Film trimming apparatus 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 for applying a film and related methods are provided. The film can be, for example, an adhesive film applied to the outer surface of an automobile.

Background Art

[0002] Automobile manufacturers use functional films and decorative films for large body applications. The 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 a significant amount of time compared to applying paint multiple times while avoiding the release 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 advantages.

Summary of the Invention

[0003] Providing consistent and high-quality results in film application can be assisted using a jig, but conventional jigs continue to present significant technical challenges. First, the outer surface of an automobile has a complex contour, which varies significantly between vehicle models and thus requires different jigs for different models. Second, the application of films using conventional jigs tends to be highly technique-dependent, resulting in an inconsistent wet-out of the film. Third, the use of a blade for cutting the film generally requires additional structures to oppose the blade for guiding the cut in order to 1) avoid the risk of injury to the user and 2) potentially damage the surface of the vehicle.

[0004] Provided herein is a trimming and application apparatus for applying tape or film onto a three-dimensional surface. The application apparatus is a jig containing a thin metal shim that is received within an elongated, flexible body capable of forming a contour to the 3D surface. To trim the film, the tool is pressed against the film, pressing the film against 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 be carried out with the help of the apparatus's inclined shelf. The inclined shelf reduces tenting on the film edge by allowing a continuous geometric radius to wet-out in the appropriate order, thereby limiting operator variability and reducing the possibility of trapping air under the film during application.

[0005] Optionally, custom cutting profiles can accommodate pre-installed roof groove clips with a pocket design. The device is quickly snapped into place using its flexible design and magnetic surface, but is not limited thereto. This trimming application is not limited to roof grooves and can be used for other trimming areas that do not have exposed edges. The provided jig and method offer easy application with limited operator skill, reduce safety concerns due to the absence of sharp objects, and add reproducibility as the film cutting position is fixed. This solution also reduces the skill level required by the operator while reducing film trimming and final wet-out time.

[0006] In a first embodiment, 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 bonding area including a groove recessed to the first panel. The method includes: placing an elongated jig within the groove, the jig having shims that extend continuously along the length of the groove and that protrude beyond the height of the first panel; applying the film to the first and second panels such that the film extends over the elongated jig; using a tool to apply pressure to the film and along the length of the shims toward the cut edges of the shims, trimming the film along the periphery; removing the elongated jig from the groove; and adhering the periphery of the film to the groove.

[0007] In a second embodiment, a jig is provided for applying a film to a first panel of a vehicle, which is connected to a second panel of the vehicle by a joining region including a groove portion recessed relative to the first panel, the jig comprising an elongated body having a convex bottom surface complementary to the groove portion and having a plurality of discontinuous segments, and a shim extending continuously along the length of the elongated body and having a cut edge portion facing away from the elongated body and having a convergence angle of 60 to 120 degrees. [Brief explanation of the drawing]

[0008] [Figure 1] This is a perspective view of a jig for applying film to a vehicle panel, according to an exemplary embodiment. [Figure 2] This is a magnified view of the jig in Figure 1. [Figure 3A] These are opposing top and bottom views of a customized component, optionally used with the jigs shown in Figures 1 and 2. [Figure 3B] These are opposing top and bottom views of a customized component, optionally used with the jigs shown in Figures 1 and 2. [Figure 4] These are longitudinal views of the jigs shown in Figures 1 to 3, which are engaged with the vehicle panel. [Figure 5] Figures 1 to 4 show distal views of the end segments of the jig, illustrating the engagement between the jig and the vehicle panel. [Figure 6] These are schematic diagrams illustrating the use of tools with jigs, as shown in Figures 1 to 6, for trimming film. [Figure 7] Figures 1-5 show perspective views of the jigs used to apply film to vehicle panels.

[0009] Where reference letters in the specification and drawings are used repeatedly, they are intended to represent the same or similar features or elements of the present disclosure. Those skilled in the art should understand that many other modifications and embodiments can be devised and that they fall within the scope and spirit of the principles of the present disclosure. The drawings may not be drawn to scale. [Modes for carrying out the invention]

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

[0011] Furthermore, the enumeration of one or more preferred embodiments does not imply that other embodiments are unhelpful, nor is it intended to exclude other embodiments from the scope of the invention.

