This is a Three-PART File Wrapper Continuation including:
`
`SN:
`
`08t056,362
`
`Filed: 04/30f93
`
`Papers
`
`1 - 13
`
`and
`
`SN:
`
`08/393,881
`
`Filed: 02/23195
`
`Papers
`
`14-21
`
`SN:
`
`081601,379
`
`Filed: 02/14t96
`
`Papers
`
`22-25
`
`now U.S. Patent No.
`
`5, 597,6!,8
`
`FAST FELT 2023, pg. 1
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`EXAMINIER
`
`t,.,’ I:::’ i::i’ T i:::’ ] lii!i 1)
`
`I::’ O i:::.’.IE 7] (7;i N t::: 1i; I ..... i N ] i ,~ .... ]Ii (:: E I\I i}) E (i;i I::7 f:~ i’.il !i{i;~;:< () ::-) i’ :7:7 / ’~!7 6
`
`Foreign priority claimed
`35 USC 119 cond~ions m~
`
`[] Yes ~--zre~o [ &~ ] STATE OR [ SHEETS [ TOTA~ [ INDEP.
`
`FILING FEE
`RECEIVED
`
`I A’I-I-ORNEY’S
`
`] DOCKET NO.
`
`::~qvl
`
`:::::::::::::::::::::::: i::ii::’ ]:iqTEL_L.iT~2I:::Ti..!f~L. l:::’Ft:iF’
`:E~I;:iX ::3:::g4.:.f7
`
`~ D::’l:
`~{7$"[ P~zfl,,,!l... I’%!.;:ar’c’,:,:, .I. :: ::~ " :’:. :I,’;;’7
`
`~
`
`U.S. DEPT. OF COMMJ PAT. & TM~PTO-436L (Ray, t2-94)
`
`PARTS OF APPLICATION
`FILED SEPARA’I’ELY
`
`NOTICE OF ALLOWANCE MAILED
`
`ISSUE FEE
`
`Amount
`
`Date Paid / _’~
`
`Assistant Examiner
`
`Label
`Area
`
`PREPARED FORISSUE
`
`The information d sc osed here n may be restricted. Unauthorized di~iol
`by the U~ited States Code ~t e 35, Sections 122, 181 anti 368./~o.ssession outside the U.S.
`Patent & Trademark Office is restricted to authorizeri empleyees~t~i~ontractors only.
`
`Form PTO..436A
`(Rev, 8192)
`
`(FACE)
`
`FAST FELT 2023, pg. 2
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`PATENT APPLICATION
`
`INITIALS’
`
`Date
`Entered
`or
`Counted
`
`CONTENTS
`
`Date
`Received
`or
`Mailed
`
`1. Applic_@tion
`
`papers.
`
`16.
`
`17.
`
`19.
`
`20.
`
`21.
`
`22.
`
`23.
`
`24.
`
`25.
`
`26.
`
`28,
`
`29.
`
`30.
`
`31.
`
`32.
`
`(FRONT)
`
`FAST FELT 2023, pg. 3
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`SEARCHED
`
`/
`
`Class
`
`Date ~fExmr.
`/
`
`/
`
`INTERFERENCE SEARCHI~D
`;Class ~Sub. ~3ate Ex~r.
`
`SEARCH NOTES
`
`Date
`
`Exmr.~
`
`¯ (RIGHT OUTSIDE)
`
`FAST FELT 2023, pg. 4
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`Staple Issue Slip Here
`
`ID NO.
`
`DATE
`
`POSITION
`
`CLASSIFIER
`
`EXAMINER
`TYPIST
`VERIFIER
`CORPS CORR.
`SPEC. HAND
`FILE MAINT.
`DRAFTING
`
`INDEX OF CLAIMS
`
`Dale
`
`SYMSOLS
`
`Objected
`
`(LEFT iNSIDE)
`
`FAST FELT 2023, pg. 5
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`VERIFIED
`
`FOREIGN FILING LICENSE GRANTED 06/01/93
`
`35 USC 11~ ~ondlttons mtt ~ ~ FILED
`
`~ PETER L. OLSON
`~ 3~ OFFICE OF INTELLECTUAL PROP. COUNSEL ......
