterned adhesive disposed on the facing material is less than 50.

2. The adhesive-coated facing material according to claim 1, wherein the critical dimension ratio is less than 40.

3. The adhesive-coated facing material according to claim 2, wherein the critical dimension ratio is less than 30.

4. The adhesive-coated facing material according to any one of claims 1 to 3, wherein the coverage of the adhesive on the facing material is less than about 100% to about 5%.

5. The adhesive-coated facing material according to any one of claims 1 to 3, wherein the coverage of the adhesive on the facing material is less than about 75%.

6. The adhesive-coated facing material according to claim 5, wherein the coverage of the adhesive on the facing material is about 35% to about 70%.

7. The adhesive-coated facing material according to claim 6, wherein the coverage of the adhesive on the facing material is about 40% to about 65%.

8. The adhesive-coated facing material according to any one of claims 1 to 7, wherein the thickness of the adhesive on the facing material is in the range of 0.1 μm to 10,000 μm.

9. The adhesive-coated facing material according to claim 8, wherein the adhesive is a pressure-sensitive adhesive.

10. The adhesive-coated facing material according to any one of claims 1 to 9, the facing material further comprising a release liner that at least partially contacts the adhesive.

11. The adhesive-coated facing material according to claim 10, wherein the release liner defines a release side, and the release liner includes a release agent on the release side.

12. The adhesive according to any one of claims 1 to 11, wherein the facing material visually indicates the presence of a liquid in contact with the patterned adhesive.

13. The adhesive according to any one of claims 1 to 11, wherein the facing material enables a gas to pass through the patterned adhesive and through the facing material.

14. The adhesive according to any one of claims 1 to 11, wherein the facing material absorbs a liquid from a surface through the patterned adhesive.

15. The adhesive according to any one of claims 1 to 11, wherein the facing material conducts electricity through the thickness of the facing material.

16. The adhesive according to any one of claims 1 to 11, wherein the facing material conducts sound through the thickness of the facing material.

17. The adhesive according to any one of claims 1 to 16, wherein the pattern is irregular or random.

18. A laminate, the laminate comprising: An adhesive-coated facing material according to any one of claims 1 to 17 and one or more additional films or one or more additional layers.

19. The laminate according to claim 18, wherein the one or more additional layers include at least one of the following: a layer or region of a functional agent sensitive to a liquid passing through the laminate, the patterned adhesive, and a layer or region of at least one of the functional agents.

20. The laminate according to claim 18 or 19, wherein the functional agent undergoes a visually visible change upon exposure to a liquid.

21. The laminate according to claim 18 or 19, wherein the functional agent is transported by a liquid flowing through the laminate.

22. The laminate according to any one of claims 18 to 21, wherein the laminate enables a gas to pass through the patterned adhesive and through the functional fabric.

23. The laminate according to any one of claims 18 to 22, wherein the laminate absorbs a liquid from a surface through the patterned adhesive.

24. The laminate according to any one of claims 18 to 22, wherein the laminate conducts electricity through the thickness of the laminate.

25. The laminate according to any one of claims 18 to 22, wherein the laminate conducts sound through the thickness of the laminate.

26. The laminate according to any one of claims 18 to 25, the laminate further comprising a carrier layer, wherein a layer or region of at least one of the functional agents is disposed between the patterned adhesive and the carrier layer.

27. A method for forming an adhesive laminate, the method comprising: providing a release liner defining a release face and an outer face in an opposite direction; applying an adhesive in a pattern to the release face of the release liner to form a release liner containing the adhesive; providing a face sheet defining an inner face and an outer face in an opposite direction; simultaneously passing the release liner containing the adhesive and the face sheet through a nip region defined between rolls of a roll assembly such that at least a portion of the adhesive contacts the inner face of the face sheet, thereby forming an adhesive laminate.

28. The method according to claim 27, the method further comprising removing the adhesive laminate from the rolls; and collecting the adhesive laminate in a roll.

29. The method according to claim 27, wherein applying the adhesive to the release face of the release liner is performed by spraying the adhesive onto the release face of the release liner.

30. The method according to claim 29, wherein the spraying is a spraying technique selected from the group consisting of inkjet, electrospinning, airless spraying, air-guided nozzle spraying, and combinations thereof.

31. The method according to claim 27, the method further comprising at least partially curing the adhesive after applying the adhesive to the release face of the release liner.

