Robotic film application tool

Abstract

Provided is an applicator for applying a film to a substrate, the applicator including a shank, a body comprising a convex engagement surface, and a joint capable of providing both x-axis rotation and y-axis rotation. The joint operatively couples the shank and the body to each other. These features help the applicator remain nearly orthogonal to the substrate surface as it is used. The applicator is provided with a contacting surface that glides easily along the film when disposed on the substrate, which can significantly reduce defects in the application process.

Description

ROBOTIC FILM APPLICATION TOOLField of the Invention

[0001] Provided are devices and related methods for applying a fdm, sheet or foil to a substrate, such as a substrate having curved contours.Background

[0002] Surfacing films are found in various commercial applications, such as vehicle exterior finishing. In order to avoid cost-intensive masking procedures, for example, the automotive industry sometimes uses colored films, and particularly adhesive-backed films. Body color film can be applied to the roof of a car in order to achieve a roof color different from the body color. An exemplary sheet adhesion device for adhering an adhesive sheet to a car body is described in WO 01 / 05902 (Shiozawa). Other surfacing film applications include protective clear coats used to protect painted automotive exteriors from impacts with airborne debris (e.g., stones and other road objects) and provide scratch resistance.

[0003] It is not uncommon for significant cosmetic issues to arise during installation of surfacing films onto the surface of a vehicle or other substrate surface. These include bubbles formed when air is trapped between the film and the substrate, marks or scratches on the surface of the film, and adhesion lines. These defects are readily observable by the end user and can result in poor acceptance. Removal and re-application of films to correct these defects can be costly, time-consuming and wasteful. The variability of surface contours found on substrates further adds to the complexity of the problem.Summary

[0004] In view of the above, technical challenges remain in applying a film, foil or sheet, e.g., and adhesive film, foil or sheet in a high visual standard. This is especially true for thin films, e.g., films having a thickness below 1 millimeter. The visibility of defects is especially problematic for high gloss films. Conventional tools and methods used to apply surfacing films have tended to be highly techniquesensitive. This can lead to inconsistent finishing results, especially when films are applied by hand.

[0005] Provided is an applicator for applying film onto a three-dimensional surface. When wetting out the film on the surface it is ideal for the applicator to remain orthogonal to the substrate surface. The device accomplishes this by utilizing a contoured surface with motion compliance along certain degrees of freedom. Advantageously, the device can further include a contoured body with a contacting surface that glides easily along the film when disposed on the substrate. The shape and surface characteristics of the body can significantly reduce defects.

[0006] In a first aspect, an applicator for applying a film to a substrate is provided. The applicator comprises: a shank; a body comprising a convex engagement surface; and a joint capable of providing x axis rotation, y-axis rotation, or both x-axis rotation and y-axis rotation, wherein the joint operatively couples the shank and the body to each other.

[0007] In a second aspect, a method of using the applicator for applying a fdm to a substrate is provided, comprising: positioning an adhesive-backed fdm over the substrate;

[0008] urging the convex engagement surface of the applicator against the adhesive-backed fdm to induce contact between the adhesive-backed fdm and the substrate; and while applying pressure against the adhesive-backed fdm, moving the applicator along a surface of the substrate to adhere the adhesive- backed fdm to the substrate, wherein rotation about its x-axis and / or y-axis is provided at the joint to reduce the degree of z-axis misalignment between a surface normal of the convex engagement surface and the surface of the substrate when in contact with each other.

[0009] Above the contoured body is a roll / pitch gimbal and a z-compliant device. In a preferred embodiment, the three added degrees of freedom allow a user or robot to be within an error of 15 degrees of tilt, about both roll and pitch axes, and 100 millimeters of height from the surface. Since the device allows for this error a roboticist can program a path from the 3D model and discrepancies in setup, part to part difference, variances from the 3D model can be accounted for by the devices compliance. When used as a hand operated tool, the z-compliance portion is removed and surface orientation is corrected for with the gimbal device.