`~ P.O. BOX 33427
`( ST. PAUL, MN 55133-3427
`
`METHOD AND APPARATUS" FOR APPLYING A COATING
`
`PARTS OF APPLICATION
`FILED SEPARATELY
`
`NOTICE OF ALLOWANCE MAILED
`
`"¯ IApplicalions Examiner
`r CLAIMS ALLOWED
`
`.
`
`¯
`
`" "
`
`Total Claims
`
`Print Claim
`
`ISSUE FP-P-
`Amount Due
`Date Paid
`
`Assistant Examine=’
`
`¯ " ¯
`
`DRAWING
`Sheete Drwg. I Figs. Drwg,
`
`ISSUE
`BATCH
`~, Primary Examiner NUMBER
`
`I Print Fig.
`
`Label
`Area
`
`PREPARED F~,RISSUE , _ ,i_’-. ,
`
`WARNING: The information disclosed herein may be restricted. i~nauthorized dieciosure may be prohibited
`by the United States Code Tille 35, Sections 122/181 and 368. Possession outside the U.S,
`Patent & Trademark Office is restricted to authorized employees and contractors only.
`
`Form PTO-43eA
`(Roy. 8~J2)
`
`(FACE)
`
`FAST FELT 2023, pg. 6
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`APPROVED FOR LICENSE
`
`INtTIALS
`
`’, Date
`ReceiVed
`
`Mailed
`
`Date
`Entered
`or
`
`Counted
`
`CONTENTS
`
`1. Application ~_/ papers.
`
`/
`
`14.
`
`15.
`
`16.
`
`17.
`
`18.
`
`19.
`
`20.
`
`21.
`
`22.
`
`23.
`
`24.
`
`25.
`
`26.
`
`27.
`
`28.
`
`29.
`
`30.
`
`31.
`
`32.
`
`(FRONT)
`
`FAST FELT 2023, pg. 7
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`SEARCHED
`
`Class
`
`Sub.
`
`Date
`
`Exmr.
`
`49&
`
`3o
`
`SEARCH NOTES
`
`Date
`
`Exmr.
`
`Ioi
`
`INTERFERENCE SEARCHED
`Sub.
`Class
`Date Exmr.
`
`(RIGHT OUTSIDE)
`
`FAST FELT 2023, pg. 8
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`Staple Issue Slip Here
`
`ID NO.
`
`DATE
`
`POSITION
`
`CLASSIFIER
`
`EXAMINER
`TYPIST
`VERIFIER
`CORPS CORR.
`SPEC. HAND
`FILE MAINT.
`DRAFTING
`
`INDEX OF CLAIMS
`
`Date
`
`Claim
`
`Date
`
`54
`55
`56
`
`5g
`
`60
`
`~7
`
`71
`
`73
`74
`75 =
`76
`
`78
`
`80
`8~
`
`87
`
`91
`92
`93
`
`95
`
`SYMBOLS
`
`.................................. A!lowed
`
`0 ................................. 0biecI~d
`
`(LEFT iNSIDE)
`
`FAST FELT 2023, pg. 9
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`PATENT DATE
`
`I PATENT
`NUMBER
`
`CLASS
`
`42"7
`
`SUBCLASS
`
`} GROUP ART UNIT
`
`I EXAMINER
`:’AIJI_., I"41",1 ,,
`
`I STATE ORl SHEETS I TOTAL I INDEP. t FILING FEE
`-,,~©rit/(cid:128)|almed
`I-I Ws ~o ~
`35U~;co~dItt ...... ~ ~. ~.o I AS ]COUNTRYIDRWGS" IcLAIMs I CLAIMS IRECEIVED
`1
`I
`I
`I
`~ ~1 FILED I
`
`A~ORNEY’S
`DOCKET NO.
`
`P~TEF~.=.I.. OLSON
`_
`O~FIo:::E OF INTELLECTUAL F’ROF’ COLINSEL
`BOX :33427 ’
`
`,
`
`MEI"I-’-[O~;~ AN[) AF’PARATUS FCIR APPLYING A I::OA’[’ING MATERIAL TO A
`
`U.$. DEPT. of COMM.-Pat. & TM Office-PTO-436L (rev. 10-78
`
`PARTS OF APPLICATION
`FILED SEPARATE~.Y
`
`NOTICE OF ALLOWANCE MAILED
`
`Assistant Examiner
`
`ISSUE FEE
`
`Date Paid
`
`Applications Examiner
`
`CLAIMS ALLOWED
`
`Total Claims
`
`Print Claim
`
`DRAWING
`Sheets Drwg. Figs. Drwg. Print Fig.