[0012] As used herein and in the appended claims, unless otherwise specified in the context, the singular forms "a," "an," and "the" refer to multiple references. Thus, for example, a reference to a component preceded by "a" or "the" may include one or more of the component and its equivalents known to those skilled in the art. Furthermore, the term "and / or" means one or all of the enumerated elements, or any combination of two or more of the enumerated elements.

[0013] Note that the term "including" and its variations are not restrictive when they appear in the attached descriptions. Furthermore, "a," "an," "the," "at least one," and "one or more" are used interchangeably herein. In this specification, relative terms such as left, right, front, rear, top, bottom, side, above, below, horizontal, and vertical may be used, in which case they refer to the viewpoint seen in the particular drawings. However, these terms are used only to simplify the description and are not in any way intended to limit the scope of the invention.

[0014] Throughout this specification, any reference to “one embodiment,” “a particular embodiment,” “one or more embodiments,” or “a certain embodiment” means that the specific features, structures, materials, or properties described in relation to that embodiment are included in at least one embodiment of the present invention. Therefore, the appearance 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 does not necessarily refer to the same embodiment of the present invention. Trademarks, where applicable, are written in all capital letters.

[0015] A jig according to an exemplary embodiment is shown in Figure 1 and will be referred to hereafter as number 100. Jig 100 has an elongated shape and is shown on an automobile roof panel 50 for size comparison. As shown, jig 100 comprises a continuous shim 102 (or wire) extending along the length of 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 also include mechanical hinges that allow adjacent segments 104 to be joined to each other. In general, the segments 104 can be manufactured in an essentially modular manner to adapt to different panel sizes and shapes.

[0016] The provided embodiments are intended for automotive roof panels, but they can be readily applied to other panels. The provided jigs and methods can generally be used to facilitate trimming film around the roof grooves, windshields, rear windows, and moonroofs of vehicles. These jigs and methods are also not limited to vehicle applications and can be adapted for use on other large assemblies where two or more outward-facing panels come together along a seam defining a alignment surface.

[0017] The discontinuity of segment 104 allows the relatively thin shim 102 to flexibly follow along the groove portion 52 that defines the perimeter of the roof panel 50, even if segment 104 itself is not relatively flexible. The groove portion 52 defines the boundary of the area to which the film is applied, as will be described in more detail later. In some cases, though not always, the groove portion 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 an alloy thereof. Preferably, this metal is highly elastic and resists permanent deformation when bent, for example, around the corner portion of the panel. However, the material of the shim 102 is not necessarily limited to metal and can also be made from a flexible polymer or ceramic material. Optionally, the segment 104 is also at least somewhat flexible and can be made from a flexible material such as a polymer, allowing for flexibility and potential lateral stretching or contraction of the material along the segment 104. Such properties can also help the segment 104 fit better into the groove portion 52 and potentially aid in fixation.

[0019] When the shim 102 is flexible, it may be possible to further assist the shim 102 in stretching along its longitudinal axis to conform the jig 100 to the boundary of the roof panel 50. In some embodiments, the shim 102 can be formed as a continuous loop that extends along the entire perimeter of the roof panel 50. Such a shim can include one or more joints that allow the segments to be reversibly attached to each other. In these embodiments, the shim itself may be divided to allow customization of the length of the jig 100.

[0020] To help fit the jig 100 to a particular panel at hand, the segment 104 can be made slidably movable along the shim 102 to accommodate sharper bends that may be encountered near the 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] The segment 104 can represent any suitable portion of the total length of the jig 100, such as 1 percent to 90 percent, 5 percent to 80 percent, 10 percent to 70 percent of the total length of the 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 total length of the jig 100.