[0010] The compliance built into applicator design can allow for greater consistency / repeatability of fdm wet out by lessening operator skill. Advantageously, application of a fdm by either a robot or human can be made substantially easier and more reproducible.Brief Description of the Drawings

[0011] FIG. 1 is a perspective view of an applicator subassembly according to one exemplary embodiment;

[0012] FIG. 2 is a perspective view of the applicator of FIG. 1 installed on a robotic arm;

[0013] FIG. 3 is an side elevational view of an applicator according to another embodiment, the applicator installed on a robotic arm; and

[0014] FIG. 4 is a perspective view of the applicator of FIG. 3 being used in a fdm installation process.

[0015] Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the disclosure. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the disclosure. The figures may not be drawn to scale.DEFINITIONS

[0016] As used herein:

[0017] “x-axis” and “y-axis” refer to mutually orthogonal directions along a plane tangent to an engagement surface of the applicator and the substrate when they are in contact with each other; and

[0018] z-axis” refers to a direction perpendicular to the engagement surface of the applicator and the substrate when they are in contact with each other;Detailed Description

[0019] As used herein, the terms “preferred” and “preferably” refer to embodiments described herein that can afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. 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.

[0020] As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a” or “the” component may include one or more of the components and equivalents thereof known to those skilled in the art. Further, the term “and / or” means one or all of the listed elements or a combination of any two or more of the listed elements.

[0021] It is noted that the term “comprises”, and variations thereof do not have a limiting meaning where these terms appear in the accompanying description. Moreover, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably herein. Relative terms such as left, right, forward, rearward, top, bottom, side, upper, lower, horizontal, vertical, and the like may be used herein and, if so, are from the perspective observed in the particular drawing. These terms are used only to simplify the description, however, and not to limit the scope of the invention in any way.

[0022] Reference throughout this specification to “one embodiment,” “certain embodiments,” “one or more embodiments” or “an embodiment” means that a particular feature, structure, material, or characteristic described relating to the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrases such as “in one or more embodiments,” “in certain embodiments,” “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the invention.

[0023] The provided applicator and methods shall be explained in greater detail with reference to adhesive paint foils or paint films or paint sheets for vehicle coloration and / or vehicle paint protection. It is to be understood, however, that the described devices and methods can be applicable to any kind of film, sheet or foil adhesively attached to a substrate. Notably, the vehicle may be a boat, a train, an automobile or car, a bus or any other vehicle that provides at least one surface that can be colored or needs protection.

[0024] An applicator according to one exemplary embodiment is shown in FIG. 1 and hereinafter referred to by the numeral 100. The applicator 100 includes three major components — a shank 102, a joint 104, and a body 106 — connected to each other in that order. The joint 104 operatively couples the shank 102 and the body 106 to each other while also enabling both x-axis rotation and y-axis rotation (sometimes referred to “pitch” and “roll”) of these components relative to each other. Optionally and as shown, the joint 104 is a 2-axis gimbal joint that includes an x-axis pivot 108 and a y-axis pivot 110. The x-axis pivot 108 and y-axis pivot 110 can operate independently of each other, allowing the shank 102 to be tilted over a range of angles in any direction, even where orientation of the body 106 is fixed.

[0025] Each of the pivots 108, 110 is a pin joint that enables pure rotation of its adjoining bodies about a common axis. In various embodiments, the x-axis pivot 108 and y-axis pivot 110 can be limited in their rotational freedom. Based on the desired symmetry of intended motion for the applicator 100 motion along the x-y plane of the substrate, it is generally desirable for both the x-axis and y-axis rotation to be similarly restricted to the extent such restrictions exist.

[0026] In one example, the joint 104 can have both x-axis and y-axis rotation limited within a range of from -30 degrees to +30 degrees (representing a total angular range of 60 degrees), from -15 degrees to +15 degrees (representing a total angular range of 30 degrees), or from -5 degrees to +5 degrees (representing a total angular range of 10 degrees). In some embodiments, the total angular range can be less than, equal to, or greater than 10 degrees, 15, 20, 25, 30, 35, 40, 45, 50, or 60 degrees.

[0027] Referring again to FIG. 1, a plurality of force modules 114 extends between the shank 102 and the body 106, each of the terminal ends of the force module 114 connected to a respective shank 102 or body 106. Here, the force modules 114 are provided by extension springs, each of which creates a resistance to a pulling force. Other types of force modules can be used, such as those based on elastic polymeric bands or telescopic springs, pressurized pistons, and dampers. Preferred force modules 114 provide some resistance and then move back to its nominal (or relaxed) state when no load is applied to it.