`
`, P,~!rnary Examine,,r
`PREPARED FOR ISSUE
`
`ISSUE
`BATCH
`NUMBER
`
`WARNING: The informalion disclosed herein may be restricted. Unauthorized disclosure may be prohibited
`by the United Stales Code "l]tle 35, Sectior~s 122, 181 and 368, Possession outside the U.S.
`Patenl & Trademark Office is restricled to authorized employees and contractors only.
`
`Label
`Area
`
`Fo~t~ PTO,436A
`(Bey, 8~92)
`
`(FACE)
`
`FAST FELT 2023, pg. 10
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`B
`
`Date
`Entered
`or
`Counted
`
`PATENT
`
`tTiON
`
`INITIALS
`
`CONTENTS
`
`Date
`Received
`or
`Mailed
`
`1. Application
`
`papers.
`
`19.
`
`20.
`
`21,
`
`22.
`
`23.
`
`24.
`
`25.
`
`26.
`
`27.
`
`29.
`
`31.
`
`(FRONT)
`
`FAST FELT 2023, pg. 11
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`SEARCHED
`
`Crass
`
`Sub. Date
`
`Exmr.
`
`~ ~ s-_., 3
`
`INTERFERENCE SEARCHED
`Sub.
`Date E×rnr.
`
`Class
`
`SEARCH NOTES
`
`Date
`
`Exmr.
`
`~1.~;~..
`
`(RIGHT OUTSIDE)
`
`FAST FELT 2023, pg. 12
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`Staple Issue Slip Here
`
`ID NO.
`
`DATE
`
`POSITION
`
`CLASSIFIER
`
`EXAMINER
`TYPIST
`VERIFIER
`CORPS CORR.
`SPEC, HAND
`FILE MAINT,
`DRAFTING
`
`INDEX OF CLAIMS
`
`Date
`
`Claim
`
`I
`
`Date
`
`51
`
`5~
`
`55
`56
`
`58
`
`67
`
`~ 69
`
`7~
`
`74
`75
`
`77
`78
`
`80~
`
`85
`
`9089
`.......
`
`91
`
`92
`
`93
`94
`95
`
`96
`
`97
`
`98
`
`99
`
`11oo
`
`SYMBOLS
`
`................................. Resldcled
`
`................................. Inlede~ence
`
`(LEFT INSIDE)
`
`FAST FELT 2023, pg. 13
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`~ ce ot Intellectual Properly Counsel
`
`PATENT
`
`056362
`
`Application Transmittal Letter
`
`%,~.’~ ~’,, *. C~~’.~,~:~’ioner of Patents and Trademarks
`~ ~’~’ !~ f~ .~’:P~,i~P(e n t Application
`~’-~"[n~ton, D.C. 20231
`Attention: ~ Application Branch
`
`[~ Assignment Branch
`
`Re: Application of Glen H. Bayer, Jr. and Timothy J. O’Leary
`For METHOD AND APPARATUS FOR APPLYING A COATING MATERIAL
`TO A SUBSTRATE
`
`~ Enclosed is the above-mentioned new patent application. It includes (?)
`of drawings.
`~J Enclosed is an application assignment to Minnesota Mining and Manufacturing
`Company.
`The fees for filing the application and recording the assignment (if indicated) are computed
`as follows:
`
`sheet(s)
`
`Claims As Filed
`
`For
`
`Number Fi~ed
`
`Number Extra
`
`Total
`Claims
`
`~edepemdenl
`Claims
`
`2 6 - 20 =
`
`4 - 3 =
`
`6
`
`l
`
`$74
`
`X $72.00
`
`Additional fee for filing one or more multiple dependent claims
`
`Fee
`
`$132.01
`
`74.01
`
`0.0(
`
`$40,00
`
`40.0~
`
`Tota~ amount due ~
`
`956.01
`
`[] Enclosed is $956- 00 __. Please charge any additional fees or credit any over pay-
`ment to Deposit Account No. 13-3723.
`
`1993
`
`Peter L. Olson
`
`Certificate of Express Maitinq
`Y~ Under37 CFR 1.10 I certify that this application is being deposited with the United
`States Postal Service "Express Mail Post Office to Addressee" service addressed to
`the Commissioner of Patents and Trademarks, Washington, D.C. 20231, on the date
`indicated below.
