Method for the Manufacture and Decoration of a Mineral-filled Resin Shower Tray with an External Coating, and Shower Tray Obtained by Said Method

Abstract

A method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, including the steps of applying an external coating layer on the internal surface of a mould, casting a mix of resin and mineral filler on the mould, curing and drying the mix, and including the prior steps of disposing on the internal surface of the mould cavity a transfer film including on one of the sides thereof a pattern printed in ink, vacuum thermoforming the transfer film against the internal surface of the mould cavity, and the subsequent step of removing the film from the surface of the mineral-filled resin shower tray with an external coating.

Claims

1. A method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, comprising manufacturing steps of: applying an external coating layer on an internal surface of a mould, casting a mix of resin and mineral filler on the mould, and curing and drying the mix; further comprising the following preliminary steps: disposing on an internal surface of the mould cavity a transfer film comprising on one of the sides thereof a pattern printed in ink, with the side not comprising the pattern printed with ink being in contact with said internal surface of the mould cavity, and vacuum thermoforming the transfer film against the internal surface of the mould cavity; and further comprising the following subsequent step: removing the film from the surface of the mineral-filled resin shower tray with an external coating.

2. The method for the manufacture and decoration of a mineral-filled resin shower tray with Gelcoat coating, according to claim 1, wherein the transfer film is a Polycarbonate (PC) film.

3. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, wherein the transfer film is a Copolyester (PETG) film.

4. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, wherein the transfer film is a water-soluble polyvinyl film.

5. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, wherein the transfer film is a vinyl film.

6. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, wherein the application of vacuum occurs by suction of the transfer film from the internal surface of the mould cavity.

7. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, wherein the application of vacuum occurs through at least one hole made in the mould.

8. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, wherein the transfer film is removed from the external surface of the shower tray by washing with water once the manufacturing process has finished.

9. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, further comprising a final stage of applying an external protection layer.

10. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 9, wherein the external protection layer is a lacquer.

11. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 9, wherein the external protection layer is a varnish.

12. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, wherein the external coating is made of Gelcoat.

13. The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating, according to claim 1, wherein the external coating is made of Polyurethane paint.

14. A shower tray decorated according to the method of claim 1, wherein the shower tray comprises a decorative layer inserted into a surface layer thereof with a depth of between 3 and 25 microns.

15. A shower tray decorated according to the method of claim 1, wherein the shower tray comprises a decorative layer inserted into a surface layer thereof with a depth of between 8 and 25 microns.

16. A shower tray decorated according to the method of claim 1, wherein the shower tray comprises a decorative layer inserted into a surface layer thereof with a depth of between 10 and 15 microns.

Description

DESCRIPTION OF THE INVENTION

[0014] As explained, the present invention provides a method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating and shower tray obtained by said method.

[0015] The method for the manufacture and decoration of a mineral-filled resin shower tray with an external coating consists of the following stages:

[0016] Application of the transfer film on the mould. The transfer film comprises on one of the sides thereof the design to be applied to the surface of the shower tray printed in ink, said side being disposed towards the interior of the mould cavity. According to one embodiment option, the transfer film used is one of the following: [0017] Polycarbonate (PC) film [0018] Copolyester (PETG) film [0019] Water soluble polyvinyl film [0020] Vinyl film

[0021] Vacuum thermoforming the transfer film against the internal surface of the mould cavity. In this stage, the edges of the transfer film are secured over the edges of the mould, heat is applied so that the transfer film softens so that when it softens it can adapt to the shape of the mould, and the vacuum between the internal surface of the mould cavity and the transfer film is preferably produced by suction.

[0022] Applying the external coating layer on the transfer film disposed on the internal surface of the mould cavity.

[0023] Pouring the mineral-filled resin mix into the internal surface of the mould cavity on the external coating layer making up the shower tray.

[0024] Stages of curing and drying the shower tray.

[0025] Removing the film from the surface of the shower tray, the ink being inserted in the external coating layer.

[0026] In this process, the ink is transferred from the film to the surface of the mineral-filled resin shower tray with an external coating during the polymerisation process of same, so that the heat facilitates the transfer of the ink that penetrates between 3 and 25 microns in the surface layer of the part, more specifically it penetrates between 8 and 25 microns, and preferably penetrates between 10 and 15 microns, producing a quality finish and wherein the decoration obtained does not detach from the shower tray, the tray maintaining the properties granted by the external coating layer.

[0027] Optionally, the process comprises a final stage of applying an external protection layer such as a lacquer or a varnish.