Transparent tinted coating for appliance exterior panels to allow for tinted surface patterns and a process for application of coating
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B23P-025/00
B23P-017/00
B05D-003/12
B05D-005/12
B05D-001/40
B05D-001/28
B05D-003/02
B05D-007/14
B05D-005/06
B05D-007/16
출원번호
US-0573851
(2014-12-17)
등록번호
US-10052655
(2018-08-21)
발명자
/ 주소
Hammond, Richard L.
McConnell, Jessica R.
출원인 / 주소
Whirlpool Corporation
대리인 / 주소
Price Heneveld LLP
인용정보
피인용 횟수 :
0인용 특허 :
21
초록▼
An exterior panel for a kitchen appliance includes a metallic substrate having a predetermined surface pattern on at least one side of the metallic substrate, wherein the metallic substrate is formed to include a predetermined contour. A coating layer is an organic paint coating composition on the a
An exterior panel for a kitchen appliance includes a metallic substrate having a predetermined surface pattern on at least one side of the metallic substrate, wherein the metallic substrate is formed to include a predetermined contour. A coating layer is an organic paint coating composition on the at least one side of the metallic substrate, the coating layer including a predetermined color and a fingerprint resistive surface, wherein the coating layer is at least partially translucent such that the predetermined surface pattern is visible with the naked eye through the coating layer, and wherein the predetermined surface pattern is modified by the coating layer to reflect the combination of the predetermined surface pattern and the predetermined color of the coating layer.
대표청구항▼
1. A process for coating an exterior panel for an appliance, the process including steps of: providing a rolled coil of metallic substrate material, wherein a predetermined surface condition is applied to at least one side of the metallic substrate material;providing an organic paint coating composi
1. A process for coating an exterior panel for an appliance, the process including steps of: providing a rolled coil of metallic substrate material, wherein a predetermined surface condition is applied to at least one side of the metallic substrate material;providing an organic paint coating composition being a thermosetting polyester that is configured to be applied by a process that is free of physical vapor deposition, wherein the organic paint coating composition consists of at least one organic material chosen from a group consisting of:a) tinted resin;b) ethylene glycol monobutyl ether;c) aromatic naphtha in a heavy form;d) xylene;e) isophorone;f) diethylene glycol butyl ether;g) aromatic naphtha in a light form;h) dipropylene glycol methyl ether;i) trimethyl benzene;j) propylene glycol;k) monomethyl ether acetate;l) methyl ethyl ketone;m) naphthalene;n) ethyl benzene;o) n-butyl alcohol;p) formaldehyde; andq) cumene;feeding the rolled coil of metallic substrate material through a reverse rolling paint assembly, wherein the metallic substrate material is unrolled from the rolled coil and fed into the reverse rolling paint assembly;reverse rolling at least one layer of the organic paint coating composition, using reverse rollers, onto the at least one side of the metallic substrate material, wherein each reverse roller rotates to engage the metallic substrate material in an opposing direction to movement of the metallic substrate material to deposit the at least one layer of the organic paint coating composition thereon,curing the organic paint coating composition at a predetermined temperature for a predetermined period of time to harden the organic paint coating composition into a coating layer that is at least partially fingerprint resistant, wherein the coating layer is at least partially transparent such that the predetermined surface condition is visible through the coating layer with a naked eye, and wherein the coating layer includes a predetermined tint that visually modifies the predetermined surface condition that reflects a combination of the predetermined surface condition and the predetermined tint of the coating layer to define a tinted predetermined surface pattern, and wherein the predetermined tint includes at least two colors, wherein each of the at least two colors are separately visible within a common portion of the metallic substrate material from distinct viewing angles;cutting the metallic substrate material into metallic substrate panels;forming the metallic substrate panels into a predetermined shape to form a shaped tint-coated outer panel; andapplying the shaped tint-coated outer panel to an appliance. 2. The process of claim 1, further comprising a step of: pretreating the at least one side of the metallic substrate material, wherein the step of pretreating the metallic substrate material includes at least one cleaning stage and at least one rinsing stage, and wherein the step of reverse rolling the at least one layer of the organic paint coating composition is preceded by the pretreating step. 3. The process of claim 2, wherein the step of pretreating the metallic substrate material also includes applying a pretreatment coating and drying the pretreatment coating. 