`
`f Express Mail Mailing Labe~ NO.
`
`RB901438043U3
`Date of Deposit
`April 30,_1993
`
`Folm 1098~], M - PWO Ray 2120192
`
`PLO: jlh
`
`Name of person Mai~ing Applicalion
`
`P e~t_~ r T,.
`
`FAST FELT 2023, pg. 14
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`¯
`ABSTRACT OF THE DISCLOSURE ~;1 ~~ "
`~ in%~e~tlon-.rela4zes~%~ application
`member for applying a coating material, such as a pressure
`sensitive adhesive, to a receiving surface, such as a
`paper substrate. The application member includes a
`cylindrical peripheral surface and a plurality of spaced,
`discrete structures projecting from the peripheral surface
`of the hub, whereby adhesive may be carried on and between
`the structures prior to being applied to the receiving
`surface. By varying the surface velocity of the
`application member relative to the velocity of the
`substrate, the characteristics of the adhesive layer
`
`applied to the substrate may be changed.~
`
`i0
`
`15
`
`20
`
`25
`
`3O
`
`35
`
`49523-9A .CLM3
`
`FAST FELT 2023, pg. 15
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`PATENT
`Docket No. 49523 USA 9A
`
`METI O ) AND AeeARATUS FOR AeeLYIN,G
`
`A COATING MATERIAL TO A SUBSTRATE
`
`J~i~,5i~’TECHNICAL FIELD
`The invention relates to a method and apparatus
`for applying coating material to a receiving surface.
`
`BACKGROUND OF THE INVENTION
`It is often desirable to coat a substrate with a
`coating material, such as ink or an adhesive, in a desired
`location on the substrate. For example, pressure sensitive
`adhesive tape includes a web substrate coated with a layer
`of pressure sensitive adhesive, similarly, 4~w~t--I~ brand
`repositionable notes, available from the Minnesota Mining
`and Manufacturing Company of St. Paul, Minnesota, include
`a substrate having a band of pressure sensitive adhesive
`coated over a portion of the substrate. In these and other
`fields, it is desirable to apply the coating material to
`the substrate in a controlled manner.
`
`One process of applying a coating material to a
`substrate is known as gravure coating, and is illustrated
`schematically in Figure i. The process includes a supply
`12 of a substrate i0, an application roller 14, and a
`supply of coating material 18 through which the
`application roller is drawn. Also shown are a backing
`roller 19 that opposes the application roller, a doctor
`blade 21 for wiping excess coating material from the
`application roller, and a winding system having one or
`more rollers 13 to draw the substrate between the
`application roller and the backing roller. As shown in
`Figure 2, the application roller includes a peripheral
`surface 30 having a multitude of individual cells 32 that
`are recessed from the peripheral surface of the
`application roller. The cells may be arranged in any
`pattern, as shown in Figure 3, wherein cells 32 are formed
`
`i0
`
`15
`
`2O
`
`25
`
`3O
`
`35
`
`FAST FELT 2023, pg. 16
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-2-
`
`in the peripheral surface at certain locations, and no
`cells are formed in locations 34.
`
`The cells collect the coating material as the
`application roller passes through the supply of coating
`material, and thus the areas of the peripheral surface
`without cells (e.q. locations 34) do not collect coating
`material. If any residual coating material collects on the
`periphera! surface of the application roller, doctor blade
`21 wipes that material from the peripheral surface prior
`to contact with the substrate.
`
`When the substrate passes the application
`interface between the application roller and the backing
`roller, the material is drawn out of each of the cells
`because the coating material has a greater affinity for
`the substrate than for the application roller. The surface
`speed of the application roller is matched to the speed of
`the substrate, to enable complete removal of the coating
`material from the individual cells. If the surface speed
`of the substrate is greater than or less than that of the
`surface of the application roller, the cells of the
`application roller will not be entirely evacuated.
`Incomplete evacuation of the cells is undesirable, because
`the predetermined amount of coating material has not been
`transferred to the substrate.
`
`Gravure coating, while having its own utility,
`is not easily modified to enable a thinner or thicker
`layer of coating material to be applied to the substrate.
