Application of polymer thermofoil to metal substrate

Abstract

The present invention is directed to a novel method for application of polymer thermofoil to a metal substrate. The method involves first coating a metal substrate with an oxidation-preventing or oxidation-limiting coating, then adhering a polymer thermofoil to the metal substrate. After application of the thermofoil, the metal substrate can be formed to the final shape. The method is advantageous in that it allows one to efficiently manufacture metal objects in a variety of aesthetically pleasing surface finishes.

What is claimed is: 
     
         1 . A method for manufacturing a thermofoil covered metal substrate, the method comprising the steps of:
 coating at least one surface of a metal substrate with an oxidation-preventing or oxidation-limiting coating;   applying adhesive to at least one surface of the coated metal substrate,   applying a thermofoil sheet to the adhesive, thus causing the thermofoil sheet to adhere to the metal substrate; and   forming the metal substrate into a desired final shape.   
     
     
         2 . The method of  claim 1  wherein the adhesive applied to the at least one surface of the coated metal substrate comprises a hot melt adhesive. 
     
     
         3 . The method of  claim 1  wherein the method further includes a final step of heating the metal substrate after the step of forming the metal substrate into a desired final shape. 
     
     
         4 . The method of  claim 1  wherein the oxidation-preventing coating comprises a powder-based coating. 
     
     
         5 . The method of  claim 1  wherein the thermofoil sheet comprises polyvinyl chloride. 
     
     
         6 . The method of  claim 1  wherein the step of forming the metal substrate into a desired final shape is accomplished using a press brake. 
     
     
         7 . A method for manufacturing a thermofoil-covered metal substrate, the method comprising the steps of:
 producing a metal blank;   coating at least one surface of the metal blank with an oxidation-preventing or oxidation-limiting coating;   applying adhesive to at least one surface of the coated metal blank;   applying a thermofoil sheet to the adhesive, thus causing the thermofoil sheet to adhere to the metal blank;   trimming any excess thermofoil from the metal blank; and   forming the metal blank into a desired final shape.   
     
     
         8 . The method of  claim 7  wherein the adhesive applied to the at least one surface of the coated metal substrate comprises a hot melt adhesive. 
     
     
         9 . The method of  claim 7  wherein the method further includes a final step of heating the metal blank after the step of forming the metal blank into a desired final shape. 
     
     
         10 . The method of  claim 7  wherein the oxidation-preventing coating comprises a powder-based coating. 
     
     
         11 . The method of  claim 7  wherein the thermofoil sheet comprises polyvinyl chloride. 
     
     
         12 . The method of  claim 7  wherein the step of forming the metal blank into a desired final shape is accomplished using a press brake. 
     
     
         13 . A method for manufacturing a thermofoil-covered metal substrate, the method comprising:
 coating at least one surface of a metal sheet with an oxidation-preventing or oxidation-limiting coating;   applying adhesive to the oxidation-preventing or oxidation-limiting coating;   applying a thermofoil sheet to the adhesive, thus causing the thermofoil sheet to adhere to the metal sheet;   cutting the thermofoil-covered metal sheet to a shape conducive to forming the metal sheet to a desired final shape; and   forming the cut metal sheet into a desired final shape.   
     
     
         14 . The method of  claim 13  wherein the adhesive applied to the oxidation-preventing or oxidation-limiting coating comprises a hot melt adhesive. 
     
     
         15 . The method of  claim 13  wherein the method further includes a final step of heating the formed metal sheet after the step of forming into a desired final shape. 
     
     
         16 . The method of  claim 13  wherein the oxidation-preventing coating comprises a powder-based coating. 
     
     
         17 . The method of  claim 13  wherein the thermofoil sheet comprises polyvinyl chloride. 
     
     
         18 . The method of  claim 13  wherein the step of forming the metal blank into a desired final shape is accomplished using a press brake.