[0028] While there are four force modules 114 used in this embodiment, this is merely exemplary and either more or fewer force modules may be used. It is generally preferable for the force modulus 114 to be evenly distributed around the peripheral edges of the shank 102 and body 106, which in this case have a generally circular profde as viewed along a z-axis of the applicator 100. The force modules 114 act collectively to bias the relative orientation of the shank 102 and body 106 to a neutral position (as shown in FIG. 1) to which the joint 104 resiliently returns when relaxed. In this neutral position, these components are preferably positioned such that there is z-axis alignment of the shank 102 and body 106 with each other.

[0029] Use of a circular profile for the body 106 is advantageous because it is non-directional in the manner in which it contacts the substrate. Operation of the applicator 100 is therefore unaffected by the rotational orientation of the body 106 about the z-axis. In applications the contour of the substrate might benefit from an asymmetric body, other shapes could be used. For example, the body could instead have an elliptical shape in which its x-axis and y-axis dimensions are significantly different from each other.

[0030] The body 106 is the component positioned towards the film and the substrate when using the applicator 100. The body 106 has a convex engagement surface 116 that faces the film and the substrate. The shape of the convex engagement surface 116 is curved and rounded outwardly like the exterior surface of a sphere. The convex engagement surface can optionally include regions that are not convex. For example, the very bottom of the engagement surface that initially contacts the substrate may be generally planar, while the surrounding annular portion of the engagement surface adjacent to the planar surface can be convex. While not to be particularly restricted, preferred three-dimensional geometriesinclude the “mushroom head” configurations described in International Patent Application No. WO 2018 / 150323 (Rudek, et al.).

[0031] Given the circular profile of the body 106, it is generally unnecessary for the body 106, and its convex engagement surface 116, to rotate about its z-axis. In various embodiments, z-axis rotation of the convex engagement surface 116 relative to the shank 102 can be restricted.

[0032] The shank 102, joint 104, and body 106 can be, independently, made from any suitable material or combination of materials. Examples of suitable materials include plastics and metals, which can be easily milled or molded to desired shapes in keeping with their function in the applicator 100.

[0033] FIG. 2 shows a robotic assembly 201 that includes an applicator 200 similar to the applicator 100 in FIG. 1. This assembly 201 includes a robotic arm 240 that operates to position and orient the applicator 200 based on instructions from a computer. The applicator 200 has a shank 202 that includes a coupling for attachment to the robotic arm 240. In a manufacturing setting, it is advantageous for the robotic arm 240 to have up to six degrees of freedom, allowing its distal end to track along the surface of a substrate with complex topologies, include for example, compound curvatures.

[0034] In this figure, the applicator 200 has the same components as applicator 100 but further includes a compliant layer 212. The compliant layer 212, as shown, is conformably disposed along the outer surface of the body, including its convex engagement surface, such that the outward-facing major surface of the compliant layer 212 has a shape essentially matching that of the convex engagement surface. A useful compliant layer 212 is a porous layer with a soft, non-scratching texture. In some embodiments, the compliant layer 212 is be made from a fibrous layer, such as a woven or non-woven fibrous cloth. The compliant layer 212 need not be fibrous. Other porous materials, such as an open- celled or closed-celled foam, could also be used.

[0035] As a further option, the compliant layer 212 of the applicator 200 can incorporate two or more distinct layers. The two or more layers can be made from different materials and have different degrees of softness or compressibility. In one exemplary embodiment, the compliant layer 212 includes an outer fibrous layer and an inner compressible layer. As an example, the two layers could be comprised of an outer layer with a low surface energy and a second layer made up of a compressible layer as described above. The low surface energy of the outer layer allows for a smooth gliding over the substrate surface with minimal vibrational forces between the convex surface and the substrate. The outer layer is also designed to be replaceable, allowing the end user to replace the layer with a new low surface energy piece as needed for optimal performance overtime.