`Because the cells on the peripheral surface have a fixed
`size and shape, and because the speed of the application
`roller and the substrate are matched, a particular
`application roller consistently applies the same pattern
`and thickness of coating material to the substrate. To
`change the pattern or thickness of coating material that
`is applied to the substrate, the application roller must
`be removed and replaced with a coating roller having
`
`I0
`
`15
`
`2O
`
`25
`
`3O
`
`35
`
`FAST FELT 2023, pg. 17
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`different surface characteristics (e.g. more or less
`cells, greater or smaller spacing between adjacent cells,
`or deeper or more shallow cells). The coating process must
`be halted while a new application roller is attached to
`the coating apparatus, and roller replacement is therefore
`costly and undesirable. It would therefore be desirable to
`provide a method and apparatus for applying a coating
`material in different amounts and in varying patterns,
`without having to replace the application roller.
`
`Planographic coating is similar to gravure
`coating in some regards, and includes such coating methods
`as flexography, lithography, and both wet and dry offset
`coating. A notable difference between gravure coating and
`planographic coating relates to the peripheral surface of
`the application roller, and the manner in which the
`coating material is carried on that surface. Whereas
`gravure coating uses an application roller having a
`plurality of cells that are recessed from the peripheral
`surface of the application roller, planographic coating
`uses a pattern roller 50 having a multitude of island
`portions 52 that are raised above peripheral surface 54,
`as shown in Figures 4 and 5. The coating material 56 is
`carried only on the outermost surface of each island
`portion 52, and the pattern roller 50 contacts the
`application roller 55 to transfer the coating material
`thereto. The application roller then transfers coating
`material 56 onto a substrate 58 in the desired pattern.
`
`Although planographic coating also has certain
`benefits, it is difficult to alter the coating parameters
`quickly and inexpensively. To change the pattern or
`thickness of coating material applied to the substrate,
`the pattern roller must typically be replaced, because the
`characteristics of a particular pattern roller determine
`the pattern and thickness of coating material that will be
`applied to the substrate. Replacement of the pattern
`roller must take place when the coating process is
`
`i0
`
`15
`
`2O
`
`25
`
`30
`
`35
`
`FAST FELT 2023, pg. 18
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-4-
`
`stopped, and is therefore undesirable for the same reasons
`as stated above with reference to gravure coating.
`Furthermore, if several different pattern rollers must be
`available for each coating apparatus to provide a desired
`coating thickness or pattern, the investment in pattern
`rollers may be substantial.
`
`It is therefore desirable to provide a method
`and apparatus for applying coating material to a
`substrate, wherein the coating characteristics may be
`altered without replacing the application roller.
`
`SUMMARY OF THE INVENTION
`The present invention includes an application
`member for transferring a coating material from a supply
`of such material to a receiving surface, and for applying
`the material to the receiving surface. The application
`member includes a hub having a central axis for rotation
`thereabout, and having a generally cylindrical peripheral
`surface, and a plurality of spaced, discrete structures
`projecting from the peripheral surface of the hub.
`Rotation of the hub about the central axis enables the
`peripheral surface to pass a source of the coating
`material to receive the coating material, and to carry the
`coating material on the peripheral surface of the hub
`between and on said projecting structures toward an
`application interface to transfer the material from the
`peripheral surface to the receiving surface. Also provided
`is an application system for applying a coating material
`to a receiving surface, including the application member
`described above, and means for rotating said hub about the
`central axis thereof at a predetermined angular velocity.
`The rotating means enables the peripheral surface to pass
`a source of the coating material to receive the coating
`material and to carry the coating material on the
`peripheral surface between and on said projecting
`structures toward an application interface between the
`peripheral surface and the receiving surface, and to
`
`i0
`
`15
`
`2o
`
`25
`
`30
`
`35
`
`FAST FELT 2023, pg. 19
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-5-
`
`transfer said coating material to the receiving surface.
`An increase in the angular velocity of the hub increases
`the amount of coating material transferred to the
`receiving surface, and a decrease in the angular velocity
`of the hub decreases the amount of coating material
`transferred to the receiving surface.
