Method of manufacturing a film having a layer with a barrier coating

Abstract

A method of manufacturing an elastic and resilient film, to be applied to a surface of an endless moving handrail, includes providing a first layer having sufficient resilience to accommodate strains occurring on the surface of the endless moving handrail, and including a barrier coating. The barrier coating includes nano-clay dispersed in an elastomeric material selected from one of neoprene, nitrile rubber, and butyl rubber. A substantially transparent layer is also provided. The first layer and the substantially transparent layer are laminated together. Optionally, a second layer is arranged between the first layer and the substantially transparent layer. The barrier coating substantially retards the transmission of staining chemicals blooming from the surface of the endless moving handrail.

1 . A method of manufacturing an elastic and resilient film to be applied to a surface of an endless moving handrail, the method comprising:
 providing a first layer having sufficient resilience to accommodate strains occurring on the surface of the endless moving handrail, the first layer comprising an adhesive on a bottom surface of the first layer, and a barrier coating on a top surface of the first layer, the barrier coating comprising nano-clay dispersed in an elastomeric material, the elastomeric material being selected from one of neoprene, nitrile rubber, and butyl rubber;   providing a second layer having sufficient resilience to accommodate strains occurring on the surface of the endless moving handrail, the second layer comprising an adhesive on a bottom surface of the second layer;   providing a substantially transparent layer having sufficient resilience to accommodate strains occurring on the surface of the endless moving handrail, the substantially transparent layer comprising an adhesive on a bottom surface of the substantially transparent layer; and   laminating the first layer, the second layer, and the substantially transparent layer together,   wherein the barrier coating substantially retards the transmission of staining chemicals blooming from the surface of the endless moving handrail.   
     
     
         2 . The method of  claim 1 , further comprising, prior to lamination, applying print to a top surface of the second layer. 
     
     
         3 . The method of  claim 2 , wherein the second layer receives the print and is thereafter laminated together with the substantially transparent layer to protect the print. 
     
     
         4 . The method of  claim 3 , wherein the combined second and substantially transparent layers are laminated onto the first layer. 
     
     
         5 . The method of  claim 3 , wherein the first and second layers are laminated together prior to application of the print. 
     
     
         6 . The method of  claim 2 , wherein, prior to application of the print, the top surface of the second layer is treated with a surface treatment to promote adhesion of the print thereto. 
     
     
         7 . The method of  claim 1 , further comprising, prior to lamination, applying reverse print to the bottom surface of the substantially transparent layer between the adhesive and the substantially transparent layer. 
     
     
         8 . The method of  claim 7 , wherein the substantially transparent layer with the reverse print is laminated onto the second layer. 
     
     
         9 . The method of  claim 8 , wherein the combined substantially transparent and second layers are laminated onto the first layer. 
     
     
         10 . The method of  claim 8 , wherein, prior to lamination of the substantially transparent layer on to the second layer, the first and second layers are laminated together. 
     
     
         11 . The method of  claim 7 , wherein, prior to application of the reverse print to the bottom surface of the substantially transparent layer, the bottom surface is treated with a surface treatment to promote adhesion of the reverse print thereto. 
     
     
         12 . The method of  claim 1 , wherein the top surface of the first layer is treated with a surface treatment to promote adhesion of the barrier coating thereto. 
     
     
         13 . The method of  claim 1 , wherein the first layer is provided with a second barrier coating on the bottom surface between the first layer and the adhesive. 
     
     
         14 . The method of  claim 13 , wherein the bottom surface of the first layer is treated with a surface treatment to promote adhesion of the second barrier coating thereto. 
     
     
         15 . The method of  claim 1 , further comprising applying the elastic and resilient film to the surface of the endless moving handrail. 
     
