Thin film coating and application method on corners

Abstract

A method of applying a paint film onto a substrate may include adhering a corner patch onto at least a portion of a corner of the substrate, and adhering the paint film sheet onto the substrate such that the corner is within a corner relief pattern of the paint film sheet. The corner relief pattern may correspond to a recess along an edge of the paint film sheet. The paint film sheet may partially overlap and interface with the corner patch, thereby providing a continuous paint film over at least the corner of the substrate. Also provided is a decorative paint film configured for adhesion onto an exterior panel of a motor vehicle.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 191,862, filed May 21, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] Incorporation by Reference All publications and patent applications mentioned in this specification are herein incorporated by reference in their entirety to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference. [Background technology]

[0003] In recent years, paint films have gained popularity as an alternative to traditional surface painting methods in many different types of applications, particularly in motorized vehicles such as automobiles, airplanes, and boats. This popularity is at least in part a result of paint films being more durable and long-lasting compared to traditional paints.

[0004] One exemplary paint film is Aero Satin Clean 200 film, a transparent film used to modify the surface of a vehicle. These films and methods of manufacture are described in U.S. Patent Publication No. 2019 / 0161646, which is incorporated herein by reference in its entirety.

[0005] Generally, the application of a paint film involves covering a substrate with a thin sheet of material, adhering the thin sheet of material to the surface of the substrate to form a protective coating. Certain geometries of substrates, such as sharp corners and edges, can be difficult to cover in a manner that provides a coating with a smooth and consistent appearance. This is due, in part, to the planar geometry of the paint film compared to the three-dimensional nature of the corners and edges of the substrate.

[0006] As an example, FIG. 10 illustrates a paint film sheet 600 on a corner portion of a substrate. The paint film sheet 600 includes a simple relief cut 601 to accommodate a corner tip 604 of the substrate. This is of the type typically used when installing a paint film over the corner of a car hood portion or similar automotive body panel. As shown, the simple relief cut 601 is a straight cut straight across from one side of the corner to the other. Note that the exposed substrate / underlying hood color is easily visible, detracting from the aesthetic appearance of the paint film. Even if the relief cut 601 is positioned as close as possible toward the corner tip 604, at least a portion of the corner tip 604 remains exposed as shown, and the corner tip 604 is not protected from the elements. Adjusting the position of the paint film sheet 600 so that the relief cut 601 is further toward the corner tip 604 may cause the paint film sheet 600 to bunch or wrinkle, resulting in a decoratively unacceptable coating at the corner tip 604. Another option may be to pull the paint film sheet 600 toward the apex of the corner tip 604 so that the paint film sheet 600 deforms to cover the corner tip 604. However, this may thin the paint film sheet 600 in the area of ​​the corner tip 604, creating a high stress point and potential failure point of the paint film sheet 600 at the corner tip 604.

[0007] It would be beneficial to have a paint film and method that can minimize decorative and functional defects in corners and other topological features of a substrate surface. Summary of the Invention

[0008] Described herein is an improved method of applying a paint film to a substrate, particularly over corners or other high aspect ratio shapes of a substrate.

[0009] Generally, in one embodiment, a method of applying a paint film onto a substrate includes forming a relief pattern cut along an edge of a paint film sheet to accommodate a corner or other surface feature of the substrate, applying a patch made of the same material as the paint film over the corner or surface feature of the substrate, and applying the paint film onto the substrate such that the paint film overlaps and is in sufficiently intimate contact with the patch to join with the patch, thereby providing a continuous paint film over the corner or surface feature. At least one of the paint film and the patch is nominally very thin, such that the overlap between the two films is not visible to the naked eye.

[0010] As used herein, a "corner" of a substrate may refer to a location or area of ​​the substrate where two or more surfaces of the substrate intersect. The angle at which at least two of the surfaces intersect may define the angle of the corner. The paint films and methods described herein may be used to provide a protective paint coating on corners having any angle. For example, the corner may be an acute angle (less than 90 degrees), a right angle (90 degrees), an obtuse angle (greater than 90 degrees), or a reflex angle (greater than 180 degrees).

[0011] The paint films and methods described herein can be used to provide protective coatings to shapes other than corners. For example, a substrate may include protrusions or recesses that would be difficult to cover with a paint film in a manner that would result in a smooth, continuous, and attractive coating. Paint film application techniques can be used to provide a smooth, continuous, and attractive coating over such difficult to coat protrusions or recesses.