[0022] FIG. 2 shows an enlarged view of the jig 100 showing its profile along the longitudinal axis of the jig 100. In this example, the shim 102 has a generally rectangular cross-sectional shape, which is defined perpendicular to the longitudinal axis of the shim 102.

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

[0024] The vertical dimension of the shim 102 is much larger than the lateral dimension, thus allowing a high degree of flexibility along the lateral direction. Non-rectangular shapes are also possible as 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 example, the upward portion of the shim 102 can generally have a "D"-shaped cross-section. The cross-section of the shim 102 may be uniform or non-uniform along its length. In some cases, the shim 102 includes one or more notches along the surface facing its bottom to facilitate bending of the shim along the plane of the roof panel 50.

[0025] Since the cross-section of the shim 102 is rectangular, each of the two cut edges that protrude beyond the segment 104 has, by definition, a 90-degree convergence angle, which is defined as the angle at which adjacent faces of the shim meet. In alternative embodiments, one or more cut edges can have a convergence angle that deviates from 90 degrees. For example, a given cut edge can have a convergence 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 cut edge of the shim 102 preferably has a corner edge suitable for cutting the 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] Although not restrictive, the lateral thickness of shim 102 may be 100 to 400 micrometers, 120 to 350 micrometers, 150 to 300 micrometers, or, in some embodiments, less than, equal to, or greater than 100, 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. Furthermore, the aspect ratio (i.e., height / width) of the cross-section of shim 102 may be 15-127, 20-80, 40-60, or in some embodiments, 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 less than, equal to, or greater than 127.

[0027] Figures 3A and 3B show the opposing bottom and top surfaces of a customized segment 106, which can be optionally used in combination with the shim 102. The customized segment 106 includes a pocket 108 that provides space for accommodating any obstructions in the groove portion 52 that would normally interfere with segments such as the roof groove clip 54 shown in Figure 3A. Figure 3B shows the upward-facing main surface of the customized segment 106 and shows a groove 110 for seating a shim (not shown in Figures 3A and 3B). The use of the customized segment 106 may also be advantageous when guiding the shim 102 along particularly sharp bends, such as along the corner portions of the vehicle panel. Although not shown here, the customized segment 106 may 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] Figure 4 shows in more detail the engagement between the jig 100, which includes the shim 102 and segment 104, and the grooved portion 52 of the roof panel 50. Although not explicitly shown, the grooved portion may extend along the boundary between two adjacent vehicle panels, for example, between the roof panel and the side panel of a vehicle. In these cases, the grooved portion preferably includes a surface that is recessed to both panels. The grooved portion 52 includes both a concave region and a convex region, represented by a double radius, as shown. These surface regions may be complementary to the mating surface of segment 104.

[0029] Optionally, as further shown in Figure 5, the mating surface extends 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 segment 104 and the groove portion 52 significantly improves the alignment between the jig 100 and the roof panel 50. This, in turn, provides higher accuracy in the cutting line obtained using the jig 100 compared to the cutting line obtained by conventional methods.

[0030] Advantageously, each segment 104 includes an inclined shelf 51 positioned between the shim 102 and the roof panel 50. After the film is cut, the inclined shelf 51 can help reduce tenting on the edges of the film by allowing the continuous geometric radii to be wet out in the correct order. This reduces the possibility of trapping air under the film during application. By providing a more consistent transfer of the adhesive-backed film from segment 104 to the roof panel 50, the inclined shelf 51 can help limit variations in film application quality due to differences in operator skill.

[0031] Figure 6 shows a schematic diagram illustrating the process of cutting a film placed on the roof panel 50 using a jig 100. In this process, the jig 100 is positioned in the groove portion 52 of the roof panel 50, as described above. When the jig 100 is properly seated, the upward surface of the shim 102 should protrude beyond the height of the roof panel 50. In some embodiments, the jig 100 extends continuously along part 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 temporary adhesive, which is later removed.

