Film trimming device and method

Abstract

An apparatus and method are provided for applying a film (120) to a first panel of a vehicle, the first panel being connected to a second panel of the vehicle by a joint area including a groove portion (52) that is recessed relative to the first panel. The method includes the steps of placing an elongated jig (100) in the groove portion (52) with a shim (102) that extends continuously along the length of the groove portion (52) and that protrudes beyond the height of the first panel, applying the film (120) to the first and second panels such that the film extends over the elongated jig (100), and then using a tool (122) to apply pressure against the film and along the length of the shim (102) toward the cut edge of the shim (102) to trim the film (120) along a periphery. The elongated jig (100) may then be removed from the groove portion (52) and the peripheral edge of the film (120) may be adhered to the groove portion (52).

Description

[Technical field]

[0001] A jig and associated method are provided for applying the film, which may be, for example, an adhesive-backed film that is applied to the exterior surface of an automobile. [Background technology]

[0002] Automotive manufacturers use functional and decorative films for large body applications. Target application areas can include the entire roof area, roof sides, or the entire vehicle. Particularly useful types of films are paint films and blackout films, which have the potential to replace the application of liquid paint in many applications. The use of these films can save significant time when compared to multiple applications of paint while avoiding the emission of volatile organic compounds. Other useful films include paint protection films that are applied over pre-painted surfaces. All of these surface films can provide both functional and decorative benefits. Summary of the Invention

[0003] Providing consistent and high quality results in film application can be assisted with jigs, but conventional jigs continue to present significant technical challenges. First, automotive exterior surfaces have complex contours that vary significantly between vehicle models, thus requiring different jigs for different models. Second, application of film using conventional jigs tends to be highly technique sensitive, resulting in inconsistent wet-out of the film. Third, the use of blades to cut the film generally requires additional structure opposing the blade to guide the cut to avoid 1) risking injury to the user, and 2) potentially damaging the vehicle's surface.

[0004] Provided herein is a trimming and application device for applying a tape or film onto a three-dimensional surface. The application device is a jig that includes a thin metal shim received in an elongated and flexible body that can be contoured to the 3D surface. To trim the film, a tool is pressed against the film, forcing it into the corners of the metal shim. Advantageously, the applied pressure cuts the film without the need for a sharp cutting blade. Once the film is trimmed in this manner, wet-out near the trimmed edge can proceed with the aid of the device's angled shelf. The angled shelf reduces tenting on the film edge by allowing successive geometric radii to be wet-out in the proper sequence, thereby limiting operator variability and reducing the possibility of trapping air under the film during application.

[0005] Optionally, the custom cutting profile can accommodate already installed roof groove clips with a pocket design. The device quickly snaps into place using, but is not limited to, its flexible design and magnetic surface. This trimming application is not limited to roof grooves and can be used for other trim areas that do not have exposed edges. The jig and method provided offers easy application with limited operator skill, reduces safety concerns due to the lack of sharp objects, and adds repeatability since the film cut location is fixed. This solution also reduces film trim and final wet out time while reducing the skill level required by the operator.

[0006] In a first aspect, a method is provided for applying a film to a first panel of a vehicle, the first panel being connected to a second panel of the vehicle by a joint area including a groove portion recessed relative to the first panel, the method including: placing an elongated jig in the groove portion, the elongated jig including a shim extending continuously along the length of the groove portion and projecting beyond a height of the first panel, applying a film to the first and second panels such that the film extends over the elongated jig, applying pressure with a tool against the film and along the length of the shim toward a cut edge of the shim to trim the film along a periphery, removing the elongated jig from the groove portion, and adhering a periphery of the film to the groove portion.

