Composite stencils, methods of making, and methods of decorating with composite stencils

Abstract

A composite stencil for applying designs to walls and other surfaces is disclosed. The stencil includes a porous textile support layer to which a flexible stencil mask is bonded by an adhesion layer. The support layer supports unconnected parts of the stencil mask without bridges common with traditional stencils. Further, the textile support layer in the open areas of the stencil can be colored with a sublimation dye to suggest to a user the colors that should be applied in the various areas of the stencil. A pressure sensitive adhesive is applied to the back of the stencil. In use, the stencil is removably adhered to a surface by the pressure sensitive adhesive, whereupon paint or other pigment is applied through the textile support layer to the surface. The lack of bridges permits the entire design to be applied with a single stencil in a single session. The stencil is cleanable and reusable to apply additional designs.

1 . A composite stencil comprising:
 a support layer configured to allow paint to pass therethrough and having a front side and a back side;   a stencil mask on the front side or the back side of the support layer and defining masked areas of the composite stencil and open areas through which paints are to be applied;   a pressure sensitive adhesive applied to the back side of the support layer in the pattern of the stencil mask for removably adhering the stencil to a surface; and   a protective sheet covering the pressure sensitive adhesive layer and being removable to expose the pressure sensitive adhesive for adhering the stencil to a surface and re-applyable for protecting the pressure sensitive adhesive when the stencil is not in use.   
     
     
         2 . A composite stencil as claimed in  claim 1  wherein the support layer comprises a woven material. 
     
     
         3 . A composite stencil as claimed in  claim 2  wherein the support layer comprises a textile. 
     
     
         4 . A composite stencil as claimed in  claim 3  wherein the textile is woven to define openings sized to allow pigments to pass through the support layer in the open areas of the stencil. 
     
     
         5 . A composite stencil as claimed in  claim 1  wherein the support layer is stabilized to enhance stability and rigidity. 
     
     
         6 . A composite stencil as claimed in  claim 5  wherein the stabilized support layer is a heat and pressure stabilized support layer. 
     
     
         7 . A composite stencil as claimed in  claim 1  wherein the stencil mask comprises a flexible polymer. 
     
     
         8 . A composite stencil as claimed in  claim 7  wherein the flexible polymer comprises a plastisol or an organosol. 
     
     
         9 . A composite stencil as claimed in  claim 8  wherein the plastisol or organosol is a printable ink prior to application. 
     
     
         10 . A composite stencil as claimed in  claim 1  wherein the protective sheet comprises a siliconized paper. 
     
     
         11 . A composite stencil as claimed in  claim 1  further comprising an adhesion layer between the stencil mask and the support layer bonding the stencil mask and support layer together. 
     
     
         12 . A composite stencil as claimed in  claim 3 , further comprising an adhesion layer between the stencil mask and the support layer bonding the stencil mask and support layer together, wherein the adhesion layer comprises a thermal polymer, termed thermal polymer, fused both to the stencil mask and into the mesh of said textile. 
     
     
         13 . A composite stencil as claimed in  claim 12  wherein the thermal polymer is applied in the same pattern as the stencil mask. 
     
     
         14 . A composite stencil as claimed in  claim 1  wherein the support layer is dyed within at least one open area. 
     
     
         15 . A composite stencil as claimed in  claim 14  wherein the at least one open area is dyed with a sublimation dye. 
     
     
         16 . A composite stencil as claimed in  claim 14  wherein at least two open areas are dyed. 
     
     
         17 . A composite stencil as claimed in  claim 16  and wherein the colors of the dyed open areas suggests colors to be applied through the open areas during use of the stencil. 
     
     
         18 . A composite stencil as claimed in  claim 1  wherein the support layer comprises a non-woven material. 
     
     
         19 . A composite stencil as claimed in  claim 18  wherein the non-woven material comprises a glass fiber material. 
     
     
         20 . A composite stencil as claimed in  claim 1  wherein the protective sheet comprises a silicon coated film. 
     
     
         21 . A composite stencil as claimed in  claim 20  wherein the film is selected from the group consisting essentially of PET, PE, and HDPE.