[0032] Next, the film 120 is placed on both the roof panel 50 and the jig 100. It is common for the film 120 to be an adhesive film, in which case the film 120 can be adhesively bonded to the roof panel 50 during such placement. Optionally, the film 120 may extend over the entire roof panel 50, but this is not required. Next, the tool 122 can be pressed against the film 120, translated along the shim 102, and pressure applied to compress the film 120 between the tool 122 and the shim 102, cutting the film along the cutting edge of the shim 102. The tool 122 is typically pressed against the film 120 manually by a human operator, but this action can also be performed in an automated manner, such as using a computer-controlled robotic arm. When a computer is used, the jig 100 can be detected using a reference marker on the jig 100 to help determine its position. This cutting step can be performed along a continuous loop around the roof panel 50 defined by the groove portion 52. It is also possible that the groove portion 52 extends only along a portion of the roof panel 50, in which case multiple cutting steps may be required to separate the portion of the film 120 placed on the roof panel 50 from the portion of the film 120 that extends beyond the roof panel 50.

[0033] Optionally, and as shown in the figure, the tool 122 has a recess 124 having a shape complementary to the shape of the cutting edge of the shim 102. This helps prevent slippage and ensure that pressure is directed to the appropriate 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 more flexible than the material of the shim 102. Such a material may be an engineering polymer such as polyoxymethylene, provided by Dupont de Nemours, Inc. (Wilmington, DE) under the trade name DELRIN. In a preferred embodiment, the tool may have an engaging surface having a Shore D hardness of up to 70D.

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

[0035] Further improvements are possible with respect to the shim 102. For example, the shim 102 may remain within the carrier (such as segment 104) until the jig 100 is positioned within the groove portion 52 of the roof panel 50. Then, when the jig 100 is fully seated within the groove portion 52, the shim 102 can be biased to slide away from the carrier. The 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 completely trimming the film 120 using the steps described above, the jig can be removed from the groove 52 of the roof panel 50. Next, the remaining edge of the newly trimmed film 120 on the roof panel 50 can be glued to the groove 52 from which the jig 100 was removed, if necessary. The excess portion of the film 120 may be called the "weed" portion and can then be discarded or reused.

[0037] Examples The purposes and benefits of this disclosure are further illustrated by the following non-limiting embodiments, but the specific materials and their configurations, as well as other conditions and details referenced in these embodiments, should not be construed as unduly limiting this disclosure.

[0038] The jigs shown in Figures 2 and 4-7 were inserted into the roof groove of a Toyota Corolla. A sufficiently long piece of 3M Paint Protection Film PUL2008, obtained from 3M Company (St. Paul, MN), was positioned to cover the roof groove (including the jig) and adhered to the first and second panels of the vehicle roof. Before applying the film to the panels, the release liner was removed from the PUL2008 film. Next, a polyoxymethylene plastic block with a recess (obtained from DuPont (Wilmington, DE) under the trade name DELRIN) was used to press the film against the shim of the jig for cutting. 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 five times the width of the shim.