[0007] In a second aspect, a jig is provided for applying a film to a first panel of a vehicle that is connected to a second panel of the vehicle by a joint area that includes a groove portion that is recessed relative to the first panel, the jig comprising: an elongate body having a convex bottom surface complementary to the groove portion, the elongate body having a plurality of discontinuous segments; and a shim extending continuously along the length of the elongate body, the shim having cutting edges facing away from the elongate body and having a convergent angle between 60 degrees and 120 degrees. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a perspective view of a jig for applying a film to a vehicle panel according to an exemplary embodiment. [Diagram 2] FIG. 2 is an enlarged view of the jig of FIG. [Figure 3A] 3A-3C are opposing top and bottom views of a customized component, optionally for use with the jig of FIGS. 1-2. [Figure 3B] 3A-3C are opposing top and bottom views of a customized component, optionally for use with the jig of FIGS. 1-2. [Figure 4] FIG. 4 is a longitudinal view of the jig of FIGS. 1-3 shown engaged to a vehicle panel. [Diagram 5] 5 is a distal view of an end segment of the jig of FIGS. 1-4, showing the engagement between the jig and a vehicle panel. FIG. [Figure 6] FIG. 7 is a schematic diagram illustrating the use of the tool with the jig of FIGS. 1-6 to trim a film. [Figure 7] FIG. 6 is a perspective view of the jig of FIGS. 1 to 5 used to apply a film to a vehicle panel.

[0009] Repeat use of reference characters in the specification and drawings is intended to represent the same or similar features or elements of the present disclosure. It is to be understood that those skilled in the art can devise numerous other modifications and embodiments that are within the scope and spirit of the principles of the present disclosure. The figures may not be drawn to scale. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] As used herein, the terms "preferred" and "preferably" refer to embodiments described herein that may offer certain advantages, under certain circumstances, although other embodiments may also be preferred, under the same or other circumstances.

[0011] Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.

[0012] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an element followed by "a" or "the" may include one or more of the element and equivalents thereof known to those skilled in the art. Furthermore, the term "and / or" refers to one or all of the listed elements or a combination of any two or more of the listed elements.

[0013] It should be noted that the term "comprises" and variations thereof do not have a limiting meaning when these terms appear in the accompanying description. Furthermore, "a", "an", "the", "at least one" and "one or more" are used interchangeably herein. Relative terms such as left, right, front, rear, top, bottom, side, above, below, horizontal, vertical, etc. may be used herein, where such terms are from the perspective seen in a particular drawing. However, these terms are used merely for ease of description and in no way limit the scope of the present invention.

[0014] Throughout this specification, references to "one embodiment," "a particular embodiment," "one or more embodiments," or "an embodiment" mean that a particular feature, structure, material, or characteristic described with respect to that embodiment is included in at least one embodiment of the invention. Thus, the appearances of phrases such as "in one or more embodiments," "in a particular embodiment," "in one embodiment," or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment of the invention. Where applicable, product names are written in all capital letters.

[0015] A jig according to an exemplary embodiment is shown in FIG. 1 and hereafter referred to as the numeral 100. The jig 100 has an elongated shape and is shown above an automobile roof panel 50 for size comparison. As shown, the jig 100 comprises a continuous shim 102 (or wire) extending along the length of the jig 100 and a plurality of discontinuous segments 104 coupled to the shim 102 and distributed along its length. In a preferred embodiment, the segments 104 are joined to each other only by the shim 102. However, alternatively, the segments 104 may include mechanical hinges that allow adjacent segments 104 to be coupled to each other. In general, the segments 104 can be made modular in nature to accommodate different panel sizes and shapes.

[0016] Although the provided embodiments are directed to automotive roof panels, they can be readily applied to other panels. The provided jigs and methods can be used to facilitate trimming of films near vehicle roof channels, windshields, rear windows, and moon roofs in general. These jigs and methods also need not be limited to vehicle applications, but can be adapted for use on other large assemblies where two or more outwardly facing panels come together along seams that define alignment surfaces.

[0017] The discontinuities in the segments 104 allow the relatively thin shim 102 to flex along the recessed channel 52 that defines the perimeter of the roof panel 50, even though the segments 104 themselves are relatively inflexible. The channel 52 defines the boundary of the area to which the film is applied, as will be described in more detail below. In some cases, but not necessarily in all cases, the channel 52 defines the boundary between adjacent panels.

[0018] For durability and strength, the shim 102 can be made from a metal such as steel, aluminum, nitinol, copper, or alloys thereof. Preferably, the metal is highly elastic and resists permanent deformation, for example when bent around a corner of a panel. However, the material of the shim 102 is not necessarily limited to metal, but can also be made from a flexible polymer or ceramic material. Optionally, the segments 104 are also at least somewhat flexible and made from a soft material, such as a polymer, allowing for material flexibility and potential lateral expansion or contraction along the segments 104. Such characteristics can also help the segments 104 to better conform to the groove portions 52, potentially aiding in fixation.

