US4978583A — Patterned metal plate and production thereof

Claim 1

Independent Claim 151 words

An uneven patterned metal plate having a surface, on which a visual decorative uneven pattern is formed by at least one pattern unit, said plate having a plurality of pattern units, said pattern units being separated from each other by unpatterned plane areas free of uneven patterns, each of said pattern units being constituted by and with a plurality of uneven dots, each of which has a size D, said uneven dots being arranged in a predetermined density to have a given ratio η of the occupied area versus the plane area in said pattern unit, said plane area having a surface roughness Ra which is equal to or less than 40 μm, said size D and area ratio η being in the range of: 10≦D≦300 (μm) 30η≦100 (%) and wherein the size of said pattern unit has a minimum axial length or width equal to or greater than 1 mm.

Claim 2

Dependent Claim 151 words

An uneven patterned metal plate having a surface, on which a visual decorative uneven pattern is formed by at least one pattern unit, said plate having a plurality of pattern units, said pattern units being separated from each other by unpatterned plane areas free of uneven patterns, each of said pattern units being constituted by and with a plurality of uneven dots, each of which has a size D, said uneven dots being arranged in a predetermined density to have a given ratio η of the occupied area versus the plane area in said pattern unit, said plane area having a surface roughness Ra which is equal to or less than 40 μm, said size D and area ratio η being in the range of: 10≦D≦300 (μm) 30η≦100 (%) and wherein the size of said pattern unit has a minimum axial length or width equal to or greater than 1 mm.

Claim 3

Dependent Claim 169 words

A process for forming an uneven pattern on a metal strip comprising the steps of: providing a work roll for temper rolling having a surface roughness Ra which is smaller than or equal to 0.40 μm; performing a dulling operation for forming a desired visually decorative uneven pattern on said metal strip, which visually decorative uneven pattern is formed by at least one pattern unit constituted by and with a plurality of uneven dots, each of which has a size D, said uneven dots being arranged in a predetermined density to have given ratio η of the occupying area versus the plane area in said pattern unit, said size D and area ratio η being in the range of: 10≦D≦300 (μm) 30≦η≦100 (%) and the size of said pattern unit is at least 1 mm in axial length or width; and setting the dulled work roll in a temper rolling mill and performing temper rolling for tempering and transferring said uneven pattern onto the surface of said metal strip.

Claim 4

Dependent Claim 169 words

A process for forming an uneven pattern on a metal strip comprising the steps of: providing a work roll for temper rolling having a surface roughness Ra which is smaller than or equal to 0.40 μm; performing a dulling operation for forming a desired visually decorative uneven pattern on said metal strip, which visually decorative uneven pattern is formed by at least one pattern unit constituted by and with a plurality of uneven dots, each of which has a size D, said uneven dots being arranged in a predetermined density to have given ratio η of the occupying area versus the plane area in said pattern unit, said size D and area ratio η being in the range of: 10≦D≦300 (μm) 30≦η≦100 (%) and the size of said pattern unit is at least 1 mm in axial length or width; and setting the dulled work roll in a temper rolling mill and performing temper rolling for tempering and transferring said uneven pattern onto the surface of said metal strip.

Claim 5

Dependent Claim 119 words

A metal plate having a surface with a visual decorative pattern which is constituted with a plurality of pattern segments, each of said pattern segments including a plurality of dots comprising a depression, a projection or a combination of a depression and a projection, each individual dot being of the size D, and said dots being arranged in said each pattern segment at a predetermined density to provide a given ratio η of occupying area versus plane area in said pattern segment, said size D and area ratio η being in the range of: 10≦D≦300 (μm) 30≦η≦100 (%) and said size of said pattern segment being greater than or equal to 1 mm in axial length and/or in width.

Claim 6

Dependent Claim 119 words

A metal plate having a surface with a visual decorative pattern which is constituted with a plurality of pattern segments, each of said pattern segments including a plurality of dots comprising a depression, a projection or a combination of a depression and a projection, each individual dot being of the size D, and said dots being arranged in said each pattern segment at a predetermined density to provide a given ratio η of occupying area versus plane area in said pattern segment, said size D and area ratio η being in the range of: 10≦D≦300 (μm) 30≦η≦100 (%) and said size of said pattern segment being greater than or equal to 1 mm in axial length and/or in width.

Claim 7

Dependent Claim 119 words

A metal plate having a surface with a visually decorative pattern which is constituted with a plurality of pattern segments, each of said pattern segments including a plurality of dots comprising a combination of an essentially circular projection and an annular depression surrounding said depression, each individual dot being in the size D, and said dots being arranged in each pattern segment at a predetermined density to provide a given ratio η of occupying area versus plane area in said pattern segment, said size D and area ratio η being in the range of: 10≦D≦300 (μm) 30≦η≦100 (%) and said size of said pattern segment being greater than or equal to 1 mm in axial length and/or in width.