32. The method according to claim 31, wherein at least partially curing the adhesive is performed before simultaneously passing the release liner containing the adhesive and the face sheet through the nip region defined between the rolls of the roll assembly.

33. The method according to claim 27, wherein the adhesive is a pressure-sensitive adhesive.

34. The method according to claim 27, wherein the release surface of the release liner contains a release agent.

35. The method according to claim 27, wherein applying the adhesive to the release surface of the release liner results in a coverage of the adhesive on the release surface of the release liner of less than about 100%.

36. The method according to claim 35, wherein the coverage is less than about 75%.

37. The method according to claim 35, wherein the coverage is greater than about 5%.

38. The method according to claim 37, wherein the coverage is greater than about 20%.

39. The method according to claim 35, wherein the coverage is from about 40% to about 65%.

40. The method according to claim 27, wherein the thickness created by the adhesive on the facing material is in the range of from about 0.1 μm to about 10,000 μm.

41. The method according to claim 27, wherein the critical dimension ratio of the adhesive on the facing material is less than about 50.

42. The method according to claim 41, wherein the critical dimension ratio of the adhesive on the facing material is less than about 40.

43. The method according to claim 42, wherein the critical dimension ratio of the adhesive on the facing material is less than about 30.

44. An adhesive laminate formed by the method according to any one of claims 27 to 43.

45. A method for forming an adhesive laminate, the method comprising: providing a release liner defining a release surface and an outer surface in an opposite direction; providing a facing material defining an inner surface and an outer surface in an opposite direction; applying an adhesive in a pattern to the inner surface of the facing material to form a facing material containing the adhesive; simultaneously passing the facing material containing the adhesive and the release liner through a nip region defined between the rollers of a roller assembly such that at least a portion of the adhesive contacts the release surface of the release liner, thereby forming an adhesive laminate.

46. The method according to claim 45, the method further comprising removing the adhesive laminate from the rollers; and collecting the adhesive laminate in a roll.

47. The method according to claim 45 or 46, wherein applying the adhesive to the inner surface of the facing material is performed by spraying the adhesive onto the inner surface of the facing material.

48. The method according to claim 47, wherein the spraying is a spraying technique selected from the group consisting of inkjet, electrospinning, airless spraying, air-guided nozzle spraying, and combinations thereof.

49. The method according to any one of claims 45 to 48, the method further comprising at least partially curing the adhesive after applying the adhesive to the inner surface of the facing material.

50. The method according to claim 49, wherein at least partially curing the adhesive is performed before simultaneously passing the facing material containing the adhesive and the release liner through the nip region defined between the rollers of the roller assembly.

51. The method according to any one of claims 45 to 50, wherein the adhesive is a pressure-sensitive adhesive.

52. The method according to any one of claims 45 to 51, wherein the release surface of the release liner contains a release agent.

53. The method according to any one of claims 45 to 52, wherein applying the adhesive to the inner surface of the facing material results in a coverage rate of the adhesive on the inner surface of the facing material of less than about 100%.

54. The method according to claim 53, wherein the coverage rate is less than about 75%.

55. The method according to claim 53, wherein the coverage rate is greater than about 5%.

56. The method according to claim 53, wherein the coverage rate is greater than about 20%.

57. The method according to claim 53, wherein the coverage rate is from about 40% to about 65%.

58. The method according to any one of claims 45 to 57, wherein the thickness produced by the adhesive on the facing material is in the range of about 0.1 μm to about 10,000 μm.

59. The method according to any one of claims 45 to 57, wherein the critical dimension ratio of the adhesive on the facing material is less than about 50.

60. The method according to claim 59, wherein the critical dimension ratio of the adhesive on the facing material is less than about 40.

61. The method according to claim 59, wherein the critical dimension ratio of the adhesive on the facing material is less than about 30.

62. An adhesive laminate formed by the method according to any one of claims 45 to 61.

63. A method for forming an adhesive-coated facing material, the method comprising: providing a release liner defining a release surface and an outer surface in an opposite direction; applying the adhesive in a pattern to the release surface of the release liner to form a release liner containing the adhesive; providing a facing material defining an inner surface and an outer surface in an opposite direction; simultaneously passing the release liner containing the adhesive and the facing material through a nip region defined between the rollers of a roller assembly such that at least a portion of the adhesive contacts the inner surface of the facing material; separating the release liner from the facing material, whereby at least a portion of the adhesive remains with the facing material to form an adhesive-coated facing material.