[0036] The compliant layer, including any constituent layers, can have an overall thickness of from 0.1 millimeters to 10 millimeters, from 0.1 millimeters to 7 millimeters, from 0.1 millimeters to 3 millimeters, or in some embodiments, less than, equal to, or greater than 0.1 millimeters, 0.2, 0.5, 1, 1.5, 2, 2.5, 3, 4, 5, 6, 7, 8, 9, or 10 millimeters.

[0037] The applicator 200 further includes a load cell 230 rigidly coupled to its shank 202. The load cell 230 serves to monitor the forces imparted on the applicator 200 during its operation, and particularly while it is in contact with the substrate. In some embodiments, the load cell 230 has six degrees offreedom. The load cell 230 electronically communicates with a computer (not shown) through a port 231. The computer can be programmed to respond appropriately when measured forces on the applicator 200 fall within pre -determined limits. The applicator 200 allows for force-controlled robotic motion and can help account for offsets in part programming.

[0038] Another member of the applicator 200 is collapsible member 236, which is directly coupled to the load cell 230 such that the load cell 230 is disposed between the collapsible member 236 and the shank 202. The collapsible member 236 that is capable of providing z-axis expansion and contraction of the applicator 200 through a sliding relation, as shown. The z-axis expansion and contraction provided by the collapsible member 236 is reversible. As will be shown in a later embodiment, the z-axis expansion and contraction can optionally occur entirely within the collapsible member.

[0039] The purpose of the collapsible member 236 is to provide flexibility for the applicator 200 to translate in a limited fashion along its z-axis (corresponding to the vertical dimension in FIG. 2) relative to the robotic arm 240. Such compliance can be beneficial in increasing tolerances with respect to z-axis deviations in the film application process.

[0040] The collapsible member 236 can be engineered to provide any suitable range of z-axis length change appropriate for the desired application. The length change can be limited within a range of from - 75 millimeters to +75 millimeters (for a total range of 150 millimeters), from -25 millimeters to +25 millimeters (for a total range of 50 millimeters), or from -13 millimeters to +13 millimeters (for a total range of 26 millimeters). In some embodiments, the total range can be less than, equal to, or greater than 10 millimeters, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, or 150 millimeters.

[0041] To facilitate its use in robotic applications, the applicators 100, 200 and other system components can be made with modular parts that easily and reversibly attach and detach from each other. For example, the collapsible member 236 and shank 202 can be removably coupled to each other.Similarly, the collapsible member 236 and robotic arm 240 can be removably coupled to each other. This has the benefit of enabling a broad variety of applicator and system components to be mixed and matched in any number of desirable combinations.

[0042] FIG. 3 shows an applicator 300 according to another embodiment. Like the applicator 200, the applicator 300 includes a shank 302, a joint 304, and a body 306 wrapped in a conformable compliant layer 312. The compliant layer 312 preferably extends over the entirety of the engagement surface of the body 306, and can further extend along at least a portion of the adjacent components of the applicator 300, such as the joint 304 and shank 302. If desired, one or more couplings may be used to secure the compliant layer 312 to the engagement surface. Such couplings can include, but are not limited to, buttons, clips, ties, clasps, and hook / loop attachment surfaces.

[0043] Unlike the applicator 200, the applicator 300 includes a collapsible member 336 directly and rigidly coupled to a robotic arm 340 at one end and to the shank 302 on its opposite end — diametrically opposite the joint 304 — without an intervening load cell. This applicator 300 can also be employed in applications where force-controlled motion is not required. In this configuration, however, thecollapsible member 336 can still provide compliance along the z-axis direction and help avoid damage to the substrate surface that might otherwise occur due to excessive forces applied by the robotic arm 340.

[0044] FIG. 4 shows an exemplary method of using the applicator 300. Prior to installation, an adhesive-backed fdm 350 is generally affixed to a frame along its peripheral edges and then positioned adjacent to and above a corresponding substrate 352. After alignment of the film 350, the applicator 300 is then guided to a pre -determined position over the film 350 and substrate 352, typically near to the center of the film 350 to be bonded. The applicator 300 then descends onto the substrate 352 to place the film 350 and substrate 352 in contact with each other.