[0039] All documents, patent documents, or patent applications cited in the above patent application relating to the patent document are incorporated herein by reference in their entirety in a consistent manner. In the event of any inconsistency or contradiction between any part of the incorporated references and this application, the information in the foregoing statement shall prevail. The foregoing statement is intended to enable a person skilled in the art to practice the disclosure set forth in the claims and should not be construed as limiting the scope of the disclosure, which is defined by the claims and all their equivalents. The following are exemplary embodiments. [Item 1] A method for applying a film to a first panel of a vehicle, wherein the first panel is connected to a second panel of the vehicle by a bonding region including a groove that is recessed relative to the first panel, An elongated jig, comprising shims that extend continuously along the length of the groove and that protrude beyond the height of the first panel, is placed within the groove. The film is attached to the first and second panels such that the film extends over the elongated jig, Using a tool, pressure is applied to the film and along the length of the shim toward the cut edge of the shim, and the film is trimmed along the periphery. The elongated jig is removed from the groove portion, The peripheral edge of the film is adhered to the groove portion, Methods that include... [Item 2] The method according to item 1, wherein the cut edge is oriented away from the vehicle. [Item 3] The method according to item 1 or 2, wherein the cut edge of the shim has a convergence angle of 60 to 120 degrees. [Item 4] The method according to item 3, wherein the cut edge of the shim has a convergence angle of 60 to 90 degrees. [Item 5] The method according to item 4, wherein the cut edge of the shim has a convergence angle of 80 to 90 degrees. [Item 6] The method according to any one of items 1 to 5, wherein the shim has a substantially rectangular cross-section, and the cross-section is defined perpendicular to the longitudinal axis of the shim. [Item 7] The method according to any one of items 1 to 6, wherein the cut edge has a radius of 10 micrometers to 400 micrometers. [Item 8] The method according to any one of items 1 to 7, wherein the shim is made of metal. [Item 9] The method according to any one of items 1 to 8, wherein the groove portion is also recessed relative to the second panel. [Item 10] The method according to any one of items 1 to 9, wherein the elongated jig further comprises a plurality of discontinuous segments coupled to the shim. [Item 11] The method according to item 10, wherein the plurality of discontinuous segments are joined to each other only by the shims. [Item 12] The method according to item 10 or 11, wherein the discontinuous segment corresponds to up to 50 percent of the total length of the elongated jig. [Item 13] The method according to any one of items 1 to 12, wherein the elongated jig can be elastically deflected along a bending radius of up to 10 centimeters without permanent deformation. [Item 14] The method according to any one of items 1 to 13, wherein the elongated jig has a bottom contour that is complementary to the contour of the groove portion. [Item 15] The method according to any one of items 1 to 14, wherein the tool has an engaging surface having a shape complementary to the cut edge of the shim. [Item 16] The method according to any one of items 1 to 15, wherein the tool has an engaging surface having a Shore D hardness greater than 70D. [Item 17] A jig for applying a film to the first panel of a vehicle, which is connected to the second panel of the vehicle by a bonding region including a recessed groove portion relative to the first panel, An elongated body having a convex bottom surface complementary to the groove portion, the elongated body having a plurality of discontinuous segments, A shim that extends continuously along the length of the elongated body, and has a cut edge portion that faces away from the elongated body and has a convergence angle of 60 to 120 degrees, A jig equipped with these features.

Claims

1. A method for applying a film to a first panel of a vehicle, wherein the first panel is connected to a second panel of the vehicle by a bonding region including a groove that is recessed relative to the first panel, A slender jig is placed within the groove portion, comprising a shim that extends continuously along the length of the groove portion and a shim that protrudes beyond the height of the first panel. The film is attached to the first and second panels such that the film extends over the elongated jig, Using a tool, pressure is applied to the film and along the length of the shim toward the cut edge of the shim, and the film is trimmed along the periphery. The elongated jig is removed from the groove portion, The peripheral edge of the film is adhered to the groove portion, Methods that include...

2. The method according to claim 1, wherein the cut edge is oriented away from the vehicle.

3. The method according to claim 1, wherein the cut edge of the shim has a convergence angle of 80 to 90 degrees.

4. The method according to claim 1, wherein the shim has a substantially rectangular cross-section, and the cross-section is defined perpendicular to the longitudinal axis of the shim.

5. The method according to claim 1, wherein the cut edge portion has a radius of 10 micrometers to 400 micrometers.

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

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

8. The method according to claim 7, wherein the discontinuous segment corresponds to up to 50 percent of the total length of the elongated jig.

9. The method according to claim 1, wherein the elongated jig can be elastically deflected along a bending radius of up to 10 centimeters without permanent deformation.

10. A jig for applying a film to the first panel of a vehicle, which is connected to the second panel of the vehicle by a bonding region including a recessed groove portion relative to the first panel, An elongated body having a convex bottom surface complementary to the groove portion, the elongated body having a plurality of discontinuous segments, A shim that extends continuously along the length of the elongated body, and has a cut edge portion that faces away from the elongated body and has a convergence angle of 60 to 120 degrees, A jig equipped with these features.

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