Process for forming a multilayered shaped film product

Abstract

A process capable of commercial scale manufacturing of inexpensive, multilayered shaped film product, without the waste of die-cutting and which products are capable of use independent of a supporting structure on which they are formed, includes placing a first mask over a substrate; delivering a first film-forming composition through the first mask to form a first raw shape on the substrate; removing the first mask; placing a second mask over the first raw shape; delivering a second film-forming composition through the second mask to form a second raw shape on the first raw shape; removing the second mask; and solidifying the first and second raw shapes to provide the shaped film product disposed on the substrate.

1 . A process for forming a multilayered shaped film product comprising the steps of:
 a. placing a first mask having at least one aperture having a design corresponding to a desired shape of a first layer of the shaped film product over a substrate;   b. delivering a first film-forming composition through the at least one aperture of the first mask to form a first raw shape on the substrate;   c. removing the first mask;   d. placing a second mask having at least one aperture having a design corresponding to a desired shape of a second layer of the shaped film product over the first raw shape;   e. delivering a second film-forming composition through the at least one aperture of the second mask to form a second raw shape on the first raw shape;   f. removing the second mask; and   g. solidifying the first and second raw shapes to provide the shaped film product disposed on the substrate.   
     
     
         2 . The process of  claim 1 , wherein the first mask is disposed on the surface of a rotary drum having an interior, and the at least one aperture of the first mask is in fluid communication with the interior of the rotary drum. 
     
     
         3 . The process of  claim 2  wherein the first and second masks are disposed on the surface of a single rotary drum. 
     
     
         4 . The process of  claim 2 , wherein the first mask is disposed on the surface of a first rotary drum, and the second mask is disposed on the surface of a second rotary drum. 
     
     
         5 . The process of  claim 1 , wherein the second mask is disposed on the surface of a rotary drum having an interior, and the at least one aperture of the second mask is in fluid communication with the interior of the rotary drum. 
     
     
         6 . The process of  claim 5 , wherein the first and second masks are disposed on the surface of a single rotary drum. 
     
     
         7 . The process of  claim 5 , wherein the first mask is disposed on the surface of a first rotary drum, and the second mask is disposed on the surface of a second rotary drum. 
     
     
         8 . The process of  claim 1 , wherein the first and second masks are stencils. 
     
     
         9 . The process of  claim 1 , wherein the step of solidifying the first flowable coating material occurs prior to the step of delivering the second flowable coating material through the at least one aperture of the second mask. 
     
     
         10 . The process of  claim 1 , wherein the step of solidifying the first and second flowable coating materials occurs after the step of delivering the second flowable coating material through the at least one aperture of the second mask. 
     
     
         11 . An integral multilayered shaped film product comprising a first layer comprising a first film material and having a side edges and a second layer comprising a second film material disposed on the first layer having side edges spaced inward from the side edges of the first layer. 
     
     
         12 . The integral multilayered shaped film product of  claim 11  wherein the second layer comprises a plurality of spaced apart regions. 
     
     
         13 . The integral multilayered shaped film product of  claim 12  wherein the plurality of spaced apart regions comprise additional film materials. 
     
     
         14 . An integral multilayered shaped film product comprising a first surface having a first film material substantially surrounded by a second film material and a second surface formed by the second film material. 
     
     
         15 . The integral multilayered shaped film product of  claim 14  further comprising additional film materials disposed in the first surface, substantially surrounded by the first film material. 
     
     
         16 . An integral multilayered shaped film product comprising a first continuous layer having side edges and a second layer having side edges disposed thereon, the second layer having a void spaced inward from its side edges. 
     
     
         17 . The integral multilayered shaped film product of  claim 16 , wherein the side edges of the second layer are spaced inward from the side edges of the first continuous layer.