[0045] Once the applicator 300 has fully descended onto the substrate 352, it is then guided by the robotic arm 340 in the x-axis and y-axis directions (e.g., in a progressively expanding spiral pattern) to wet out the film 350 onto the substrate 352. Advantageously, the convex shape of the body 306 and the slight degree of compressibility of the compliant layer 312 disposed thereon can help prevent shock lines and wrinkles from developing as the film 350 is laminated to the substrate 352. After the entirety of the film 350 is fully laminated, the process is complete and the robotic arm 340 can lift the applicator 200 away from the substrate 352.

[0046] During the process of translating the applicator 300 along the x-y plane of the substrate, the joint 304 provides a suitable degree of angular tolerance, helping the body 306 maintain a perpendicular orientation with respect to the substrate 352, or within 5% of a perpendicular orientation. Doing so can help centralize the contact point between the applicator 300 and the film 350 and provide a uniform pressure on the film 350 as it is wet out on the substrate 352. In an exemplary embodiment, the three degrees of freedom provided by the applicator 300 allows the robotic arm 340 to be within an error of 10 degrees of tilt and 100 millimeters of height from the surface. At the same time, the collapsible member 336 can reduce the degree of z-axis misalignment between a surface normal of the convex engagement surface of the applicator 300 and the contacting surface of the substrate 352.

[0047] With this amount of allowable error, a roboticist can program a path of motion based on a digital 3D model of a given substrate, and discrepancies in setup, part-to-part variability, and deviations from the 3D model can be accounted for by the inherent compliance built into the applicator 300.

[0048] Where the applicator is being used as a manually operated tool, the z-compliance portion is generally removed. Surface orientation can be corrected for with a gimbal joint or other suitable joint. For convenience, the shank can be adapted for removable attachment to a handle, such as an ergonomic handle shaped to conform to the human hand, that assists an operator in gripping the applicator. Such attachment can be provided by a quick-release latch that rigidly couples the handle and shank to each other.

[0049] Exemplary Embodiments1. An applicator for applying a film to a substrate, the applicator comprising: a shank; a body comprising a convex engagement surface; anda joint capable of providing x-axis rotation and / or y-axis rotation, wherein the joint operatively couples the shank and the body to each other. The applicator of embodiment 1, wherein the joint is capable of providing both x-axis rotation and y-axis rotation. The applicator of embodiment 1 or embodiment 2, further comprising a collapsible member that is capable of z-axis expansion and contraction, the collapsible member being coupled to the shank diametrically opposite the joint. The applicator of embodiment 3, wherein the collapsible member has z-axis length change limited within a range of from -25 millimeters to +25 millimeters. The applicator of embodiment 4, wherein the collapsible member has z-axis length change limited within a range of from -13 millimeters to +13 millimeters. The applicator of any one of embodiments 3-5, wherein the collapsible member and the shank are removably coupled to each other. The applicator of any one of embodiments 1-6, wherein the joint comprises a 2-axis gimbal. The applicator of any one of embodiments 1-7, wherein the convex engagement surface has a circular profile when viewed along its z-axis. The applicator of any one of embodiments 1-8, wherein z-axis rotation of the convex engagement surface relative to the shank is restricted. The applicator of any one of embodiments 1-9, further comprising a compliant layer conformably disposed along the convex engagement surface. The applicator of embodiment 10, wherein the compliant layer comprises a fibrous layer. The applicator of embodiment 11, wherein the compliant layer further comprises a compressible layer disposed between the convex engagement surface and the fibrous layer. The applicator of any one of embodiments 1-12, wherein the shank includes a coupling for a robotic arm.14. The applicator of any one of embodiments 1-12, wherein the shank includes a handle for manual operation.15. The applicator of any one of embodiments 1-14, wherein the joint has both x-axis and y-axis rotation limited within a range of from -30 degrees to +30 degrees.16. The applicator of any one of embodiments 15, wherein the joint has both x-axis and y-axis rotation limited within a range of from -15 degrees to +15 degrees.17. The applicator of any one of embodiments 16, wherein the joint has both x-axis and y-axis rotation limited within a range of from -5 degrees to +5 degrees.18. The applicator of any one of embodiments 1-17, wherein the joint, when relaxed, resiliently returns to a neutral position wherein there is z-axis alignment of the shank and the body to each other.19. A method of using the applicator of any one of embodiments 1-18, the method comprising: positioning an adhesive-backed fdm over the substrate; urging the convex engagement surface of the applicator against the adhesive-backed film to induce contact between the adhesive-backed film and the substrate; and while applying pressure against the adhesive-backed film, moving the applicator along a surface of the substrate to adhere the adhesive-backed film to the substrate, wherein rotation about its x-axis and / or y-axis is provided at the joint to reduce the degree of z-axis misalignment between a surface normal of the convex engagement surface and the surface of the substrate when in contact with each other.20. The method of embodiment 19, wherein the applicator comprises a compliant layer conformably disposed along the convex engagement surface, and further comprising applying a dry lubricant to the compliant layer prior to urging the convex engagement surface of the applicator against the adhesive-backed film.