[0012] According to some embodiments, a method of applying a paint film onto a substrate is described, the method including adhering a corner patch onto at least a portion of a corner of the substrate, and adhering the paint film sheet onto the substrate such that the corner is within a corner relief pattern of the paint film sheet, the corner relief pattern corresponding to a recess along an edge of the paint film sheet, the paint film sheet partially overlapping and joining the corner patch, thereby providing a continuous paint film onto at least the corner of the substrate. The corner patch can be a paint film made from the same material as the paint film sheet. The corner patch can have a first thickness and the paint film can have a second thickness, the first thickness being less than the second thickness. The ratio of the first thickness to the second thickness can be in the range of 1:4 to 3:4. The first thickness can be in the range of 100 to 500 microns and the second thickness can be in the range of 50 to 200 microns. Adhering the paint film sheet onto the substrate may include applying pressure along a surface of the paint film sheet with a tool having a flat edge to smooth out trapped air bubbles between the paint film sheet and the substrate. The paint film sheet may be bonded to the corner patch by intimately contacting the paint film sheet with the corner patch. Adhering the paint film sheet onto the substrate may include exposing the paint film sheet to heat. Exposing the paint film sheet to heat may bond the paint film sheet with the corner patch. The color of the corner patch may match the color of the paint film sheet within an engineering vehicle exterior paint color matching standard. The engineering vehicle exterior paint color matching standard may be based on a visual evaluation at 3 feet or higher. The corner patch may be bonded onto the corner of the substrate prior to adhering the paint film sheet. The paint film sheet may be bonded onto the corner of the substrate prior to adhering the corner patch. The method may further include forming a corner patch in the paint film based on the measured dimensions of the corner of the substrate.

[0013] According to some embodiments, a decorative paint film adhered onto an exterior panel of a motor vehicle is described, the decorative paint film including a corner patch adhered onto a corner of the exterior panel of the motor vehicle, and a paint film sheet adhered onto a portion of the exterior panel adjacent the corner, the paint film sheet having a corner relief pattern corresponding to a recess along an edge of the paint film sheet, the paint film sheet being positioned such that at least a portion of the corner is within the corner relief pattern, the paint film sheet overlapping and interfacing with the corner patch to provide a continuous paint film over at least the corner of the exterior panel. The exterior panel can be a hood, spoiler, door, or bumper of a passenger vehicle. The motor vehicle can be a car, truck, airplane, or boat. The corner patch can have a first thickness, and the paint film sheet can have a second thickness, the first thickness can be less than the second thickness. A ratio of the first thickness to the second thickness is in a range of 1:4 to 3:4. The first thickness may be in the range of 100 to 500 microns and the second thickness may be in the range of 50 to 200 microns. The color of the corner patch may match the color of the paint film sheet within an engineering vehicle exterior paint color match standard. The engineering vehicle exterior paint color match standard may be based on visual evaluation at 3 feet or higher.

[0014] These and other aspects and advantages are described herein.

[0015] The novel features of the embodiments described herein are set forth with particularity in the appended claims. A better understanding of the features and advantages of the embodiments may be obtained by reference to the following detailed description, which sets forth illustrative embodiments and the accompanying drawings. [Brief description of the drawings]

[0016] [Figure 1] 1 illustrates a cross-sectional view of an exemplary paint film. [Figure 2A]1 illustrates a top view of a portion of an exemplary paint film sheet having a corner relief pattern; [Figure 2B] 1 illustrates a top view of a portion of an exemplary paint film sheet having a corner relief pattern, and FIG shows a close-up view of the corner relief pattern. [Figure 2C] 2C illustrates a cross-sectional view of a portion of an exemplary substrate coated with the paint film of FIGS. 2A and 2B, showing an edge of the substrate coated with a flap portion of the paint film. [Figure 2D] 2C illustrates a cross-sectional view of a portion of an exemplary substrate coated with the paint film of Figures 2A and 2B, showing a corner of the substrate partially covered with a protruding portion of the corner relief pattern of the paint film. [Figure 3A] 1 illustrates various views of another paint film sheet and a corner patch on a substrate. FIG 1 shows a paint film sheet positioned on a substrate such that the corner relief pattern is aligned with a corner of the substrate. [Figure 3B] 1 illustrates various views of another paint film sheet and a corner patch on a substrate. FIG 1 shows a corner patch adhered onto a corner of a substrate. [Figure 3C] 1 illustrates various views of another paint film sheet and a corner patch on a substrate. FIG 1 shows a paint film sheet adhered onto a substrate and joined with a corner patch. [Figure 4A] 1 illustrates another exemplary paint film sheet and corner patch. 1 shows the corner patch adhered to a corner. [Figure 4B] 1 illustrates another exemplary paint film sheet and corner patch.