`
`i0
`
`15
`
`2O
`
`25
`
`3O
`
`35
`
`In another aspect of the present invention, a
`method is provided for applying a coating material to a
`receiving surface. The method includes the steps of
`providing a hub having a central axis of rotation, and
`having a generally cylindrical peripheral surface
`including a plurality of spaced, discrete structures
`projecting from the peripheral surface; providing a source
`of the coating material in sufficient proximity to the
`peripheral surface to enable the peripheral surface to
`receive the coating material and to carry the coating
`material between and on said projecting structures;
`contacting a receiving surface with the peripheral surface
`of the hub at an application interface to enable the
`peripheral surface to transfer the coating material to the
`receiving surface at the interface; and rotating the hub
`to receive the coating material from the material source
`and to transfer the material to the receiving surface at
`the application interface. Also provided is a substrate
`coated with a coating material according to the method
`described above.
`
`A method is also provided for making an
`application member for applying a coating material to a
`receiving surface. The method includes the steps of
`providing a hub having a generally cylindrical peripheral
`surface; forming a plurality of discrete indentations in
`the peripheral surface; and retaining a particle within
`substantially all of the indentations, such that a portion
`of each particle projects above the peripheral surface of
`the hub. Thus, the application member is adapted to carry
`
`FAST FELT 2023, pg. 20
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-6-
`
`the coating material on and between the particles prior to
`application to the receiving surface.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`The present invention will be described with
`reference to the appended Figures, wherein like structure
`is represented by like numbers throughout the several
`views, and wherein:
`Figure i is a schematic illustration of a
`gravure coating process according to the prior art;
`Figure 2 is a sectional view of a gravure
`application roller according to the prior art;
`Figure 3 lS a plan view of the face of a gravure
`application roller according to the prior art;
`Figure 4 is a schematic illustration of a
`planographic coating process according to the prior art;
`Figure 5 is a plan view of the face of a
`planographic transfer roller;
`Figure 6 is a cross-sectional view of the
`applicator apparatus of the present invention;
`Figure 7 is a cross-sectional view of an
`applicator roller according to the present invention,
`including a layer of material coated over the outer
`surface of the roller;
`Figure 8 is a schematic representation of the
`application of a material to a substrate, when the surface
`velocity of the application roller is approximately equal
`to the surface speed of the substrate;
`Figure 9 is a schematic representation of the
`application of material to a substrate, when the surface
`velocity of the application roller is less than the
`velocity of the substrate; and
`Figure i0 is a schematic representation of the
`application of materia! to a substrate, when the surface
`velocity of the application roller is greater than the
`velocity of the substrate.
`
`I0
`
`15
`
`2o
`
`25
`
`3o
`
`35
`
`FAST FELT 2023, pg. 21
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-7-
`
`DETAILED DESCRIPTION OF THE INVENTION
`The present invention relates broadly to an
`application member for applying a coating material to a
`receiving surface. The coating material may be any
`suitable material, including but not limited to adhesive
`(e.g. pressure sensitive adhesive) and ink. The receiving
`surface may be, for example, a substrate, such a
`continuous web of paper or polymeric material, or a belt
`or roller that receives the material and transfers the
`material to a substrate. Thus, the present invention,
`although described primarily with reference to the
`application of adhesive to a substrate, also has broad
`applicability to other coating operations as well.
`
`Figure 6 illustrates an applicator for applying
`a coating material to a receiving surface, in the
`illustrated embodiment, an applicator apparatus i00 is
`shown for applying an adhesive 102 to a substrate 104,
`such as paper. The substrate is provided by supply roll
`103, and is collected at collection roll 105. The
`applicator includes a hub 106 having a generally
`cylindrical peripheral surface 108 and a central axis
`about which the hub is adapted to rotate. The hub is
`rotatively supported at each end by support structure (not
`shown). Substrate 104 is fed between backing roller 107
`and hub 106, and adhesive 102 is applied to the substrate
`104 at application interface iii.
`
`Also provided is a source ii0 of adhesive 102,
`and means for rotating the hub about the central axis at a
`predetermined rotational velocity. In the illustrated
`embodiment, the rotating means comprises a motor 112. The
`hub is supported proximate the adhesive source ii0, such
`that adhesive may be disposed on the peripheral surface of
`the hub at a controlled rate. Also provided is a metering
`bearing 114, which controls the amount of coating material
`that is allowed to accumulate on the surface of the
`application roller. Metering bearing 114 also seals
`
`i0
`
`15
`
`2O
`
`25
`
`3o
`
`35
`
`FAST FELT 2023, pg. 22
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`coating material reservoir 116, to prevent coating
`material from leaking out of the reservoir. Reservoir 116
`is preferably provided by a body 117 having a chamber 119
`in which the application roller is rotatively supported,
`although alternate configurations can be provided instead.
