Partially Perforated Adhesive Assembly for Air Bubble Escape

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Solution Overview

Problem

Non-perforated self-adhesive vinyl films applied to substrates often form air bubbles that are difficult to remove, and differential thermal expansion of glass windows due to varying ink reflectivity can lead to delamination and sound reflection issues, as glass surfaces reflect a high proportion of sound energy.

Innovation Solution

A partially perforated assembly comprising a perforated film layer, a perforated adhesive layer, and a non-perforated overlaminate film layer with an interconnected void network that allows air passage between perforation holes, created by embossing techniques during the manufacturing process, which helps in air escape and sound absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a non-perforated self-adhesive vinyl film is applied to a substrate, then the film provides a continuous adhesive surface, but air bubbles form between the adhesive and substrate that are difficult to remove

Engineering Contradiction:

Improvecontinuous adhesive surfaceVSAvoidair bubble removal

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The patent applies a porous or micro-perforated release liner to the adhesive layer, creating a network of tiny voids that allow air bubbles to escape during application. This porous structure maintains the continuous adhesive surface while providing air escape pathways, resolving the contradiction between surface continuity and air bubble removal ease.

Inventive Principle:

Principle #31Porous materials

2Reliability

If a non-perforated overlaminate is applied to a perforated film layer, then the overlaminate protects the imaged surface from abrasion and environmental damage, but air pressure builds up in the perforation holes

Engineering Contradiction:

Improvesurface protectionVSAvoidair pressure in perforation holes

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent uses a porous or micro-perforated release liner that allows air pressure to dissipate through the adhesive layer, preventing pressure buildup in the perforation holes while the non-perforated overlaminate provides surface protection. The porous structure acts as a pressure relief mechanism.

Inventive Principle:

Principle #31Porous materials

3Loss of information

If glass windows are imaged with adjacent areas of ink of different reflectivity, then the graphic assembly provides visual information, but differential thermal expansion causes glass breakage

Engineering Contradiction:

Improvevisual information transmissionVSAvoiddifferential thermal expansion

Core Design Contradiction:

Loss of informationVSObject-affected harmful factors

Solution Approach 1:

The porous or micro-perforated release liner creates air channels that allow air movement and pressure equalization, reducing the impact of differential thermal expansion on the glass substrate. The air circulation through the porous structure helps dissipate thermal stresses.

Inventive Principle:

Principle #31Porous materials

4Loss of energy

If sound absorption panels with perforated face material and fibrous core material are used, then sound energy is absorbed, but the assembly becomes complex and bulky

Engineering Contradiction:

Improvesound energy absorptionVSAvoidassembly structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent combines the release liner function with the sound absorption function by using a porous or micro-perforated adhesive layer that provides both adhesive properties and sound absorption capabilities. This merging of functions eliminates the need for separate sound absorption materials, reducing assembly complexity and bulk.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The interconnected void network facilitates air escape from air bubbles, reduces the risk of delamination due to thermal expansion, and enhances sound absorption by dissipating sound energy through air movement and friction within the assembly.

Implementation Method 1

an inter-connected void network within at least one of said remaining layers of said assembly allows the passage of air from one perforation in said film layer and said adhesive layer to another perforation in said film layer and said adhesive layer

Methodology Applied

Scientific EffectAir movement through interconnected voids: Porosity

Implementation Method 2

Sound absorption panels are known comprising a perforated face material and a fibrous core material or foamic materials, typically having a non-planar, deformed surface

Methodology Applied

Scientific EffectSound absorption: Acoustic Absorption

Data Source

PatentUS11325359B2Partially perforated assembly

Publication Date: 2022.05.10 CONTRA VISION

AI summary

A partially perforated assembly includes a perforated film layer, a perforated adhesive layer applied to one side of said film layer, a non-perforated overlaminate film layer on the other side of said perforated film layer, and a release liner on the side of said perforated adhesive layer remote from said perforated film layer. When the release liner is removed and the remaining layers of the assembly are applied to a substrate, the remaining layers of the assembly comprise a void network. The void network fluidly interconnects at least two discrete perforation holes in the perforated film and adhesive layers with each other and/or the ambient environment around the assembly so as to facilitate air communication among the holes and/or between the holes and the ambient environment.