[0023] FIG. 1 shows a paint film sheet adhered to a substrate and joined with a corner patch. [Diagram 5] 1 illustrates a flow chart showing an exemplary method of applying a paint film onto a substrate having corners. [Figure 6] 1 illustrates a top view of a corner patch of an exemplary paint film. [Figure 7]7 illustrates a top view of the corner patch of FIG. 6 when used in conjunction with the exemplary paint film sheet of FIG. 2B on a corner of a substrate. [Figure 8A] 1 illustrates a top view of a corner patch of an exemplary paint film, highlighting a narrow area of ​​the corner patch. [Figure 8B] 8B illustrates a side cross-sectional view of a narrow area of ​​the corner patch of FIG. 8A wrapped around a corner edge of a substrate. [Figure 9A] 1 illustrates a top view of a corner patch of an exemplary paint film, highlighting the large area of ​​the corner patch. [Figure 9B] 9B illustrates a side cross-sectional view of a wide area of ​​the corner patch of FIG. 9A wrapped around a corner edge of a substrate. [Figure 10] Illustrates an exemplary paint film having a simple relief cut of the type typically used when installing a paint film over the corners of a passenger vehicle hood. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] Described herein is an improved method of applying paint films to substrates, particularly over sharp corners and other protruding surface features of substrates. The method may be well suited for applying paint films to decorative surfaces of motorized vehicles such as automobiles, airplanes, and boats. The disclosed paint film method may advantageously provide a smooth and continuous coating with improved decorative and protective qualities compared to paint films formed using conventional techniques.

[0018] The paint films described herein may be made of polymeric materials and may be manufactured as thin sheets. In some cases, the paint films may include one or more adhesive layers. FIG. 1 illustrates an exemplary paint film 101 on a surface 102 (e.g., the surface of a motorized vehicle). The paint film 101 includes a polymer film layer 108 and an adhesive layer 106. The paint film 101 may be a polymer laminate. In one embodiment, the polymer film layer 108 may be a polyurethane or a polyacrylate. For example, the polymer film layer 108 may be a polymer containing urethane (also known as carbamate) linkages, urea linkages, or a combination thereof (i.e., in the case of poly(urethane-urea)). Thus, the polymer film layer 108 may contain at least urethane linkages, urea linkages, or a combination thereof. In some embodiments, the polymer film layer 108 may have a polymer backbone with at least 40%, at least 60%, or at least 80% urethane and / or urea repeating linkages formed in situ during the polymerization process. The adhesive layer 106 may include a pressure-sensitive adhesive. In some embodiments, the pressure-sensitive adhesive may include (meth)acrylates (i.e., acrylates and methacrylates). For example, the pressure-sensitive adhesive may include 2-ethylhexyl acrylate, vinyl acetate, and acrylic acid monomers polymerized and crosslinked with conventional aluminum or melamine crosslinkers. In some embodiments, the adhesive layer 106 may include synthetic and natural rubber, polybutadiene and its copolymers, polyisoprene and its copolymers, and / or silicones (e.g., polydimethylsiloxane and polymethylphenylsiloxane). In some embodiments, the paint film 101 may additionally include a pigmented base coat. Additional exemplary paint film configurations are described in U.S. Patent Publication No. 2019 / 0161646, entitled "Paint Film Appliques with Reduced Defects, Articles and Methods," which is incorporated herein by reference in its entirety.

[0019] The method of applying the paint film described herein may include positioning the paint film (e.g., paint film 101) on the surface of the substrate such that the adhesive layer adheres thereto. In some cases, a fluid layer (e.g., water) may be provided between the paint film and the substrate during manufacture to aid in positioning and air removal prior to adhesion of the paint film sheet onto the substrate. In other cases, the paint film may be applied in a dry application process.

[0020] The methods described herein may advantageously allow for the installation of paint films with improved decorative and protective qualities. According to some aspects, the methods described herein involve forming a corner relief pattern in the paint film that is shaped to accommodate the corner tip and designed to bond with a corner patch. The corner patch may be a strip of film made from the same material as the paint film. The paint film and the corner patch may be made from materials configured to bond with each other when brought into intimate contact with each other. When bonded together, the paint film and the corner patch may cooperate to form a protective and aesthetically pleasing coating on the corner of the substrate.

[0021] FIG. 2A illustrates a plan view of a portion of an exemplary paint film sheet 200 having a corner relief cut pattern 202. FIG. 2B illustrates a close-up view of the corner relief cut pattern 202. The dotted lines 209 indicate where the edges of the underside surface of the substrate are, including the corners 204 of the substrate. The paint film sheet 200 can be cut according to the dimensions of the corners 204 of the substrate. The paint films herein can be configured to cover corners 204 having any angle, for example, acute angles (less than 90 degrees), right angles (90 degrees), obtuse angles (greater than 90 degrees), or reflex angles (greater than 180 degrees). The paint films herein can also be configured to cover corners 204 having any thickness. For stamped metal panels, the thickness of the panel typically depends on the thickness of the sheet metal and how tightly the edges are folded. It can be any thickness, but is often about 0.5 mm to about 20 mm.

[0022] In the example shown, the paint film sheet 200 includes a main section 210, a first flap section 212, and a second flap section 214. The main section 210 can be configured to cover a first surface of a substrate, the second section 212 can be configured to cover a second surface of the substrate, and the third section 214 can be configured to cover a third surface of the substrate. For example, the main section 210 can be configured to cover a top surface of the substrate, and the first 212 and second 214 flap sections can be configured to fold over an edge surface of the substrate adjacent the corner 204.