[0019] If the shim 102 is flexible, it may be possible for the shim 102 to stretch along its longitudinal axis to further assist in conforming the jig 100 to the boundaries of the roof panel 50. In some embodiments, the shim 102 may be formed into a continuous loop that extends along the entire perimeter of the roof panel 50. Such shims may include one or more joints that allow the segments to be reversibly attached to one another. In these embodiments, the shim itself may be segmented to allow for customization of the length of the jig 100.

[0020] To aid in adapting the jig 100 to the particular panel at hand, the segments 104 can be slidably moveable along the shim 102 to accommodate sharper bends that may be encountered near corners of the film. The shim 102 can be thinned as needed along its lateral direction to provide an appropriate degree of flexibility. In some embodiments, the jig 100 can be elastically deflected along a bend radius of up to 30 centimeters, up to 20 centimeters, or up to 10 centimeters without permanent deformation.

[0021] Segment 104 may represent any suitable portion of the overall length of jig 100, such as between 1 percent and 90 percent, between 5 percent and 80 percent, between 10 percent and 70 percent of the overall length of jig 100, or in some embodiments, less than, equal to, or greater than 1 percent, 2, 3, 4, 5, 7, 10, 20, 30, 40, 50, 60, 70, 80, or 90 percent of the overall length of jig 100.

[0022] 2 shows a close-up view of the jig 100, showing its profile along the longitudinal axis of the jig 100. In this embodiment, the shim 102 has a generally rectangular cross-sectional shape, with the cross-section defined perpendicular to the longitudinal axis of the shim 102.

[0023] The shims 102 are partially embedded in each segment 104 such that one of the narrow sides of the shims 102 faces upward (i.e., away from the vehicle panel when installed) and is fully exposed along the entire length of the jig 100. The shims 102 preferably protrude a certain amount beyond the top surface of the segments 104. As an example, at least 5 percent, at least 10 percent, or at least 15 percent of the shims 102 can protrude beyond the segments 104.

[0024] The vertical dimension of the shim 102 is much larger than its lateral dimension, thus allowing a high degree of flexibility along the lateral direction. Non-rectangular shapes are also possible, so long as the cross-section of the shim has at least one upward corner that protrudes beyond the segment 104, thereby providing a continuous cut edge for the film. In one embodiment, the upwardly facing portion of the shim 102 may have a generally "D" shaped cross-section. The cross-section of the shim 102 may or may not be uniform along its length. In some cases, the shim 102 includes one or more notches along its bottom-facing surface to facilitate bending of the shim along the plane of the roof panel 50.

[0025] Because the cross section of the shim 102 is rectangular, each of the two cutting edges that protrude beyond the segment 104 by definition has a convergent angle of 90 degrees, the convergent angle being defined as the angle at which the adjacent faces of the shim come together. In alternative embodiments, one or more cutting edges can have a convergent angle that deviates from 90 degrees. For example, a given cutting edge can have a convergent angle of 60 degrees to 120 degrees, 60 degrees to 90 degrees, 80 degrees to 90 degrees, or in some embodiments less than, equal to, or greater than 60 degrees, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, or 120 degrees. At least one cutting edge of the shim 102 preferably has a corner edge suitable for cutting a film, such as a corner radius of up to 400 micrometers, up to 200 micrometers, up to 100 micrometers, or up to 10 micrometers.

[0026] Without being limited thereto, the lateral thickness of the shim 102 may be between 100 micrometers and 400 micrometers, between 120 micrometers and 350 micrometers, between 150 micrometers and 300 micrometers, or in some embodiments may be less than, equal to, or greater than 100 micrometers, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 160, 170, 180, 190, 200, 220, 240, 250, 260, 280, 300, 320, 340, 350, 360, 380, or 400 micrometers. Additionally, the cross-sectional aspect ratio (i.e., height / width) of the shim 102 may be between 15 and 127, between 20 and 80, between 40 and 60, or in some embodiments may be less than, equal to, or greater than 15, 17, 20, 22, 25, 27, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, or 127.

