Adhesives having a microreplicated topography and methods of making and using same

Abstract

Adhesives having a microreplicated topography are prepared from contacting a microembossed pattern to a layer of adhesive. When an adhesion interface is established between the layer of adhesive and a supporting substrate, the topography of the adhesive surface controls the performance of the adhesion interface. Articles having microreplicated adhesive surfaces are also disclosed that have an advantage of providing microchannels for fluid egress for an effective period of time. Multiple microembossed patterns produce microreplicated adhesive surfaces having both microchannels for fluid egress and pegs for improved adhesive properties.

1 . A method of applying an adhesive article to a substrate, comprising: 
 (A) providing an adhesive article comprising:    (a) a continuous pressure sensitive adhesive layer having a first major surface and a second major surface, said first major surface including: (i) a plurality of lands that provide a bonding surface for bonding the article to the substrate; and (ii) a plurality of channels between the lands that extend below the lands to a depth of about 3 μm to about 45 μm, and enable fluid egress when the article is applied to the substrate, wherein the channels occupy about 1% to about 65% of the total area of the first major surface of the adhesive layer; and    (b) a backing on the second major surface of the adhesive layer;    (B) positioning the article on the substrate until the article is in a desired location;    (C) forming at the desired location a bond between the lands and the substrate; and    (D) removing fluid through the channels.    
   
   
       2 . The method of  claim 1 , wherein the adhesive article further comprises a release liner having a first major surface contacting the first major surface of the adhesive layer, and the method further comprises removing the release liner prior to step (B).  
   
   
       3 . The method of  claim 2 , wherein the first major surface of the release liner comprises (a) plurality of lands corresponding to the lands of the first major surface of the adhesive layer, and (b) a plurality of ridges corresponding to the channels of the first major surface of the adhesive layer.  
   
   
       4 . The method of  claim 1 , wherein the backing has (i) a first major surface on the second major surface of the adhesive layer and (ii) a second major surface, wherein the second major surface of the backing further comprises a graphic image.  
   
   
       5 . The method of  claim 4 , wherein the adhesive article is in the form of a large format image graphic film.  
   
   
       6 . The method of  claim 1 , wherein the backing has (i) a first major surface on the second major surface of the adhesive layer and (ii) a second major surface, wherein the second major surface of the backing is capable of being graphically imaged.  
   
   
       7 . The method of  claim 6 , wherein the adhesive article is in the form of a large format image graphic film.  
   
   
       8 . The method of  claim 1 , wherein the substrate comprises a surface of a vehicle.  
   
   
       9 . The method of  claim 1 , wherein the substrate comprises a large flat surface interrupted by rivets, seams, and the like.  
   
   
       10 . The method of  claim 1 , wherein the pressure sensitive adhesive and channel structure are selected such that once the bond is established between the lands and the substrate, at least a portion of the channels remain open for a period of time sufficient to remove fluid from the interface between the article and the substrate.  
   
   
       11 . The method of  claim 1 , wherein the pressure sensitive adhesive and channel structure are selected such that at least a portion of the channels remain open during the period in which the article is applied to a substrate and a bond is established between the lands and the substrate.  
   
   
       12 . The method of  claim 11 , wherein the channels occupy about 2% to about 50% of the total area of the first major surface of the adhesive layer.  
   
   
       13 . The method of  claim 11 , wherein the channels occupy about 5% to about 15% of the total area of the first major surface of the adhesive layer.  
   
   
       14 . The method of  claim 1 , wherein the pressure sensitive adhesive and channel structure are selected such that at least a portion of the channels remain open (a) during the period in which the article is applied to a first substrate and a bond is established between the lands and the first substrate, and (b) thereafter when the article is removed from the first substrate and re-applied to a substrate that may be the same as, or different from, the first substrate.  
   
   
       15 . The method of  claim 14 , wherein the channels occupy about 2% to about 50% of the total area of the first major surface of the adhesive layer.  
   
   
       16 . The method of  claim 14 , wherein the channels occupy about 5% to about 15% of the total area of the first major surface of the adhesive layer.  
   
   
       17 . The method of  claim 1 , wherein the pressure sensitive adhesive and channel structure are selected such that following application of the article to a substrate and establishment of a bond between the lands and the substrate, at least a portion of the channels remain open for at least one hour at 22° C. and 50% relative humidity.  
   
   
       18 . The method of  claim 1 , wherein the pressure sensitive adhesive and channel structure are selected such that following application of the article to a substrate and establishment of a bond between the lands and the substrate, at least a portion of the channels remain open for at least 24 hours at 22° C. and 50% relative humidity.  
   
   
       19 . The method of  claim 1 , wherein the pressure sensitive adhesive and channel structure are selected such that following application of the article to a substrate and establishment of a bond between the lands and the substrate, at least a portion of the channels remain open for at least 8 days at 22° C. and 50% relative humidity.  
   
   
       20 . The method of  claim 1 , wherein the pressure sensitive adhesive and channel structure are selected such that following application of the article to a substrate and establishment of a bond between the lands and the substrate, at least a portion of the channels remain open for at least 24 hours in an oven maintained at 66° C.  
   
   
       21 . The method of  claim 1 , wherein the pressure sensitive adhesive and channel structure are selected such that following application of the article to a substrate and establishment of a bond between the lands and the substrate, at least a portion of the channels remain open for at least 8 days in an oven maintained at 66° C.