[0023] The corner relief pattern 202 may correspond to a recess cut along an edge of the paint film 202. The corner relief pattern 202 may have a shape that is configured to cover at least a portion of a corner 204 of the substrate. In this case, the corner relief pattern 202 includes a protruding portion 216 between a first flap edge 218 and a second flap edge 220 of the paint film 200. The protruding portion 216 may protrude outward relative to the first 218 and second 220 flap edges. The first 218 and second 220 flap edges may be set back from the adjacent panel edge 209 as shown, allowing the protruding portion 216 to have an included angle that is greater than the angle of the panel corner 204. In some embodiments, the set back is less than the length of the protruding portion 216 (from the substrate corner 204 and the edge of the protruding portion 216). The shape of protruding portion 216 and the extent to which protruding portion 216 protrudes (e.g., height) may depend on the geometry of the corner tip. For example, protruding portion 216 may be narrower and / or protrude farther when configured to cover a sharper corner compared to a shallower corner.

[0024] In some cases, the protruding portion 216 may have a curved outer edge, as shown in the example of Figures 2A and 2B. This may allow for a smoother, less noticeable blend of the paint film when joined with a corresponding corner patch, as described herein. In other examples, the protruding portion 216 may have a differently shaped outer edge. For example, the protruding portion 216 may include a pointed outer edge.

[0025] The corner relief pattern 202 may be formed in the paint film sheet 200 prior to adhering the paint film sheet 200 over the corners of a substrate. In some cases, the corner relief pattern 202 is formed by cutting the paint film sheet 200. In other cases, the paint film sheet 200 is manufactured with the corner relief pattern 202 formed therein.

[0026] The dimensions of the corner relief cut pattern 202 can vary depending on the corner geometry of the substrate. For example, the length L of the flap section 212 or 214 f (from the substrate edge 209 and the edge of the flap section 212 or 214), as well as the length of the protruding portion 216 (from the substrate corner 204 and the edge of the protruding portion 216) can depend on the thickness of the substrate and whether the substrate edge has a curvature.

[0027] FIG. 2C illustrates an enlarged cross-sectional view of an edge of an exemplary substrate covered with flap section 212 or 214 of paint film sheet 200. s can vary. However, the edge of a typical automobile body panel has a thickness in the range of about 4 mm to 10 mm. In this case, the edge of the substrate has a curved cross-section having a hemispherical cross-section. In some examples, the length L of the flap section 212 or 214 is f is (1 / 2)(π)T s FIG. 2D illustrates an enlarged cross-sectional view of a corner of a substrate covered with a protruding portion 216 of a paint film sheet 200. The length L of the protruding portion 216 may be 1 / 2 mm. p is the length L of the flap section 212 or 214f In some examples, the length L of the protruding portion 216 may be less than 100 mm. p is (1 / 8)(π)T s It could be.

[0028] 3A-3C illustrate an exemplary paint film sheet 300 having a corner relief pattern 302 similar to paint film sheet 200 applied to a corner of a substrate having a corner patch. In this example, the substrate is a passenger vehicle hood. FIG. 3A shows paint film sheet 300 positioned on a corner of the substrate showing corner relief pattern 302 aligned on corner apex 304. Note that FIG. 3A shows paint film sheet 300 on substrate for illustrative purposes. In practice, paint film sheet 300 may not be applied on substrate until after corner patch has been applied to substrate.

[0029] As shown in FIG. 3A , the main section 310 of the paint film sheet 300 can be configured to cover a main surface 350 (e.g., an outer surface) of the substrate, the first flap section 312 can be configured to bend around a first edge surface 352 of the substrate, and the second flap section 314 can be configured to bend around a second edge surface 354 of the substrate. The protruding portion 316 of the corner relief cut pattern 302 can be configured to extend beyond the main surface 350 of the substrate and over at least a portion of the corner tips 304 without deforming the paint film sheet 300. For example, a user may not need to substantially deform the paint film sheet 300 over the corner tips 304, thereby reducing the opportunity to thin the paint film sheet 300.

[0030] The thickness of the paint film sheet 300 may vary depending on the characteristics of the paint film sheet 300 (e.g., type of material, color, and / or opacity) and / or the surface of the substrate. For example, a lighter colored paint film sheet 300 may need to be thicker than a darker colored paint film sheet 300, especially if the lower surface of the substrate is dark in color. In some examples, the paint film sheet 300 has a thickness ranging between any two of the following values: 100 micrometers (microns), 150 microns, 200 microns, 250 microns, 300 microns, 350 microns, 400 microns, 450 microns, and 500 microns.