Claim 8

Dependent Claim 119 words

A metal plate having a surface with a visually decorative pattern which is constituted with a plurality of pattern segments, each of said pattern segments including a plurality of dots comprising a combination of an essentially circular projection and an annular depression surrounding said depression, each individual dot being in the size D, and said dots being arranged in each pattern segment at a predetermined density to provide a given ratio η of occupying area versus plane area in said pattern segment, said size D and area ratio η being in the range of: 10≦D≦300 (μm) 30≦η≦100 (%) and said size of said pattern segment being greater than or equal to 1 mm in axial length and/or in width.

Claim 9

Dependent Claim 143 words

A laminated patterned metal plate the surface of which includes flat areas and a multiplicity of impressions arranged in groups in accordance with a predetermined geometric pattern on the surface of said plate, said impressions including raised portions and depressed portions extending respectively outwardly and inwardly of said flat areas, and said impression having a size D which is the dimension of said peak portion and which is in the range of 10 to 300 μm, said impression having a surface occupation density which is the ratio of plate surface area occupied by said impressions to surface area unoccupied by said impressions, and which is 30-100%. said patterned groups having minimum lengths and widths in the range of 1 mm or greater, and a surface lamination applied to said plate surface, said lamination being thicker at said flat areas than in said depressions.

Claim 10

Dependent Claim 143 words

A laminated patterned metal plate the surface of which includes flat areas and a multiplicity of impressions arranged in groups in accordance with a predetermined geometric pattern on the surface of said plate, said impressions including raised portions and depressed portions extending respectively outwardly and inwardly of said flat areas, and said impression having a size D which is the dimension of said peak portion and which is in the range of 10 to 300 μm, said impression having a surface occupation density which is the ratio of plate surface area occupied by said impressions to surface area unoccupied by said impressions, and which is 30-100%. said patterned groups having minimum lengths and widths in the range of 1 mm or greater, and a surface lamination applied to said plate surface, said lamination being thicker at said flat areas than in said depressions.

Claim 11

Dependent Claim 15 words

The patterned metal plate defined in claim 5 wherein said surface lamination is a metal.

Claim 12

Dependent Claim 17 words

The patterned metal plate defined in claim 5 wherein said surface lamination is a resin coating layer.

Claim 13

Dependent Claim 24 words

The patterned metal plate defined in claim 5 wherein the surface lamination is also thicker at said raised portions than at said flat areas.

Claim 14

Dependent Claim 158 words

A metal plate having a substantially flat surface provided with a specially patterned plane area, the surface of said plane area being modified by the presence of a multiplicity of spaced-apart impressions formed in said plate and arranged in groups in accordance with a predetermined pattern and at a predetermined density on said substantially flat surface, said impressions being positioned between plane areas and including peak portions which extend beyond said substantially flat surface and depressed portions which extend within said plate beneath said substantially flat surface, said impressions having a size D which is the dimension of said peak portion and which is in the range of 10 to 300 μm, said impressions having a surface occupying density which is the ratio of plate surface area occupied by said impressions to surface area unoccupied by said impressions, and which is 30-100%, said patterned groups having minimum lengths and widths in the range of 1 mm or greater.

Claim 15

Dependent Claim 158 words

A metal plate having a substantially flat surface provided with a specially patterned plane area, the surface of said plane area being modified by the presence of a multiplicity of spaced-apart impressions formed in said plate and arranged in groups in accordance with a predetermined pattern and at a predetermined density on said substantially flat surface, said impressions being positioned between plane areas and including peak portions which extend beyond said substantially flat surface and depressed portions which extend within said plate beneath said substantially flat surface, said impressions having a size D which is the dimension of said peak portion and which is in the range of 10 to 300 μm, said impressions having a surface occupying density which is the ratio of plate surface area occupied by said impressions to surface area unoccupied by said impressions, and which is 30-100%, said patterned groups having minimum lengths and widths in the range of 1 mm or greater.

Claim 16

Dependent Claim 26 words

An uneven patterned metal plate as set forth in claim 9, wherein said impressions are formed into essentially circular configuration having said predetermined diameter of D.

Claim 17

Dependent Claim 51 words

An uneven patterned metal plate as set forth in claim 9, wherein said impressions are formed on said metal plate through a temper rolling process by means of a dulled work roll on which an uneven pattern corresponding to the uneven pattern to be formed on said metal plate is formed.

Claim 18

Dependent Claim 23 words

An uneven patterned metal plate as set forth in claim 11, wherein the dulling operation is performed by means of high energy beam.

Claim 19

Dependent Claim 53 words

An uneven patterned metal plate as set forth in claim 9, wherein said pattern group is in the form of a line having a width greater than or equal to 1 mm and said pattern group is spaced from the next pattern group at a distance equal to or greater than 1 mm.

Claim 20

Dependent Claim 21 words

An uneven patterned metal plate as set forth in claim 9, which is formed with a plating layer on said surface.

Claim 21

Dependent Claim 36 words

An uneven patterned metal plate as set forth in claim 14, wherein said plating layer has a greater thickness at the projecting peak portion of each impression than that at the depressed portion of each impression.