4. The process of claim 1, further comprising a step of: rolling the metallic substrate material with the coating layer applied to the at least one side onto a coil of coated metallic substrate material, wherein the step of cutting the metallic substrate material is preceded by the step of rolling the metallic substrate material with the coating layer applied and wherein the step of rolling is performed by a reverse rolling mechanism. 5. The process of claim 1, wherein the steps of rolling the organic paint coating composition and curing the organic paint coating composition define a coating application process that is repeated a predetermined number of times in order to achieve the predetermined tint of the coating layer, wherein the coating layer has a thickness within a range of from approximately 0.2 mils to approximately 0.6 mils. 6. The process of claim 5, wherein each coating application process is followed by a quenching step, wherein the metallic substrate material and the coating layer are cooled to a predetermined temperature. 7. The process of claim 5, wherein the coating application process is repeated two times, and wherein the organic paint coating composition is not capable of being physical vapor deposited onto the at least one side of the metallic substrate material. 8. The process of claim 1, further comprising a step of: applying a protective laminate to an outer surface of the coating layer, wherein the step of cutting the metallic substrate material is preceded by the step of applying the protective laminate. 9. The process of claim 1, wherein the step of feeding the rolled coil of metallic substrate material includes feeding the rolled coil of metallic substrate material as a continuous sheet of the metallic substrate material, and wherein the metallic substrate material is stainless steel. 10. A process for manufacturing a shaped tint-coated outer panel for installation on a kitchen appliance, the process comprising steps of: providing a stainless steel substrate material;applying a surface condition into at least one side of the stainless steel substrate material;rolling the stainless steel substrate material onto a coil;feeding the stainless steel substrate material from the coil into a reverse rolling paint assembly;providing a thermosetting polyester paint composition for applying to the at least one side of the stainless steel substrate material, wherein the thermosetting polyester paint composition consists of only organic components that define an organic paint coating composition;reverse rolling the thermosetting polyester paint composition onto the at least one side of the stainless steel substrate material, wherein the step of reverse rolling operates a roller across the stainless steel substrate material and in a direction opposite to movement of the stainless steel substrate material;curing the thermosetting polyester paint composition onto the at least one side of the stainless steel substrate material to form a coated metallic substrate material, wherein the curing occurs at a temperature within a range of from approximately 440 degrees Fahrenheit to approximately 500 degrees Fahrenheit for a time period within a range of from approximately 20 seconds to approximately 45 seconds to form a coating layer, wherein the coating layer is at least partially transparent and includes a predetermined tint that filters a predetermined wavelength of visible light, thereby causing the surface condition to visually define a tinted surface condition having a different color than the surface condition, and wherein the tinted surface condition includes at least two colors, wherein each of the at least two colors are separately visible within a common portion of the coated metallic substrate material from distinct viewing angles;cooling the coated metallic substrate material;rolling the coated metallic substrate material onto a coil for delivery to a cutting assembly;cutting the coated metallic substrate material into predetermined metallic substrate panels;forming the metallic substrate panels into a predetermined shape to form a shaped tint-coated outer panel; andapplying the shaped tint-coated outer panel to an appliance. 11. The process of claim 10, wherein a thickness of the reverse rolled thermosetting polyester paint composition applied to the at least one side is within a range of from approximately 0.8 mils and 1.2 mils, and wherein the cured transparent coating layer has a thickness within a range of from approximately 0.2 mils to approximately 0.6 mils. 12. The process of claim 10, further comprising a step of: pretreating the at least one side of the stainless steel substrate material, wherein the step of reverse rolling the thermosetting polyester paint composition is preceded by the step of pretreating the at least one side of the stainless steel substrate material, wherein the step of pretreating the at least one side of the stainless steel substrate material includes at least one cleaning stage, at least one rinsing stage, followed by applying a pretreatment coating to the at least one side and drying the pretreatment coating. 