[0031] 3B shows the substrate after a corner patch 330 has been applied to the corner tip 304 of the substrate without the paint film sheet 300. The corner patch 330 can be a strip of polymer film and adhesive, similar to the paint film sheet 300. In some cases, the corner patch 330 can be made of the same material and / or have the same color as the paint film sheet 300. The thickness of the corner patch can vary depending on the characteristics of the corner patch 330 (e.g., type of material, color, and / or opacity) and / or the characteristics of the substrate. In some examples, the corner patch 330 has a thickness ranging between any two of the following values: 50 microns, 60 microns, 70 microns, 80 microns, 90 microns, 100 microns, 150 microns, and 200 microns.

[0032] The corner patch 330 may be applied onto the substrate using any of a variety of techniques. In some cases, the corner patch 330 is simply applied onto the corner tip 304 and pressure is applied to adhere the corner patch 330 and conform to the shape of the corner tip 304. In some cases, a fluid layer (e.g., water) may be provided between the paint film sheet 300 and the substrate to help with positioning and air removal prior to adhesion of the paint film sheet 300 to the substrate. In other cases, the paint film sheet 300 may be applied in a dry application process (i.e., substantially without a fluid layer).

[0033] FIG. 3C shows the substrate after the paint film sheet 300 has been adhered onto the substrate and combined with the corner patch 330. During the adhesion process, heat may be applied to the paint film sheet 300 to allow the paint film sheet 300 to bond with the substrate and the corner patch 330, thereby creating a conformal coating on at least the corner tip 304 of the substrate. The heat may soften the polymeric material of the paint film sheet 300, reducing the force required to stretch the paint film sheet 300. Thus, the elevated temperature may allow for improved conformability of the paint film sheet 300, allowing the paint film sheet 300 to come into intimate contact with the substrate and the corner patch 330. Heating may also improve bonding of the paint film sheet 300 by allowing the adhesive of the paint film sheet 300 to "wet" the surface of the substrate (and the corner patch 330). In this context, "wetting out" may refer to the adhesive flowing and coating the substrate (and corner patch 330) to maximize the contact area and the attractive forces between the adhesive and the substrate (and corner patch 330). In some cases, a fluid (e.g., water) may be used to help the adhesive "wet out" the substrate surface, which may allow for intimate contact between the adhesive and the substrate without entrapping air. Entrapped air may prevent or reduce adhesion in the affected areas and may result in decoratively unattractive air bubbles. When the paint film sheet 300 is laminated, most (if not all) of the fluid may be evacuated from between the adhesive and the substrate. An extremely thin layer of fluid may be quickly absorbed by the paint film sheet 300 and delivered to the environment as water vapor. Because the adhesive may be in full contact with the substrate, it may be fully wetted out. Virtually any elevated temperature may allow for increased compatibility and adhesion, but it is preferred to stay below the melting point of any individual layers and / or materials of the paint film sheet 300 and / or corner patch 330, such as the adhesive. For example, it may be preferable to heat the paint film sheet 300 and / or the corner patch 330 to about 70% or less of the melting point of either the paint film sheet 300 and / or the corner patch 330 materials.

[0034] It should be noted that in some cases, the paint film sheet 300 may be applied before the corner patch 330. Heating the paint film sheet 300 and / or the corner patch 330 may similarly bond the two together to create a conformal coating on at least the corner tip 304 of the substrate. However, this configuration may be less desirable depending on the dimensions of the paint film sheet and the corner patch. For example, if the corner patch 330 is applied underneath the paint film sheet 300, a majority of the corner patch 330, including the edges of the corner patch 330, may be covered by the paint film sheet 300, making the corner patch 330 less noticeable. If the corner patch 330 is applied over the paint film sheet 300, a majority of the corner patch 330, including the edges of the corner patch 330, may be exposed, making the corner patch 330 more noticeable.

[0035] As shown, the material of the paint film sheet 300 blends with the material of the corner patch 330 to form a smooth and continuous coating on the substrate. For example, the shape of the cutout of the corner relief cut pattern 302, including the protruding portion 316, may no longer be visually apparent from a certain distance (e.g., at least 3 feet away). Because the paint film sheet 300 was not substantially thinned in the area around the corner tip 304, the result is a robust protective paint film around the corner 304 of the substrate. In some cases, the color of the corner patch 330 and the paint film sheet 300 are substantially the same, resulting in a visually continuous display of color around the corner tip 304.

[0036] In some cases, the thickness of the corner patch 330 relative to the thickness of the paint film sheet 300 may play a role in the appearance and / or tactile quality of the paint film around the corner tip 304. For example, in some cases, it may be beneficial for the corner patch 330 to have a thickness equal to or less than the thickness of the paint film sheet 300 since the two will overlap to some extent. In some cases, it may be preferable for the corner patch 330 to be thinner than the paint film sheet 300. Having a corner patch 330 that is too thick may make the overlap between the paint film sheet 300 and the corner patch 330 visually apparent and / or tactilely thick. However, a corner patch 330 that is too thin may change the visual characteristics of the corner patch 330, such as reducing the opacity of the corner patch 330, causing undesirable visual differences between the corner patch 330 and the paint film sheet 300. Additionally, a very thin corner 330 patch may be difficult for a user to handle during the gluing process. In some examples, the ratio of the thickness of the corner patch 330 to the thickness of the paint film sheet 300 ranges between any two of the following values: 1:4, 1:3, 1:2, 2:3, 3:4, and 1:1.