`
`A particular feature of the present invention
`relates to the topography Qf peripheral surface 108 of hub
`106. The peripheral surface, in contrast to that of the
`application rollers of the prior art, includes a plurality
`of spaced, discrete structures projecting from the
`peripheral surface of the hub, between and on which
`structures the adhesive is carried. That is, the adhesive
`coats the entire peripheral surface of the application
`member, including the projecting structures. In one
`embodiment, the projecting structures are generally
`hemispherical, and measure on the order of 0.76 mm (0.003
`in) high, relative to the remainder of the peripheral
`surface. Projecting structures 115 may be regularly spaced
`or irregularly spaced about the peripheral surface, and
`may be hemispherical, square, triangular, or any other
`suitable shape.
`
`An exploded sectional view of a portion of the
`application roller 106, peripheral surface 108, and
`projecting structures 115 is shown in Figure 7. Adhesive
`102 is carried both between projecting structures 115 (in
`contrast to planographic application processes) and atop
`projecting structures 115 (in contrast to gravure coating
`processes). Metering bearing 114 controls the thickness of
`the layer of adhesive coated over and between the
`projecting structures.
`
`At the application interface iii, adhesive 102
`is transferred to substrate 104 as shown in Figure 8.
`Application roller 106 is rotating with a surface velocity
`V1 (the velocity of the surface at the application
`interface), and substrate 104 is travelling with a
`
`10
`
`15
`
`20
`
`25
`
`3O
`
`35
`
`FAST FELT 2023, pg. 23
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-9-
`
`velocity V2 that is approximately equal to VI. Adhesive 102
`is transferred to substrate 104 at the application
`interface iiI, because the adhesive has a greater affinity
`for substrate 104 than for the peripheral surface 108 of
`application roller 106. Projecting structures 115 prevent
`adhesive from being transferred to substrate 104 at
`imprints 120.
`
`This peripheral surface topography and transfer
`mechanism is believed to provide certain benefits. For
`example, complete adhesive coverage of the substrate may
`be achieved, and yet the adhesive surface 122 is
`discontinuous. A discontinuous adhesive surface has
`certain utility in conjunction with repositionable
`substrates, because the object to which the substrate is
`applied is not fully contacted by the adhesive surface
`122. By providing application rollers having greater or
`fewer projecting structures, a greater or lesser
`percentage of the adhesive surface will be interrupted by
`imprints 120.
`
`Another feature of the applicator of the present
`invention relates to the ability to change the
`characteristics of the adhesive layer without substituting
`application rollers. For example, Figure 9 illustrates the
`operation of the present application roller when the
`surface velocity of the application roller V1 is less than
`the velocity of the substrate V2. Adhesive 102 is applied
`to substrate 104 as described previously, but because
`projecting structures 115 are travelling more slowly than
`substrate 104, the projecting structures tend to wipe
`away, or "sweep out" adhesive at imprints 120’. The degree
`to which the projecting structures sweep out adhesive
`depends on the difference in velocity between the roller
`and the substrate at the interface, which may be desirable
`for providing a repositionable substrateo
`
`5
`
`i0
`
`15
`
`2O
`
`25
`
`3O
`
`35
`
`FAST FELT 2023, pg. 24
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-i0-
`
`Another method of operating the applicator of
`the present invention is illustrated in Figure i0, wherein
`the surface velocity of the application roller V1 is
`greater than the velocity of the substrate V2. Adhesive
`i02 is appliedto substrate 104 as described previously,
`but because projecting structures 115 are travelling
`faster than substrate 104, the adhesive tends to build up,
`or be "loaded" onto the substrate. Adhesive loading may be
`beneficial because a thicker layer of adhesive may be
`applied to the substrate merely by changing the operating
`speed of the applicator roller, rather than having to
`change application rollers as with the prior art.
`Furthermore, adhesive surface 122’’ is virtually devoid of
`imprints, and thus the entire adhesive surface is
`presented for contact with an object to which the
`substrate is to be attached.