[0027] 3A and 3B show opposing bottom and top surfaces of a customized segment 106 that can be optionally used in combination with the shim 102. The customized segment 106 includes a pocket 108 that provides space to accommodate any obstructions in the groove portion 52 that would normally interfere with a segment such as the roof groove clip 54 shown in FIG. 3A. FIG. 3B shows the upwardly facing major surface of the customized segment 106, showing a groove 110 for seating a shim (not shown in FIGS. 3A and 3B). The use of the customized segment 106 can also be advantageous in guiding the shim 102 along particularly sharp bends, such as along corners of a vehicle panel. Although not shown here, it is possible for the customized segment 106 to have a configuration that is mechanically attached to the clip 54 to provide a reference point for positioning the jig 100 relative to the roof panel 50.

[0028] 4 illustrates in more detail the engagement between the jig 100, including the shim 102 and the segment 104, and the groove portion 52 of the roof panel 50. Although not explicitly illustrated, the groove portion may extend along the boundary between two adjacent vehicle panels, such as between a roof panel and a side panel of the vehicle. In these cases, the groove portion preferably includes a surface that is recessed relative to both panels. The groove portion 52 includes both concave and convex surface areas, represented by a double radius, as illustrated. These surface areas may be complementary to the mating surfaces of the segment 104.

[0029] Optionally, as further shown in FIG. 5, the mating surfaces extend along at least two adjacent faces of each segment 104. These adjacent faces are generally the bottom and side faces of the segment 104. The mating engagement between the segments 104 and the groove portions 52 can significantly improve alignment between the jig 100 and the roof panel 50. This, in turn, can provide greater precision in the cut lines obtained using the jig 100 as compared to cut lines obtained by conventional methods.

[0030] Advantageously, each segment 104 includes an angled shelf 51 disposed between the shim 102 and the roof panel 50. After the film is cut, the angled shelf 51 can help reduce tenting on the edges of the film by allowing successive geometric radii to be wetted out in the proper sequence, thereby reducing the possibility of trapping air under the film during application. By providing a more consistent transfer of adhesive-backed film from the segment 104 to the roof panel 50, the angled shelf 51 can help limit variability in the quality of the film application due to differences in operator technique.

[0031] 6 shows a schematic diagram illustrating the process of using a jig 100 to cut a film disposed on a roof panel 50. In this process, the jig 100 is placed in the groove portion 52 of the roof panel 50, as described above. When the jig 100 is properly seated, the upwardly facing surface of the shim 102 should protrude beyond the height of the roof panel 50. In some embodiments, the jig 100 extends continuously along some or all of the length of the groove portion 52. Although not required, it is possible to secure the jig 100 to the groove portion 52 using tape or a temporary adhesive, which is subsequently removed.

[0032] Next, the film 120 is placed over both the roof panel 50 and the jig 100. It is common for the film 120 to be an adhesive backed film, in which case the film 120 can be adhesively bonded to the roof panel 50 during such placement. Optionally, the film 120 extends across the entire roof panel 50, but this need not be required. The tool 122 can then be pressed against the film 120 and translated along the shim 102, applying pressure to compress the film 120 between the tool 122 and the shim 102 and cut the film along the cut edge of the shim 102. The tool 122 is typically pressed against the film 120 manually by a human operator, although this action can also be performed in an automated manner, such as using a robotic arm controlled by a computer. If a computer is used, the jig 100 can be detected using fiducial markers on the jig 100 that assist in identifying its location. This cutting step may occur along a continuous loop around the perimeter of the roof panel 50 defined by the groove portion 52. It is also possible that the groove portion 52 extends along only a portion of the perimeter of the roof panel 50, in which case multiple cutting steps may be required to separate the portion of the film 120 disposed on the roof panel 50 from the portion of the film 120 that extends beyond the roof panel 50.

[0033] Optionally, and as shown, the tool 122 has a recess 124 having a shape complementary to the shape of the cutting edge of the shim 102. This can help prevent slippage and ensure that pressure is directed to the proper portion of the film to obtain a cleaner cut line. To facilitate cutting, the tool 122 is generally made from a material that is slightly flexible relative to the material of the shim 102. Such a material can be an engineering polymer such as polyoxymethylene offered under the trade name DELRIN by Dupont de Nemours, Inc. (Wilmington, Del.). In a preferred embodiment, the tool can have an engagement surface with a Shore D hardness of up to 70D.