[0037] The resulting paint film may have decorative properties according to one or more engineering standards. One such engineering standard is the Jaguar Land Rover Limited Technical Standard (STJLR.01.5026) "Exterior Paint: Cosmetic Appearance", which defines the following criteria for parts of the exterior paint of motor vehicles: Class "A" - High visibility parts, Class "B" - Low visibility parts, and Class "C" - Non-visible parts. In some embodiments, the applied paint film described herein meets one or more criteria of Class "A" of such standards. For example, visual Class "A" color match criteria (also referred to as "4" or "5" rated color match) are as follows: "5" rating - no discernible color difference between master and sample when placed edge to edge), or "4" rating - negligible difference when viewed edge to edge and no discernible difference when viewed with a 3 mm gap. Under such criteria, in some embodiments, the applied paint film sheet 300 and corner patch 330 meet the visual class "A" criteria for color match. In some cases, the color match criteria are based on whether there is a discernible difference at least three feet away.

[0038] 4A and 4B illustrate another substrate 410 having a corner covered with another exemplary paint film. As shown in FIG. 4A, the substrate 410 includes an edge having a corner 404. A corner patch 430 having a size and shape to cover at least a portion of the corner 404 is adhered onto the substrate 410. In this case, the corner patch 430 has a rectangular shape. FIG. 4B shows a paint film sheet 400 being applied onto the substrate 410. The paint film sheet 400 has a corner relief pattern 402 sized and shaped to overlap the corner patch 430. In this case, the corner relief pattern 402 has a rectangular shape that matches the rectangular shaped corner patch 430. Once applied onto the substrate 410, heat can be applied to the paint film sheet 400 and the corner patch 430 to bond the two together.

[0039] FIG. 5 is a flow chart illustrating an exemplary method of applying a paint film onto a substrate having corners. At 500, a corner relief pattern is formed in a paint film sheet to accommodate a corner of the substrate. In some cases, the corner relief pattern may correspond to a recessed portion along an edge of the paint film sheet. The corner relief pattern may be cut into the film. The corner relief pattern may enable the paint film sheet to cover at least a portion of a corner, such as a tip (e.g., an apex) of the corner. In some cases, the corner relief pattern may be cut into the paint film sheet by a user (e.g., as part of the paint film application process).

[0040] In other cases, the paint film sheet may include a corner relief pattern already formed therein. Such preformed corner relief patterns may be created during the manufacturing process. In such cases, the paint film may be precut into a shape that matches the dimensions of the substrate (e.g., an automobile panel). Because the dimensions (e.g., angles) at the corners of the precut paint sheet are known, the corner relief pattern may be cut into the paint sheet based on the known dimensions. Corner patches may be cut at the same time the corner relief pattern has dimensions sufficient to cover a portion of the substrate that is not covered.

[0041] At 502, a corner patch is formed having a size and shape configured to cover at least a portion of the corner. The corner patch may be made from a paint film. In some cases, the corner patch may be made from the same material as the paint film sheet. In some cases, the thickness of the corner patch may be less than the thickness of the paint film sheet.

[0042] At 504, the corner patch is adhered to the corner of the substrate. This may involve positioning the corner patch paint film over the corner and applying even pressure on the top surface of the corner patch paint film until the corner patch paint film is decoratively smooth and free of underlying air bubbles. In some cases, heat may be applied to the corner patch.

[0043] At 506, the paint film sheet is adhered to the substrate. This may involve applying even pressure on the top surface of the paint film sheet until the paint film sheet is decoratively smooth and free of any underlying air bubbles. The corner relief pattern of the paint film sheet may be aligned to overlap the corner patch on the corner. The paint film sheet may be placed in intimate contact with the corner patch to bond them together. In some cases, heat is applied to the paint film sheet and / or the corner patch to help bond the paint film sheet and corner patch together where they overlap. The resulting paint film may be smooth and continuous on the corner. In some cases, the paint film sheet and corner patch are sufficient color match that when applied onto the substrate, there is no discernible color difference between the paint film sheet and the corner patch (e.g., more than 3 feet apart).

[0044] Note that in some cases, the paint film sheet may be applied (506) prior to applying the corner patch (502). Heating the paint film sheet and / or the corner patch may also aid in bonding the two together to create a conformal coating on at least the corner tip 304 of the substrate.

