Multi-layer dry paint decorative laminate having discoloration prevention barrier

Abstract

A decorative dry paint wall film includes a layer of dry paint, a pressure-sensitive adhesive layer on one side of the dry paint layer, and a release liner in releasable contact with the dry paint layer on a side opposite from the pressure-sensitive adhesive (PSA). The release liner has a matte release coat layer that contacts the dry paint layer. The release liner is released from the dry paint layer after the PSA side is attached to a wall. The matte release coat transfers a matte finish to the dry paint layer when the release liner is removed. The wall film includes a barrier layer to protect against significant discoloration of the color in the dry paint layer caused by migration of azo-type pigments from a painted wall surface. The barrier layer in one embodiment comprises a dry emulsion containing ethylene-vinyl alcohol and a dispersed polymeric material which in one embodiment comprises a urethane material.

1 . A multi-layer decorative laminate for applying a layer of color to a substrate surface, the laminate comprising: 
 a flexible decorative dry paint layer comprising a color layer which includes a resinous binder and a pigment,    a pressure-sensitive adhesive layer overlying a surface of the decorative dry paint layer and adapted for adhering the laminate to a substrate surface; and    a thin, flexible barrier layer disposed between the adhesive layer and the color layer, the barrier layer comprising an ethylene vinyl alcohol material forming a dry film form emulsion that retards migration of discoloration-causing pigments from a painted surface of the substrate through the adhesive layer to the color layer.    
   
   
       2 . The article according to  claim 1  in which the barrier layer produces a color shift of less than about 0.40 Δb* C.I.E. color units at 60° C. for at least 400 hours.  
   
   
       3 . The article according to  claim 1  in which the barrier layer retards degradation of the adhesive layer caused by constituents migrating from the color layer toward the adhesive layer.  
   
   
       4 . The article according to  claim 1  in which the barrier layer has a glass transition temperature (T g ) greater than about 50° C.  
   
   
       5 . The article according to  claim 1  in which the barrier layer material inhibits migration of azo-type discoloration-causing pigments.  
   
   
       6 . The article according to  claim 1  in which the barrier layer comprises an emulsion containing ethylene-vinyl alcohol blended with a dispersed polymeric material.  
   
   
       7 . The article according to  claim 6  in which the dispersed polymeric material comprises a urethane material.  
   
   
       8 . The article according to  claim 6  in which the barrier layer contacts both the pressure-sensitive adhesive layer and the color layer in the absence of separate adhesive tie layers.  
   
   
       9 . The article according to  claim 6  in which the ethylene vinyl alcohol component is thermoplastic or crosslinked.  
   
   
       10 . The article according to  claim 6  in which the dispersed polymeric material migrates to form a boundary layer on a side of the barrier layer.  
   
   
       11 . A multi-layer decorative laminate for applying a layer of color to a substrate surface, the laminate comprising: 
 a flexible decorative dry paint layer comprising a color layer which includes a resinous binder and a pigment,    a pressure-sensitive adhesive layer overlying the decorative dry paint layer; and    a thin, flexible barrier coat between the adhesive layer and the color layer, the barrier coat made from an emulsion of ethylene-vinyl alcohol copolymer and a migratory polymeric material in dry film form to provide a barrier layer as a stable emulsion with an internal boundary layer formed by the migratory polymeric material, the barrier layer and its internal boundary layer effective to inhibit migration of discoloration-causing azo-type pigments from a painted surface of the substrate through the adhesive layer to the color layer sufficiently to essentially prevent migrating pigments from a painted surface of the substrate from causing noticeable color change in the color layer under room temperature conditions.    
   
   
       12 . The process according to  claim 11  in which the migratory polymeric material comprises a urethane material.  
   
   
       13 . The process according to  claim 11  in which the barrier layer emulsion is a thermoplastic or crosslinked material.  
   
