Multi-layer dry paint decorative laminate having discoloration prevention barrier

Abstract

A decorative dry paint transfer laminate 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 surface. The matte release coat adheres to the dry paint layer to provide a protective function but also to transfer a decorative matte finish to the dry paint layer when the release liner is removed from it. The laminate includes a barrier layer to protect against significant discoloration of the color in the dry paint layer caused by migration of mono azo pigments from a painted surface.

1 . A multi-layer decorative laminate for applying a layer of color to a substrate surface, the laminate comprising: 
 a dry paint layer comprising a color layer which includes a binder and a pigment, the dry paint layer having an upper surface and a lower surface,    a pressure-sensitive adhesive layer overlying the upper surface of the dry paint layer and adapted for adhering the laminate to a substrate surface at room temperature;    a release liner overlying the lower surface of the dry paint layer, the release liner removable from the dry paint layer at room temperature for exposing an outer surface of the dry paint layer when the pressure-sensitive adhesive layer adheres the laminate to the substrate surface under application of pressure and the release liner is thereafter peeled away from the dry paint layer; and    a thin flexible barrier layer disposed between the adhesive layer and the color layer of the laminate,    wherein the decorative laminate, excluding the release liner, has a total dry film thickness of 1.6 mils or less,    wherein the barrier layer has a dry film thickness from about 0.05 to about 0.20 mil, and    wherein the barrier layer comprises a polymeric film containing a barrier material that inhibits migration of or captures migrating discoloration-causing pigments from a painted surface of the substrate through the adhesive layer to the color layer of the laminate sufficiently to essentially prevent noticeable color change caused by the migrating pigments from occurring in the color layer of the laminate under room temperature conditions.    
   
   
       2 . The article according to  claim 1  in which the barrier layer material inhibits or captures migrating mono azo discoloration-causing pigments.  
   
   
       3 . A multi-layer decorative laminate for applying a layer of color to a substrate surface, the laminate comprising: 
 a dry paint layer comprising a color layer which includes a binder and a pigment, the dry paint layer having an upper surface and a lower surface,    a pressure-sensitive adhesive layer overlying the upper surface of the dry paint layer and adapted for adhering the laminate to a substrate surface at room temperature;    a release liner overlying the lower surface of the dry paint layer, the release liner removable from the dry paint layer at room temperature for exposing an outer surface of the dry paint layer when the pressure-sensitive adhesive layer adheres the laminate to the substrate surface under application of pressure and the release liner is thereafter peeled away from the dry paint layer; and    a thin flexible barrier layer disposed between the adhesive layer and the color layer of the laminate, the barrier layer comprising a polymeric film containing a material that inhibits migration of or captures migrating discoloration-causing azo-type pigments from a painted surface of the substrate through the adhesive layer to the color layer of the laminate, in which the decorative laminate, excluding the release liner, has a total dry film thickness of 1.6 mils or less, and in which the barrier material has a dry film thickness of not more than about 10% of the total thickness of the decorative laminate (exclusive of the release liner).    
   
   
       4 . A multi-layer decorative laminate for applying a layer of color to a substrate surface, the laminate comprising: 
 a dry paint layer comprising a color layer which includes a binder and a pigment, the dry paint layer having an upper surface and a lower surface,    a pressure-sensitive adhesive layer overlying the upper surface of the dry paint layer and adapted for adhering the laminate to a substrate surface at room temperature;    a release liner overlying the lower surface of the dry paint layer, the release liner removable from the dry paint layer at room temperature for exposing an outer surface of the dry paint layer when the pressure-sensitive adhesive layer adheres the laminate to the substrate surface under application of pressure and the release liner is thereafter peeled away from the dry paint layer; and    a thin flexible barrier layer disposed between the adhesive layer and the color layer of the laminate,    wherein the decorative laminate, excluding the release liner, has a total dry film thickness of 1.6 mils or less,    wherein the barrier layer has a dry film thickness from about 0.05 to about 0.20 mil, and    wherein the barrier layer comprises an acrylic resinous material and a fine particulate additive comprising a metal compound, a metal oxide and/or a metal salt dispersed in the acrylic resinous material in an amount that reduces migration of or captures migrating discoloration-causing pigments from a painted surface of the substrate through the adhesive layer to the color layer of the laminate.    
   
   
       5 . The article according to  claim 4  in which the barrier layer material inhibits or captures migrating mono azo discoloration-causing pigments.  
   