[0045] 6 illustrates a plan view of an exemplary paint film corner patch 620. As shown, the corner patch 620 is generally a dogbone formed with a narrow region 622 spanning between two wider regions 624. In some embodiments, the overall length of the corner patch 622 is approximately 2π×L. p and about 3πxL p Between L p is the length of the protruding portion 216, as shown in FIG. 2B.

[0046] 7 illustrates a top view of a corner patch 622 when used in conjunction with a painted film sheet 210 on the corners of a substrate. In some embodiments, the film sheet 210 overlaps each end of the corner patch 622 by between about 10% and about 40% of the patch 622.

[0047] Figure 8A illustrates a top view of a corner patch 620, highlighting the narrow region 622 of the corner patch. Figure 8B illustrates a side cross-sectional view of the narrow region 622 wrapped around the corner edge of a substrate.

[0048] Figure 9A illustrates a top view of corner patch 620, highlighting the wide area 624 of the corner patch. Figure 9B illustrates a side cross-sectional view of the wide area 624 wrapped around the corner edge of a substrate.

[0049] In this specification, when a shape or element is referred to as being "on" another shape or element, it may be directly on the other shape or element, or there may be intervening shapes and / or elements. In contrast, when a shape or element is referred to as being "directly on" another shape or element, there are no intervening shapes or elements. When a shape or element is referred to as being "connected," "attached," or "coupled" to another shape or element, it will also be understood that it may be directly connected, attached, or coupled to the other shape or element, or there may be intervening shapes or elements. In contrast, when a shape or element is referred to as being "directly connected," "directly attached," or "directly coupled" to another shape or element, there are no intervening shapes or elements. Although described or illustrated with respect to one embodiment, the shapes and elements so described or illustrated may be applicable to other embodiments. Those skilled in the art will also understand that a reference to a structure or shape disposed "adjacent" to another shape may have portions that overlap the adjacent shape or that are under the adjacent shape.

[0050] The terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting of the invention. For example, as used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," as used herein, specify the presence of the stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items and may be abbreviated as " / ."

[0051] Spatially relative terms such as "under," "below," "lower," "over," "upper," and the like may be used herein for ease of description to describe the relationship of one element or feature to another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, an element described as "under" or "beneath" another element or feature would be oriented "over" the other element or feature. Thus, the exemplary term "under" may encompass both an "over" and "under" orientation. A device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms "upwardly," "downwardly," "vertical," "horizontal," etc. are used herein for descriptive purposes only, unless specifically indicated otherwise.

[0052] The terms "first" and "second" may be used herein to describe various features / elements (including processes), but these features / elements should not be limited by these terms unless the context indicates otherwise. These terms may be used to distinguish one feature / element from another. Thus, a first feature / element discussed below may be referred to as a second feature / element, and similarly, a second feature / element discussed below may be referred to as a first feature / element, without departing from the teachings of the present invention.

[0053] Throughout this specification and the claims that follow, unless otherwise required by context, the word "comprise," as well as variations such as "comprises" and "comprising," mean that various components may be employed together in methods and articles (e.g., compositions and apparatuses, including devices and methods). For example, the term "comprising" is understood to mean the inclusion of any described element or step but not the exclusion of any other element or step.

[0054] In general, any of the devices and methods described herein should be understood to be inclusive, but alternatively, all or a subset of the components and / or steps may be exclusive and may be expressed as "consisting of" or alternatively "consisting essentially of" the various components, steps, subcomponents, or substeps.

[0055] As used in this specification and claims, including as used in the examples, unless expressly specified otherwise, all numbers may be read as if they are preceded by the word "about" or "approximately", even if the term does not explicitly appear. When describing a size and / or location, the phrase "about" or "approximately" may be used to indicate that the stated value and / or location is within a reasonable expected range of values ​​and / or locations. For example, a numerical value may have a value that is + / -0.1% of the stated value (or range of values), + / -1% of the stated value (or range of values), + / -2% of the stated value (or range of values), + / -5% of the stated value (or range of values), + / -10% of the stated value (or range of values), etc. Any numerical value provided herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value "10" is disclosed, then "about 10" is also disclosed. Any numerical ranges recited herein are intended to include all subranges subsumed therein. As would be well understood by one of ordinary skill in the art, when a value is disclosed to be "less than or equal to" that value, it is also understood that "greater than or equal to" that value and possible ranges between that value are also disclosed. For example, when a value "X" is disclosed, "less than or equal to X" as well as "greater than or equal to X" (e.g., X is a numerical value) are also disclosed. It is also understood that throughout this application, data is provided in several different formats, and this data represents endpoints and starting points, as well as ranges for any combination of data points. For example, when a specific data point "10" and a specific data point "15" are disclosed, it is understood that values ​​between 10 and 15, as well as values ​​greater than 10, greater than or equal to 10, less than 10, less than or equal to 10, and equal to 10, greater than 15, greater than or equal to 15, less than 15, less than or equal to 15, and equal to 15 are considered to be disclosed. It is also understood that each unit between two specific units is also disclosed. For example, when 10 and 15 are disclosed, 11, 12, 13, and 14 are also disclosed.