64. The method according to claim 63, the method further comprising removing the adhesive-coated facing material from the roller; and collecting the adhesive-coated facing material.

65. The method according to claim 63 or 64, wherein applying the adhesive to the release surface of the release liner is performed by spraying the adhesive onto the release surface of the release liner.

66. The method according to claim 65, wherein the spraying is a spraying technique selected from the group consisting of inkjet, electrospinning, airless spraying, air-guided nozzle spraying, and combinations thereof.

67. The method according to any one of claims 63 to 66, the method further comprising at least partially curing the adhesive after applying the adhesive to the release surface of the release liner.

68. The method according to claim 67, wherein at least partial curing of the adhesive is performed before passing the release liner carrying the adhesive and the facing material simultaneously through a nip region defined between the rollers of the roller assembly.

69. The method according to any one of claims 63 to 68, wherein the adhesive is a pressure - sensitive adhesive.

70. The method according to any one of claims 63 to 69, wherein the release surface of the release liner contains a release agent.

71. The method according to any one of claims 63 to 70, applying the adhesive to the release surface of the release liner results in a coverage of the adhesive on the release surface of the release liner of less than about 100%.

72. The method according to claim 71, wherein the coverage is less than about 75%.

73. The method according to claim 71, wherein the coverage is greater than about 5%.

74. The method according to claim 71, wherein the coverage is greater than about 20%.

75. The method according to claim 71, wherein the coverage is from about 40% to about 65%.

76. The method according to any one of claims 63 to 75, wherein the thickness created by the adhesive on the facing material is in the range of about 0.1 μm to about 10,000 μm.

77. The method according to any one of claims 63 to 76, wherein the critical dimension ratio of the adhesive on the facing material is less than about 50.

78. The method according to claim 77, wherein the critical dimension ratio of the adhesive on the facing material is less than about 30.

79. An adhesive - coated facing material formed by the method according to any one of claims 63 to 78.

80. A method for forming an adhesive - coated facing material, the method comprising: providing a release liner defining a release surface and an outer surface in an opposite direction; providing a facing material defining an inner surface and an outer surface in an opposite direction; applying the adhesive in a pattern to the inner surface of the facing material to form a facing material carrying the adhesive; passing the facing material carrying the adhesive and the release liner simultaneously through a nip region defined between the rollers of a roller assembly such that at least a portion of the adhesive contacts the release surface of the release liner; separating the release liner from the facing material.

81. The method according to claim 80, the method further comprising removing the adhesive - coated facing material from the rollers; and collecting the adhesive - coated facing material.

82. The method according to claim 80 or 81, wherein applying the adhesive to the inner surface of the facing material is performed by spraying the adhesive onto the inner surface of the facing material.

83. The method according to claim 82, wherein the spraying is a spraying technique selected from the group consisting of inkjet, electrospinning, airless spraying, air - assisted nozzle spraying, and combinations thereof.

84. The method according to any one of claims 80 to 83, the method further comprising at least partially curing the adhesive after applying the adhesive to the inner surface of the facing material.

85. The method according to claim 84, wherein at least partial curing of the adhesive is performed before passing the adhesive-containing facing material and the release liner simultaneously through a nip region defined between the rollers of the roller assembly.

86. The method according to any one of claims 80 to 85, wherein the adhesive is a pressure-sensitive adhesive.

87. The method according to any one of claims 80 to 86, wherein the release surface of the release liner contains a release agent.

88. The method according to any one of claims 80 to 87, wherein applying the adhesive to the inner surface of the facing material results in a coverage of the adhesive on the inner surface of the facing material of less than about 100%.

89. The method according to claim 88, wherein the coverage is less than about 75%.

90. The method according to claim 88, wherein the coverage is greater than about 5%.

91. The method according to claim 88, wherein the coverage is greater than about 20%.

92. The method according to claim 88, wherein the coverage is from about 40% to about 65%.

93. The method according to any one of claims 80 to 92, wherein the thickness created by the adhesive on the facing material is in the range of about 0.1 μm to about 10,000 μm.

94. The method according to any one of claims 80 to 93, wherein the critical dimension ratio of the adhesive on the facing material is less than about 50.

95. The method according to claim 94, wherein the critical dimension ratio of the adhesive on the facing material is less than about 40.

96. The method according to claim 95, wherein the critical dimension ratio of the adhesive on the facing material is less than about 30.

97. An adhesive-coated facing material formed by the method according to any one of claims 80 to 96.

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