   
       6 . A self-wound multi-layer laminate for applying a layer of color to a substrate surface, the laminate comprising: 
 a dry paint layer comprising a color layer which includes a binder and a pigment, the dry paint layer having an upper surface and a lower surface,    a pressure-sensitive adhesive layer overlying the upper surface of the dry paint layer and adapted for adhering the laminate to a substrate surface at room temperature;    a release liner overlying the lower surface of the dry paint layer, the release liner having a matte release coat releasably adhered to the lower surface of the dry paint layer, and an adhesive release coat layer on a side of the release liner opposite from the dry paint layer, the release liner and the matte release coat removable from the dry paint layer at room temperature,    the matte release coat transferring a matte finish to an exposed surface of the dry paint layer when the pressure-sensitive adhesive layer adheres the laminate to the substrate surface under application of pressure and the release liner is thereafter peeled away from the dry paint layer,    the laminate adapted for being self-wound into a roll with the pressure-sensitive adhesive layer in contact with the adhesive release coat layer,    the adhesive release coat layer and the pressure-sensitive adhesive layer having an unwind release force between them which is lower than a carrier release force between the matte release coat and the dry paint layer, such that the adhesive release coat preferentially releases the liner from contact with the pressure-sensitive adhesive layer when unwinding the laminate from its roll form, while the matte release coat on the release liner maintains contact with the dry paint layer when the laminate is being unwound from its roll form and the laminate is adhered to the substrate via the pressure-sensitive adhesive, and    a barrier layer disposed between the adhesive layer and the color layer of the laminate,    wherein the decorative laminate, excluding the release liner, has a total dry film thickness of 1.6 mils or less, and    wherein the barrier layer has a dry film thickness from about 0.05 to about 0.20 mil,    the barrier layer comprising a polymeric film containing a barrier material that inhibits migration of or captures migrating discoloration-causing pigments from a painted surface of the substrate to which the adhesive side of the laminate is adhered, the barrier material made of a composition adapted to essentially prevent noticeable color change caused by the migrating pigments from occurring in the color layer of the laminate under room temperature conditions.    
   
   
       7 . The article according to  claim 6  in which the barrier layer material inhibits or captures migrating mono azo discoloration-causing pigments.  
   
   
       8 . A process for making a multi-layer decorative laminate for applying a layer of color to a substrate surface, the process comprising: 
 forming a dry paint layer on a release liner, the dry paint layer comprising a color layer which includes a binder and a pigment, the dry paint layer having an upper surface and a lower surface,    applying a pressure-sensitive adhesive layer to the upper surface of the dry paint layer, the adhesive layer adapted for adhering the laminate to a substrate surface at room temperature;    the release liner overlying the lower surface of the dry paint layer, the release liner removable from the dry paint layer at room temperature for exposing an outer surface of the dry paint layer when the pressure-sensitive adhesive layer adheres the laminate to the substrate surface under application of pressure and the release liner is peeled away from the dry paint layer; and    applying a thin flexible barrier layer between the adhesive layer and the color layer, the barrier layer made from a material that inhibits migration of or captures migrating discoloration-causing azo-type pigments from a painted surface of the substrate through the adhesive layer to the color layer sufficiently to essentially prevent noticeable color change caused by the migrating pigments from occurring in the color layer under room temperature conditions.    
   
   
       9 . The process according to  claim 8  in which the adhesive layer is direct-coated on the barrier layer.  
   
   
       10 . The article according to  claim 1  in which the dry paint layer further includes an outer clear coat layer overlying the color layer and in releasable contact with the release liner.  
   
   
       11 . The article according to  claim 1  in which the release liner has a matte release coat releasably adhered to the lower surface of the dry paint layer, the matte release coat transferring a matte finish to the exposed surface of the dry paint layer when the release liner is peeled away from the dry paint layer.  
   
   
       12 . The article according to  claim 3  in which the dry paint layer further includes an outer clear coat layer overlying the color layer and in releasable contact with the release liner.  
   
   
       13 . The article according to  claim 3  in which the release liner has a matte release coat releasably adhered to the lower surface of the dry paint layer, the matte release coat transferring a matte finish to the exposed surface of the dry paint layer when the release liner is peeled away from the dry paint layer.  
   
   
       14 . The article according to  claim 4  in which the dry paint layer further includes an outer clear coat layer overlying the color layer and in releasable contact with the release liner.  
   
   
       15 . The article according to  claim 4  in which the release liner has a matte release coat releasably adhered to the lower surface of the dry paint layer, the matte release coat transferring a matte finish to the exposed surface of the dry paint layer when the release liner is peeled away from the dry paint layer.