`
`There are a legion of variations of the method
`and apparatus described above. For example, the projecting
`structures could be adapted to lightly contact the
`substrate at the application interface, thereby preventing
`any adhesive from being transferred to the substrate. The
`rotational velocity of the application roller could be
`altered during the production run, such that a portion of
`a substrate is coated with a relatively large amount of
`adhesive, and an adjacent portion is coated with a
`relatively small amount of adhesive. Alternatively,
`segments of the application roller can have different
`sizes or densities of particles, or both, to produce lanes
`or strips of different coating thicknesses, or different
`surface contact areas, or both. These strips would extend
`along the length of the substrate in generally parallel
`fashion.
`
`A further description of the topography of the
`peripheral surface may be particularly described by the
`process used to produce that surface. A hub with a
`cylindrical peripheral surface was provided, where the
`
`i0
`
`15
`
`2O
`
`25
`
`3O
`
`35
`
`FAST FELT 2023, pg. 25
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-ii-
`
`surface was made of steel and was machined to a relatively
`smooth finish. The peripheral surface was then grit
`blasted to produce a plurality of indentations in the
`surface. The indentations were approximately hemispherical
`with a radius of approximately 1.0 m~ (0.004 in). After
`the indentations were formed, spherical particles of
`tungsten carbide (WO) (or nickel chromium> were impelled
`against the surface, and were lodged within the
`indentations due to the frictional force between the
`particle and the edges of the indentations. A portion of
`each of the particles projected above the peripheral
`surface, which formed the projecting structures in the
`peripheral surface of the application roller.
`
`To facilitate the transfer of the adhesive from
`the peripheral surface to the receiving surface at the
`application interface, a release coating was applied over
`the peripheral surface of th~,hub. The r%e~ease coating,
`
`whlch comprlsed a fluorocarbo~n ~-~-~f-l~, was spray
`applied over the entire peripheral surface of the hub. The
`thickness of the release coating applied to the peripheral
`surface was approximately 0.76 mm (0.003 in).
`
`The foregoing method of making a hub according
`to the present invention is intended to be illustrative,
`rather than limiting. Other methods of providing
`projecting structures on a peripheral surface, whereby a
`coating material is carried between and on the structures,
`will be apparent, and are intended to be within the scope
`of the present invention.
`
`Example
`As an illustration of the method and apparatus
`of the present invention, the application roller described
`above was used to provide an adhesive coating on a
`substrate. The substrate was 20 ib bond paper, and was
`conveyed past the application roller at a velocity of
`approximately 1.52 m/s (300 ft/min).
`
`i0
`
`15
`
`2O
`
`25
`
`3O
`
`35
`
`FAST FELT 2023, pg. 26
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`-12-
`
`An adhesive comprising 84 grams of isooctyl
`acrylate, 75 grams of octyl decyl acrylate (at 48% solids
`in ethyl acetate), 121 grams of ethyl acetate, and 0.92
`grams of 4-acryloyl-oxy-benzophenone (at 25% solids in
`ethyl acetate) was prepared as follows. The components
`were charged in a 500 ml, four-necked reaction vessel. The
`reaction vessel was equipped with a stirrer, a
`thermometer, a condenser, an addition funnel, and a
`thermowatch. An solution of 0.36 grams catalyst of the
`type available from the E.I. DuPont de Nemours Corporation
`of Bloomington, Delaware under the designation "VAZO 64"
`in 20 grams of ethyl acetate was added to the addition
`funnel. Both the solution in the reaction vesse! and the
`materials in the addition funnel were then purged with
`nitrogen. The solution in the reaction vessel was then
`stirred and heated to 55~ C and initiator was added. After
`about 20 hours, a 98-99% conversion was obtained. After
`drying, the adhesive was suitable for application to a
`backing by the method and apparatus of the present
`invention.
`
`The application roller was rotated at a
`rotational velocity sufficient to produce a surface
`velocity approximately equal to that of the substrate -
`approximately 2.4 m/s (300 ft/min). A metering bearing was
`used to restrict the adhesive to a layer measuring
`approximately 0.3 mm (0.0012 in) thick across the entire
`surface of the applicator roller and projecting
`structures. At the application interface, the material was
`transferred to the surface of the paper, resulting in a
`layer of adhesive measuring approximately 0.3 mm (0.0012
`in) being disposed on the paper. The projecting structures
`left a plurality of indentations in the adhesive layer,
`corresponding to the size and spacing of the structures.
`The paper coated with adhesive in this manner was useful
`for application to a surface.
`
`i0
`
`15
`
`2O
`
`25
`
`3