Segmented film adhesive, method of making the adhesive and method of applying the adhesive to a non-planar surface

Abstract

A segmented film adhesive comprises a liner having a first major surface and a second major surface opposing the first major surface. An adhesive layer is on the liner. The adhesive layer comprises a plurality of contiguous, discrete adhesive segments on the first major surface of the liner.

What is claimed is: 
     
         1 . A segmented film adhesive, comprising:
 a liner having a first major surface and a second major surface opposing the first major surface; and   an adhesive layer on the liner, the adhesive layer comprising a plurality of contiguous, discrete adhesive segments on the first major surface of the liner.   
     
     
         2 . The segmented film adhesive of  claim 1 , wherein the plurality of discrete adhesive segments comprise a first adhesive segment and a plurality of second adhesive segments that are contiguous to the first adhesive segment. 
     
     
         3 . The segmented film adhesive of  claim 2 , wherein the first adhesive segment can be released from the liner independently of each of the second adhesive segments. 
     
     
         4 . The segmented film adhesive of  claim 1 , wherein each of the adhesive segments have a first major surface contacting the liner and a second major surface opposite the first major surface, the second major surface of the adhesive segments being in a shape of a polygon. 
     
     
         5 . The segmented film adhesive of  claim 1 , wherein the liner comprises a material chosen from polyethylene, polyurethane, polyvinylidene difluoride [PVDF], polytetrafluoroethylene [PTFE], polyoxymethylene, silicone coated paper and silicone coated polymers. 
     
     
         6 . The segmented film adhesive of  claim 1 , wherein the adhesive segments comprise a pressure sensitive adhesive. 
     
     
         7 . The segmented film adhesive of  claim 1 , wherein the adhesive segments comprise a material chosen from polyurethane, epoxy, isocyanate, polyester and mixtures thereof. 
     
     
         8 . A method of applying an adhesive to a non-planar surface, the method comprising:
 providing a segmented film adhesive, the segmented film adhesive comprising: (i) a liner; and (ii) an adhesive layer on the liner, the adhesive layer comprising a plurality of contiguous, discrete adhesive segments;   positioning the segmented film adhesive on a non-planar surface of a first adherend so that a first portion of the discrete adhesive segments are in contact with the non-planar surface and a second portion of the discrete adhesive segments are not in contact with the non-planar surface; and   removing the liner from the non-planar surface, wherein only the first portion of the discrete adhesive segments remain on the non-planar surface of the first adherend.   
     
     
         9 . The method of  claim 8 , wherein after removing the liner from the non-planar surface, the second portion of the discrete adhesive segments remain on the liner. 
     
     
         10 . The method of  claim 8 , further comprising positioning a second adherend in contact with the discrete adhesive segments remaining on the non-planar surface of the first adherend, thereby adhering the first adherend to the second adherend. 
     
     
         11 . The method of  claim 9 , further comprising heating the discrete adhesive segments remaining on the non-planar surface of the first adherend to a sufficient temperature to melt or cure the adhesive. 
     
     
         12 . The method of  claim 9 , wherein the first adherend and second adherend together form an acoustic panel configured for use in an aircraft. 
     
     
         13 . The method of  claim 12 , wherein the first adherend comprises a honeycomb cell structure. 
     
     
         14 . The method of  claim 13 , wherein the first adherend comprises paper. 
     
     
         15 . The method of  claim 12 , wherein the second adherend is perforated. 
     
     
         16 . A method of making a segmented film adhesive, the method comprising:
 providing a liner having a first major surface and a second major surface opposing the first major surface; and   forming a segmented adhesive layer on the liner, the segmented adhesive layer comprising a plurality of contiguous, discrete adhesive segments on the first major surface of the liner.   
     
     
         17 . The method of  claim 16 , wherein forming the segmented adhesive layer comprises depositing an adhesive material in a continuous layer and then separating the continuous layer into the plurality of discrete adhesive segments. 
     
     
         18 . The method of  claim 17 , wherein separating the continuous layer into segments comprises cutting the continuous layer. 
     
     
         19 . The method of  claim 16 , wherein forming the segmented adhesive layer comprising selectively depositing the plurality of discrete adhesive segments onto the liner.