Decorative stainless steel rolled sheet with embossed patterns and method of manufacturing the same

• US 8,906,180 B2
• Filed: 04/01/2013
• Issued: 12/09/2014
• Est. Priority Date: 10/11/2010
• Status: Expired due to Fees

• Current Assignee: Daejin DSP Co., Ltd.
• Original Assignee: Daejin DSP Co., Ltd.
• Inventors: Kim, Jin Hyung
• Primary Examiner(s): BELL, WILLIAM P
• Application Number:
  US13/854,300
• Publication Number:
  US 20130276965A1
• Time in Patent Office: 617 Days
• Field of Search: 156/209, 156/219, 156/220
• US Class Current: 156/209
• CPC Class Codes: B29C 59/046 for layered or coated substantially flat surfaces
• CPC Class Codes: B29C 65/40 Applying molten plastics, e.g. hot melt using welding bar combined with hot gases B29C65/12; by moulding B29C65/70
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/484 Moisture curing adhesives
• CPC Class Codes: B29C 65/524 by applying the adhesive from an outlet device in contact with, or almost in contact with, the surface of the part to be joined
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/74283 Iron or alloys of iron, e.g. steel
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2305/20 in the form of a non-woven mat
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2311/30 Iron, e.g. steel
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 38/08 Impregnating
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 7/06 : permitting easy separation
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 156/1023 : Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 428/14 : Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/1438 : Metal containing
• CPC Class Codes: Y10T 428/1443 : Aluminum
• CPC Class Codes: Y10T 428/1486 : Ornamental, decorative, pattern, or indicia
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24628 : Nonplanar uniform thickness material
• CPC Class Codes: Y10T 428/24736 : Ornamental design or indicia

Abstract

A decorative stainless steel rolled sheet has an embossed pattern, suitable for use as a surface finish or an interior surface finish of products, wherein a thin stainless steel sheet subjected to surface treatment including nanoceramic coating or PVD ionic coating resulting in various colors and a release sheet alone or with a nonwoven fabric layer bonded thereto by means of a hot melt adhesive layer are embossed together and bonded to each other with the embossed pattern, thus exhibiting superior bonding strength, heat resistance, fire resistance, scratch resistance, shape stability, flexibility and wrinkling resistance. In the method of manufacturing such a decorative stainless steel rolled sheet, the rolled sheet can be mass produced at uniform quality using a continuous process.

Claims

1. A method of manufacturing a decorative stainless steel rolled sheet having an embossed pattern, comprising:

unwinding a thin stainless steel sheet, having a thickness of 0.05 to about 0.15 mm and subjected to a surface treatment having selected from the group consisting of nanoceramic coating and PVD (Physical Vapor Deposition) ionic coating, from a thin stainless steel sheet take-up roll and feeding it between first feed rolls;

applying a hot melt adhesive on one side of the thin stainless steel sheet, which moves by means of the first feed rolls, using an adhesive feed roll and the first feed rolls, thus forming a hot melt adhesive layer on one side of the thin stainless steel sheet;

unwinding a release sheet having a thickness of 0.05 to about 0.10 mm and made of a polyethylene or polypropylene film from a release sheet take-up roll and feeding it between second feed rolls so that it is bonded onto the hot melt adhesive layer formed on one side of the thin stainless steel sheet;

embossing the thin stainless steel sheet and the release sheet bonded thereto by means of the hot melt adhesive layer using an emboss roll composed of a positive pattern roll and a smooth roll, thus forming the embossed pattern;

winding a resulting product in rolled sheet form on a take-up roll; and

bonding a double-sided adhesive sheet having release paper on one side thereof to the hardened hot melt adhesive layer, after the release sheet has been removed.

2. The method as set forth in claim 1, further comprising bonding a nonwoven fabric layer having a thickness of 0.05 to about 10 mm onto the hot melt adhesive layer formed on one side of the thin stainless steel sheet.

3. The method as set forth in claim 1, wherein the hot melt adhesive layer is formed to have a thickness of 0.05 to about 0.012 mm.

4. The method as set forth in claim 1, wherein the embossed pattern is formed to have a depth of 50 to about 200 μ

m.

5. A method of manufacturing a decorative stainless steel rolled sheet having an embossed pattern, comprising:

unwinding a thin stainless steel sheet, having a thickness of 0.05 to about 0.15 mm and subjected to a surface treatment having selected from the group consisting of nanoceramic coating and PVD (Physical Vapor Deposition) ionic coating, from a thin stainless steel sheet take-up roll and feeding it between first feed rolls;

applying a hot melt adhesive on one side of the thin stainless steel sheet, which moves by means of the first feed rolls, using an adhesive feed roll and the first feed rolls, thus forming a hot melt adhesive layer on one side of the thin stainless steel sheet;

unwinding a release sheet having a thickness of 0.05 to about 0.10 mm and made of a polyethylene or polypropylene film from a release sheet take-up roll and feeding it between second feed rolls so that it is bonded onto the hot melt adhesive layer formed on one side of the thin stainless steel sheet;

embossing the thin stainless steel sheet and the release sheet bonded thereto by means of the hot melt adhesive layer using an emboss roll composed of a positive pattern roll and a smooth roll, thus forming the embossed pattern;

winding a resulting product in rolled sheet form on a take-up roll; and

forming an additional adhesive layer on the hardened hot melt adhesive layer and bonding a sheet member comprising an aluminum sheet or a plating steel sheet having a thickness of 0.2 to about 1.2 mm onto the additional adhesive layer, after the release sheet has been removed.