[0056] Although various illustrative embodiments have been described above, any of a number of modifications may be made to the various embodiments without departing from the scope of the invention, as set forth by the claims. For example, the order in which the various described method steps are performed may often be changed in alternative embodiments, and in other alternative embodiments, one or more method steps may be skipped entirely. Optional features of the various device and system embodiments may be included in some embodiments and not included in other embodiments. Thus, the foregoing description has been provided primarily for illustrative purposes and should not be construed as limiting the scope of the invention, as set forth in the claims.

[0057] The examples and illustrations contained herein show, by way of illustration and not limitation, specific embodiments in which the subject matter may be practiced. As noted above, other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such embodiments of the subject matter of the present invention may be referred to herein, individually or collectively, by the term "invention" for mere convenience, and there is no intention to spontaneously limit the scope of this application to any single invention or inventive concept when more than one invention is actually disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to encompass any and all adaptations or variations of the various embodiments. Combinations of the above-described embodiments, and other embodiments not specifically described herein, will be apparent to those skilled in the art upon reviewing the above description.

Claims

1. 1. A method for applying a paint film onto a substrate, comprising: adhering a corner patch onto at least a portion of a corner of the substrate; and adhering the paint film sheet onto the substrate such that the corner is within a corner relief pattern of the paint film sheet, the corner relief pattern corresponding to a recess along an edge of the paint film sheet, wherein the paint film sheet partially overlaps and interfaces with the corner patch, thereby providing a continuous paint film over at least the corner of the substrate.

2. The method of claim 1 , wherein the corner patch is a paint film made from the same material as the paint film sheet.

3. The method of claim 1 , wherein the corner patch has a first thickness and the paint film sheet has a second thickness, the first thickness being less than the second thickness.

4. The method of claim 3, wherein a ratio of the first thickness to the second thickness ranges from 1:4 to 3:

4.

5. The method of claim 3, wherein the first thickness is in the range of 100 to 500 microns and the second thickness is in the range of 50 to 200 microns.

6. 10. The method of claim 1, wherein adhering the paint film sheet onto the substrate comprises applying pressure along a surface of the paint film sheet with a tool having a flat edge to smooth out any trapped air bubbles between the paint film sheet and the substrate.

7. The method of claim 1 , wherein the paint film sheet is bonded to the corner patch by intimately contacting the corner patch with the paint film sheet.

8. The method of claim 1 , wherein adhering the paint film sheet onto the substrate comprises exposing the paint film sheet to heat.

9. The method of claim 8 , wherein exposing the paint film sheet to heat bonds the paint film sheet to the corner patch.

10. The method of claim 1 , wherein the color of the corner patch matches the color of the paint film sheet within an engineering vehicle exterior paint color matching standard.

11. 11. The method of claim 10, wherein the engineering vehicle exterior paint color matching criteria is based on visual evaluation at 3 feet or greater.

12. The method of claim 1 , wherein the corner patch is adhered to the corner of the substrate prior to adhering the paint film sheet.

13. The method of claim 1 , wherein the paint film sheet is adhered to the corner of the substrate prior to adhering the corner patch.

14. The method of claim 1 , further comprising forming the corner patch in the paint film based on the measured dimensions of the corner of the substrate.

15. A decorative paint film adhered onto an exterior panel of a motor vehicle, comprising: a corner patch adhered onto a corner of an exterior panel of the motor vehicle; a paint film sheet adhered onto a portion of the exterior panel adjacent the corner, the paint film sheet having a corner relief pattern corresponding to a recess along an edge of the paint film sheet, the paint film sheet being positioned such that at least a portion of the corner is within the corner relief pattern, the paint film sheet overlapping and joining the corner patch to provide a continuous paint film over at least the corner of the exterior panel.

16. 16. The decorative paint film of claim 15, wherein the exterior panel is a hood, spoiler, door, or bumper of a passenger vehicle.

17. 16. The decorative paint film of claim 15, wherein the motor vehicle is a car, a truck, an airplane, or a boat.

18. 16. The decorative paint film of claim 15, wherein the corner patch has a first thickness and the paint film sheet has a second thickness, the first thickness being less than the second thickness.

19. 20. The decorative paint film of claim 18, wherein a ratio of said first thickness to said second thickness ranges from 1:4 to 3:

4.

20. 20. The decorative paint film of claim 18, wherein said first thickness is in the range of 100 to 500 microns and said second thickness is in the range of 50 to 200 microns.

21. 16. The decorative paint film of claim 15, wherein the color of the corner patch matches the color of the paint film sheet within an engineering vehicle exterior paint color matching standard.

22. 22. The decorative paint film of claim 21, wherein said engineering vehicle exterior paint color matching criteria is based on visual evaluation at 3 feet or greater.

Images