[0034] A significant technical advantage of the present technology is that the cutting edge of the shim 102 does not act like a sharp blade in the traditional sense. In various embodiments, it has a 90 degree edge that uses a scissoring action or compression-based mechanism to cut the film 120, making the operation safer for a human operator. In some embodiments, depending on the composition of the film being trimmed, the shim 102 can be preheated to facilitate cutting the film.

[0035] Further improvements are possible with respect to the shim 102. For example, the shim 102 may be retained within a carrier (such as segment 104) until the jig 100 is placed within the groove portion 52 of the roof panel 50. The shim 102 can then be slidably biased out of the carrier when the jig 100 is fully seated within the groove portion 52. An advantage of this configuration is that it can help avoid scratching any painted surface on the roof panel 50 while the jig 100 is being applied.

[0036] After the film 120 has been completely trimmed using the steps above, the jig can be removed from the groove portion 52 of the roof panel 50. The remaining edge portion of the newly trimmed film 120 on the roof panel 50 can then be glued, if desired, to the portion of the groove portion 52 where the jig 100 left off. The excess portion of the film 120, sometimes referred to as the "weed" portion, can then be discarded or reused.

[0037] Working Example The objects and advantages of the present disclosure are further illustrated by the following non-limiting examples, in which the specific materials and configurations thereof, as well as other conditions and details, are not to be construed as unduly limiting the present disclosure.

[0038] The jig shown in Figures 2 and 4-7 was inserted into the roof groove of a Toyota Corolla vehicle. A full length strip of 3M Paint Protection Film PUL2008 obtained from 3M Company, St. Paul, MN, was placed over the roof groove (including the jig) and adhered to the first and second panels of the vehicle roof. The release liner was removed from the PUL2008 film before the film was applied to the panels. A polyoxymethylene plastic block with a recess (obtained under the trade name DELRIN from DUPONT, Wilmington, DE) was then used to press the film against the shim of the jig that cut the film. The height of the recess was equal to the height of the exposed shim embedded in the jig. The width of the recess was designed to be no more than 5 times the width of the shim.

[0039] All documents, patent documents or patent applications cited in the above patent application on Letters Patent are incorporated herein by reference in their entirety in a consistent manner. In the event of any inconsistency or discrepancy between any of the incorporated references and this application, the information in the foregoing description shall prevail. The foregoing description is intended to enable a person skilled in the art to practice the disclosure as set forth in the claims, and should not be construed as limiting the scope of the present disclosure, which is defined by the claims and all equivalents thereof.

Claims

1. 1. A method of applying a film to a first panel of a vehicle, the first panel being connected to a second panel of the vehicle by a bonding area including a groove portion that is recessed relative to the first panel, the method comprising: placing an elongated jig in the groove portion, the shim extending continuously along the length of the groove portion, the shim protruding beyond a height of the first panel; applying the film to the first and second panels such that the film extends over the elongated jig; applying pressure with a tool against the film and along the length of the shim toward a cut edge of the shim to trim the film along a periphery; removing the elongated jig from the groove portion; Adhering the peripheral portion of the film to the groove portion; A method comprising:

2. The method of claim 1 , wherein the cutting edge is directed away from the vehicle.

3. The method of claim 1 , wherein the cutting edges of the shim have a convergent angle of between 80 degrees and 90 degrees.

4. The method of claim 1 , wherein the shim has a generally rectangular cross-section, the cross-section being defined perpendicular to a longitudinal axis of the shim.

5. The method of claim 1 , wherein the cutting edge has a radius of between 10 micrometers and 400 micrometers.

6. The method of claim 1 , wherein the shim is metal.

7. The method of claim 1 , wherein the elongated jig further comprises a plurality of discontinuous segments coupled to the shim.

8. The method of claim 7 , wherein the discontinuous segments represent up to 50 percent of the overall length of the elongated jig.

9. The method of claim 1 , wherein the elongated jig is capable of being elastically deflected along a bend radius of up to 10 centimeters without permanent deformation.

10. 1. A jig for applying a film to a first panel of a vehicle, the first panel being connected to a second panel of the vehicle by a bonding area including a groove portion recessed relative to the first panel, an elongate body having a convex bottom surface complementary to said groove portion, said elongate body having a plurality of discontinuous segments; a shim extending continuously along the length of the elongate body, the shim having cutting edges facing away from the elongate body and having a converging angle between 60 degrees and 120 degrees; Equipped with a jig.

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