   
       14 . A multi-layer decorative wall film for applying a layer of color to a substrate surface, the wall film comprising: 
 a flexible decorative dry paint layer comprising a color layer which includes a resinous binder and a pigment;    a pressure-sensitive adhesive layer overlying a surface of the dry paint layer and adapted for adhering the laminate to a substrate surface;    a release liner overlying a surface of the dry paint layer opposite from the adhesive layer, the release liner removable from the dry paint layer for exposing an outer surface of the decorative dry paint layer when the pressure-sensitive adhesive layer adheres the laminate to the substrate surface and the release liner is peeled away from the decorative dry paint layer; and    a thin, flexible barrier layer disposed between the adhesive layer and the color layer, the barrier layer made from an ethylene-vinyl alcohol material that in dry film form inhibits migration of discoloration-causing pigments from a painted surface of the substrate through the adhesive layer to the color layer sufficiently to retard noticeable color change, caused by such pigments, from occurring in the color layer under room temperature conditions.    
   
   
       15 . The article according to  claim 14  in which the barrier layer material inhibits migration of azo-type discoloration-causing pigments.  
   
   
       16 . The article according to  claim 14  in which the barrier layer comprises an emulsion containing ethylene-vinyl alcohol and a dispersed polymeric material.  
   
   
       17 . The article according to  claim 16  in which the dispersed polymeric material is selected from the group which includes urethane, acrylic, polyester resins, ethylene vinyl acetate copolymer, and combinations thereof.  
   
   
       18 . The article according to  claim 17  in which the barrier layer contacts both the pressure-sensitive adhesive layer and the color layer in the absence of separate adhesive tie layers.  
   
   
       19 . The article according to  claim 14  in which the decorative dry paint layer has a dry film thickness from about 0.6 to about 1.6 mils to provide the decorative, protective and opacity properties sufficient to function as a wall paint.  
   
   
       20 . A multi-layer decorative laminate for applying a layer of color to a substrate surface, the laminate comprising: 
 a flexible decorative dry paint layer comprising a color layer which includes a resinous binder and a pigment;    a pressure-sensitive adhesive layer overlying a surface of the decorative dry paint layer and adapted for adhering the laminate to a substrate surface;    a release liner overlying a surface of the decorative dry paint layer opposite from the adhesive layer, the release liner removable from the decorative dry paint layer for exposing an outer surface of the dry paint layer when the pressure-sensitive adhesive layer adheres the laminate to the substrate surface and the release liner is peeled away from the dry paint layer; and    a thin, flexible barrier layer disposed between the adhesive layer and the color layer, the barrier layer made from an ethylene-vinyl alcohol material that in dry film form inhibits migration of discoloration-causing azo-type pigments from a painted surface of the substrate through the adhesive layer to the color layer, in which the barrier layer produces a color shift of less than about 0.4 Δb* C.I.E. color units at 60° C. for at least 400 hours.    
   
   
       21 . The article according to  claim 20  in which the barrier layer comprises an emulsion containing ethylene-vinyl alcohol and a dispersed polymeric material that improves adhesion of the barrier layer to the adhesive layer and the color layer.  
   
   
       22 . The article according to  claim 21  in which the dispersed polymeric material comprises a urethane material.  
   
   
       23 . The article according to  claim 22  in which the barrier layer contacts both the pressure-sensitive adhesive layer and the color layer in the absence of separate adhesive tie layers.  
   
   
       24 . A multi-layer decorative wall film for applying a layer of color to a substrate surface, the wall film comprising: 
 a flexible decorative dry paint layer comprising a color layer which includes a resinous binder and a pigment;    a decorative pressure-sensitive adhesive layer overlying a surface of the dry paint layer and adapted for adhering the wall film to a substrate surface; and    a thin, flexible barrier layer disposed between the adhesive layer and the color layer, the barrier layer comprising an emulsion of ethylene-vinyl alcohol copolymer and a dispersed urethane material in either a thermoplastic or crosslinked dry film form that reduces migration of discoloration-causing pigments from a painted surface of the substrate through the adhesive layer to the color layer.    
   
   
       25 . The article according to  claim 24  in which the barrier layer material inhibits migration of azo-type discoloration-causing pigments to an amount less than about 0.4Δb* C.I.E. color units at 60° C. for at least 400 hours.