초록 ▼

A self-adhesive reinforced foam gasket comprising a release liner having an upper surface which is a release surface, a layer of pressure sensitive adhesive applied to the release surface, a layer of flexible polymeric film, preferably polyester film, applied to the pressure sensitive adhesive layer

A self-adhesive reinforced foam gasket comprising a release liner having an upper surface which is a release surface, a layer of pressure sensitive adhesive applied to the release surface, a layer of flexible polymeric film, preferably polyester film, applied to the pressure sensitive adhesive layer, and a layer of flexible foam, preferably closed cell PVC flexible foam, thermally bonded to the flexible polymeric film layer. A length of material for die-cutting the gasket therefrom is provided, along with a method of making the length of material. The gasket may be used in automobiles and other applications.

대표청구항 ▼

1. A method of making a length of material suitable for die-cutting a self-adhesive reinforced foam gasket therefrom, said method comprising the steps of (a) providing a substrate having a release liner, a layer of pressure sensitive adhesive and a layer of flexible polymeric film, said release line

1. A method of making a length of material suitable for die-cutting a self-adhesive reinforced foam gasket therefrom, said method comprising the steps of (a) providing a substrate having a release liner, a layer of pressure sensitive adhesive and a layer of flexible polymeric film, said release liner having an upper surface which is a release surface, said pressure sensitive adhesive layer adhering to said release surface, said flexible polymeric film layer adhering to said pressure sensitive adhesive layer, and (b) providing a layer of liquid flexible foam precursor including a blowing agent onto said flexible polymeric a film layer, heating said flexible foam precursor, activating said blowing agent and expanding and curing said flexible foam precursor to yield a cured flexible foam layer which is thermally o bonded to said flexible polymeric film layer to yield a length of material suitable for die-cutting a self-adhesive reinforced foam gasket therefrom, said flexible foam being polyvinyl chloride flexible foam having a density of at least 5 lb/ft3,said flexible foam layer contacting said flexible polymeric film layer, said thermal bond between said flexible foam layer and a said flexible polymeric film layer being greater than the tear strength of said flexible foam, said flexible polymeric film layer being effective to inhibit leaching of plasticizer from said flexible foam layer into said pressure sensitive adhesive layer, said flexible polymeric film layer and said flexible foam layer being separate, distinct layers made of different materials. 2. A method according to claim 1, wherein said flexible polymeric film is polyester film. 3. A method according to claim 1, wherein said flexible foam is closed cell polyvinyl chloride flexible foam. 4. A method according to claim 1, wherein said cured flexible foam layer is 1/16 to 3/4 inch thick. 5. A method according to claim 1, wherein said flexible polymeric film layer is 0.5 to 4 mils thick. 6. A method according to claim 1, wherein said cured flexible foam layer has a density of 5 to 20 lb/ft3. 7. A method according to claim 1, wherein said length of material is at least one foot wide and at least fifty feet long. 8. A method according to claim 1, wherein said pressure sensitive adhesive is a high-temperature pressure sensitive adhesive. 9. A method according to claim 1, wherein said pressure sensitive adhesive is a high-temperature hot melt pressure sensitive adhesive. 10. A method according to claim 1, wherein the liquid flexible foam precursor is a liquid polyvinyl chloride plastisol. 11. A method according to claim 1, wherein said flexible foam precursor is heated in an oven at about 380-420° F. to activate the blowing agent and expand the precursor. 12. A method according to claim 1, wherein said flexible foam precursor is heated in an oven for about 3 to 4 minutes to activate the blowing agent and expand the precursor. 13. A method according to claim 1, wherein said length of material is at least 4 feet wide and east 200 feet long. 14. A method according to claim 1, further comprising the step of providing at least a portion of said length of material to a die-cutting machine and die-cutting a self-adhesive reinforced foam gasket therefrom. 15. A method according to claim 1, further comprising the step of providing a release coating on a surface selected from the group consisting of a top surface of said flexible foam layer and a bottom surface of said release liner. 16. A method according to claim 7, further comprising the step of slitting said length of material prior to a die-cutting operation. 17. A method according to claim 1, said method consisting essentially of said steps (a) and (b). 18. A method according to claim 1, said length of material being at least eight inches wide and at least twenty feet long.