13. The process of claim 10, wherein the steps of reverse rolling the thermosetting polyester paint composition and curing the thermosetting polyester paint composition define a coating application process that is repeated a predetermined number of times in order to achieve the predetermined tint of the coating layer, wherein the organic paint coating composition includes at least one organic material chosen from a group consisting of: a) aromatic naphtha in a heavy form;b) diethylene glycol butyl ether;c) aromatic naphtha in a light form;d) dipropylene glycol methyl ether;e) trimethyl benzene;f) monomethyl ether acetate;g) ethyl benzene;andh) cumene. 14. The process of claim 13, wherein each coating application process is followed by a quenching step, wherein the stainless steel substrate material and the coating layer are cooled to a predetermined temperature. 15. The process of claim 14, wherein the coating application process is repeated at least two times. 16. The process of claim 10, further comprising a step of: applying a protective laminate to an outer surface of the coated metallic substrate material, wherein the step of cutting the coated metallic substrate material is preceded by the step of applying the protective laminate. 17. The process of claim 10, wherein the surface condition includes at least one surface condition chosen from a group consisting of: a) mill finish;b) mechanically polished finish;c) brushed finish;d) patterned finish;e) bead blasted finishf) shot blasted finishg) electro-polished finishh) photoresist finishi) acid etched finish; andj) ground finish. 18. A method for forming a tint-coated outer panel for installation on a kitchen appliance, the method comprising steps of: providing a stainless steel substrate material, wherein the stainless steel substrate material is one of grade 201 stainless steel and grade 430 stainless steel;brushing the stainless steel substrate material to form a brushed stainless steel surface in at least one side of the stainless steel substrate material;feeding the stainless steel substrate material into a reverse rolling paint assembly;providing a thermosetting polyester paint composition for applying to the at least one side of the stainless steel substrate material, wherein the thermosetting polyester paint composition is an organic paint coating composition, wherein the organic paint coating composition includes at least one organic material chosen from a group consisting of:a) aromatic naphtha in a heavy form;b) diethylene glycol butyl ether;c) aromatic naphtha in a light form;d) dipropylene glycol methyl ether;e) trimethyl benzene;f) monomethyl ether acetate;g) ethyl benzene;andh) cumene;reverse rolling the thermosetting polyester paint composition onto the brushed stainless steel surface of the stainless steel substrate material, wherein an applicator roll rotates in an opposing direction to movement of the stainless steel substrate material through the reverse rolling paint assembly;curing the thermosetting polyester paint composition onto the brushed stainless steel surface of the stainless steel substrate material to form a coated metallic substrate material, wherein the curing occurs at a temperature within a range of from approximately 440 degrees Fahrenheit to approximately 500 degrees Fahrenheit for a time period within a range of from approximately 20 seconds to approximately 45 seconds to form a coating layer, wherein the coating layer is at least partially fingerprint resistant and is at least partially transparent and includes a predetermined tint that filters a predetermined wavelength of visible light, thereby causing the brushed stainless steel surface to visually define a tinted surface condition having a different color than the brushed stainless steel surface;cooling the coated metallic substrate material;applying a protective laminate to an outer surface of the coated metallic substrate material;cutting the coated metallic substrate material into predetermined metallic substrate panels; andforming the metallic substrate panels into a predetermined shape to form a shaped tint-coated outer panel configured to be applied to a kitchen appliance. 19. The method of claim 18, wherein the steps of reverse rolling the thermosetting polyester paint composition and curing the thermosetting polyester paint composition define a coating application process that is repeated at least two times in order to achieve the predetermined tint of the coating layer, and wherein each coating application process is followed by a quenching step to cool the stainless steel substrate material and the coating layer to a predetermined temperature. 20. The method of claim 18, further comprising a step of: pretreating the at least one side of the stainless steel substrate material, wherein the step of reverse rolling the thermosetting polyester paint composition is preceded by the step of pretreating the at least one side of the stainless steel substrate material, and wherein the step of pretreating the at least one side of the stainless steel substrate material includes at least one cleaning stage, at least one rinsing stage, followed by applying a pretreatment coating to the at least one side and drying the pretreatment coating.
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