Claim 22

Dependent Claim 195 words

In a process for forming a metal plate having a substantially flat surface provided with a specifically patterned plane area, the steps which comprise dulling to the surface of said plane area a multiplicity of spaced-apart impressions formed in said plate and arranged in groups in accordance with a predetermined pattern and at a predetermined density on said substantially flat surface, said dulling being applied by a temper roll having a surface roughness Ra equal to or less than 0.40 μm, said impression being positioned between plane areas and including peak portions which extend beyond said substantially flat surface and depressed portions which extend within said plane beneath said substantially flat surface, said impressions having a size D which is the dimension of said peak portion and which is in the range of 10 to 300 μm, said impressions having a surface occupation density which is the ratio of plate surface area occupied by said impressions to surface area unoccupied by said impressions, and which is 30-100%, said patterned groups having minimum lengths and widths in the range of 1 mm or greater, and transferring the spaced-apart impressions to the surface of said metal plate.

Claim 23

Dependent Claim 195 words

In a process for forming a metal plate having a substantially flat surface provided with a specifically patterned plane area, the steps which comprise dulling to the surface of said plane area a multiplicity of spaced-apart impressions formed in said plate and arranged in groups in accordance with a predetermined pattern and at a predetermined density on said substantially flat surface, said dulling being applied by a temper roll having a surface roughness Ra equal to or less than 0.40 μm, said impression being positioned between plane areas and including peak portions which extend beyond said substantially flat surface and depressed portions which extend within said plane beneath said substantially flat surface, said impressions having a size D which is the dimension of said peak portion and which is in the range of 10 to 300 μm, said impressions having a surface occupation density which is the ratio of plate surface area occupied by said impressions to surface area unoccupied by said impressions, and which is 30-100%, said patterned groups having minimum lengths and widths in the range of 1 mm or greater, and transferring the spaced-apart impressions to the surface of said metal plate.

Claim 24

Dependent Claim 27 words

A process as set forth in claim 16, wherein said dulling operation for forming impressions constituting said pattern is performed by means a high density energy beam.

Claim 25

Dependent Claim 20 words

A process as set forth in claim 17, wherein said dulling operation is performed by means of a laser beam.

Claim 26

Dependent Claim 25 words

A process as set forth in claim 16, wherein the surface roughness Ra of said plane area is smaller than or equal to 0.40 μm.

Claim 27

Dependent Claim 24 words

A process as set forth in claim 16, wherein said impressions are formed into an essentially circular configuration having a predetermined diameter of D.

Claim 28

Dependent Claim 22 words

A process as set forth in claim 16, wherein said pattern group has a width greater than or equal to 1 mm.

Claim 29

Dependent Claim 23 words

A process as set forth in claim 16, wherein said pattern group has an axial length greater than or equal to 1 mm.

Claim 30

Dependent Claim 48 words

A process as set forth in claim 16, wherein said impressions are formed on said metal plate through a temper rolling process by means of a dulled work roll on which an uneven pattern corresponding to the uneven pattern to be formed on said metal plate is formed.

Claim 31

Dependent Claim 21 words

A process as set forth in claim 23, wherein said dulling operation is performed by means of a high energy beam.

Claim 32

Dependent Claim 57 words

A process as set forth in claim 16, wherein said pattern group is in the form of a line having a width greater than or equal to 1 mm and wherein said pattern group in the form of line is spaced apart from the next pattern group at a distance greater than or equal to 1 mm.

Claim 33

Dependent Claim 18 words

A process as set forth in claim 16, which is formed with a plating layer on said surface.

Claim 34

Dependent Claim 31 words

A process as set forth in claim 26, wherein said plating layer has less thickness at the projecting peak portion of each impression than at the depressed portion of each impression.

Claim 35

Dependent Claim 45 words

A process as set forth in claim 26, wherein said temper rolling operation is performed with by driving one of said temper rolls and a roll with a plane surface and contacting with said temper roll to cause a relative shift in the axial direction.

Claim 36

Dependent Claim 37 words

A process as set forth in claim 28, wherein the shifting magnitude of relative shift between said work roll and said plane surface roll is greater than or equal to half of the interval between the lines.

Claim 37

Dependent Claim 27 words

A process as set forth in claim 29, wherein said relative shift in axial direction of said work roll and said plane surface roll is performed continuously.

Claim 38

Dependent Claim 29 words

A process as set forth in claim 30, wherein said relative shifting speed is substantially lower than the line speed of the metal strip in the temper rolling process.

Claim 39

Dependent Claim 44 words

A process as set forth in claim 16, wherein said temper rolling operation is performed by driving one of said temper rolls and a roll with a plane surface and contacting with said temper roll to cause a relative shift in the axial direction.

Claim 40

Dependent Claim 27 words

A process as set forth in claim 32, wherein said relative shift in axial direction of said work roll and said plane surface roll is performed continuously.

Claim 41

Dependent Claim 29 words

A process as set forth in claim 33, wherein the relative shifting speed is substantially lower than the line speed of the metal strip in the temper rolling process.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1993-12-17	1994-06-18	1994-12-18	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1997-12-17	1998-06-18	1998-12-18	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2001-12-17	2002-06-18	2002-12-18	$7700.00	Window Closed / Lapsed

Patterned metal plate and production thereof

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