[0050] Other options are also possible. For instance, it can be beneficial to apply a dry (i.e., particulate) lubricant to the compliant layer prior to urging the convex engagement surface of the applicator against the adhesive-backed film to be applied. Use of a porous compliant layer, such as a fibrous compliant layer, can be advantageous in this regard because the dry lubricant can be retained in the interstices of the compliant layer during installation.

[0051] All cited references, patents, and patent applications in the above application for letters patent are herein incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description shall control. The preceding description, given in order to enable one of ordinary skill in the art to practice the claimed disclosure, is not to be construed as limiting the scope of the disclosure, which is defined by the claims and all equivalents thereto.

Claims

CLAIMSWhat is claimed is:

1. An applicator for applying a film to a substrate, the applicator comprising: a shank; a body comprising a convex engagement surface; and a joint capable of providing x-axis rotation and / or y-axis rotation, wherein the joint operatively couples the shank and the body to each other.

2. The applicator of claim 1, wherein the joint is capable of providing both x-axis rotation and y- axis rotation.

3. The applicator of claim 1 or claim 2, further comprising a collapsible member that is capable of z-axis expansion and contraction, the collapsible member being coupled to the shank diametrically opposite the joint.

4. The applicator of any one of claim 3, wherein the collapsible member and the shank are removably coupled to each other.

5. The applicator of any one of claims 1-4, wherein the joint comprises a 2-axis gimbal.

6. The applicator of any one of claims 1-5, wherein z-axis rotation of the convex engagement surface relative to the shank is restricted.

7. The applicator of any one of claims 1-6, further comprising a compliant layer conformably disposed along the convex engagement surface.

8. The applicator of claim 7, wherein the compliant layer further comprises a compressible layer disposed between the convex engagement surface and the fibrous layer.

9. The applicator of any one of claims 1-8, wherein the shank includes a coupling for a robotic arm or a handle for manual operation.

10. The applicator of any one of claims 1-9, wherein the joint has both x-axis and y-axis rotation limited within a range of from -30 degrees to +30 degrees.

11. The applicator of claim 10, wherein the joint has both x-axis and y-axis rotation limited within a range of from -15 degrees to +15 degrees.

12. The applicator of claim 11, wherein the joint has both x-axis and y-axis rotation limited within a range of from -5 degrees to +5 degrees.

13. The applicator of any one of claims 1-12, wherein the joint, when relaxed, resiliently returns to a neutral position wherein there is z-axis alignment of the shank and the body to each other.

14. A method of using the applicator of any one of claims 1-13, the method comprising: positioning an adhesive-backed fdm over the substrate; urging the convex engagement surface of the applicator against the adhesive-backed film to induce contact between the adhesive-backed film and the substrate; and while applying pressure against the adhesive-backed film, moving the applicator along a surface of the substrate to adhere the adhesive-backed film to the substrate, wherein rotation about its x-axis and / or y-axis is provided at the joint to reduce the degree of z-axis misalignment between a surface normal of the convex engagement surface and the surface of the substrate when in contact with each other.

15. The method of claim 14, wherein the applicator comprises a compliant layer conformably disposed along the convex engagement surface, and further comprising applying a dry lubricant to the compliant layer prior to urging the convex engagement surface of the applicator against the adhesive-backed film.

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