     
         16 . A method of manufacturing an elastic and resilient film to be applied to a surface of an endless moving handrail, the method comprising:
 providing a first layer having sufficient resilience to accommodate strains occurring on the surface of the endless moving handrail, the first layer comprising an adhesive underlying a bottom surface of the first layer, and a barrier coating on at least one of a top surface and the bottom surface of the first layer, the barrier coating comprising nano-clay dispersed in an elastomeric material, the elastomeric material being selected from one of neoprene, nitrile rubber, and butyl rubber;   providing a substantially transparent layer having sufficient resilience to accommodate strains occurring on the surface of the endless moving handrail, the substantially transparent layer comprising an adhesive on a bottom surface of the substantially transparent layer; and   laminating the first layer and the substantially transparent layer together,   wherein the barrier coating substantially retards the transmission of staining chemicals blooming from the surface of the endless moving handrail.   
     
     
         17 . The method of  claim 16 , comprising one of:
 when the barrier coating is provided on the bottom surface of the first layer, print is applied to the top surface of the first layer prior to lamination; and   when the barrier coating is provided on the top surface of the first layer, print is applied to a top surface of the barrier coating prior to lamination.   
     
     
         18 . The method of  claim 17 , wherein the first layer receives the print and is thereafter laminated together with the substantially transparent layer to protect the print. 
     
     
         19 . The method of  claim 17 , wherein, prior to application of the print, the top surface of the first layer or the top surface of the barrier coating is treated with a surface treatment to promote adhesion of the print thereto. 
     
     
         20 . The method of  claim 16 , wherein at least one of the top and bottom surfaces of the first layer is treated with a surface treatment to promote adhesion of the barrier coating thereto. 
     
     
         21 . The method of  claim 16 , wherein reverse print is applied to a bottom surface of the substantially transparent layer between the adhesive and the substantially transparent layer prior to lamination. 
     
     
         22 . The method of  claim 21 , wherein, prior to application of the reverse print to the bottom surface of the substantially transparent layer, the bottom surface is treated with a surface treatment to promote adhesion of the reverse print thereto. 
     
     
         23 . The method of  claim 16 , wherein the barrier coating is formed by:
 continuously applying a liquid coating material as a solution comprising a solvent and particles onto the at least one of the top and bottom surfaces of the first layer;   controlling the liquid coating material to provide a coating having a substantially uniform thickness; and   promoting vaporization of the solvent, causing the liquid coating material to dry to leave the particles as the barrier coating and having sufficient resilience to accommodate the strains occurring on the surface of the endless moving handrail.   
     
     
         24 . The method as claimed in  claim 23 , wherein the step of controlling the liquid coating material comprises controlling the thickness of the coating by one of a post-metered or pre-metered process. 
     
     
         25 . The method as claimed in  claim 23 , wherein the step of controlling the liquid coating material comprises using a knife-over-roll technique to control the thickness of the coating. 
     
     
         26 . The method as claimed in  claim 23 , wherein the barrier coating is formed by two or more separate applications of the liquid coating material. 
     
     
         27 . The method as claimed in  claim 26 , wherein prior to application of a second of the two or more applications of the liquid coating material, a first application of the barrier coating is treated with a surface treatment. 
     
     
         28 . The method as claimed in  claim 23 , further comprising a step of forming a second barrier coating on a surface of the first layer opposite that which the first barrier coating is applied. 
     
     
         29 . The method of  claim 16 , further comprising applying the elastic and resilient film to the surface of the endless moving handrail. 
     
     
         30 . A method of manufacturing an elastic and resilient film to be applied to a surface of an endless moving handrail, the method comprising:
 providing a first layer comprising a top surface, a bottom surface, and a barrier coating arranged on at least one of the top and bottom surfaces, the barrier coating comprising nano-clay dispersed in an elastomeric material, the elastomeric material being selected from one of neoprene, nitrile rubber, and butyl rubber;   providing a substantially transparent film layer; and   laminating the first layer and the substantially transparent layer together,   wherein the first layer, the barrier coating and the substantially transparent layer each have sufficient resilience to accommodate strains occurring on the surface of the endless moving handrail, and   wherein the barrier coating substantially retards the transmission of staining chemicals blooming from the surface of the endless moving handrail.