Method for preparing a textile/resin composite part

Abstract

The present invention relates to a method for manufacturing a textile/thermoplastic resin composite part, comprising the following steps: (a) providing a mould; (b) applying at least one composition (A) comprising at least one thermoplastic resin; (c) heating the mould; (d) applying the textile to the heated thermoplastic resin; (e) cooling the mould; (f) unmoulding.

Claims

1. A method for manufacturing a textile composite part comprising a textile and a thermoplastic resin, the method comprising, in the following order: a) providing a mold having a bottom; a0) depositing a varnish composition at the bottom of the mold, heating the mold to produce a varnish layer as an external surface of the textile composite part; a1) depositing a colored composition comprising at least one thermoplastic or thermosetting resin on all or a portion of the varnish layer, heating the mold, providing colored pattern(s), and obtaining a varnish layer having this/these colored pattern(s); b) applying at least one composition (A), comprising at least one thermoplastic resin, on top of the varnish layer; c) heating the mold including the at least one composition (A); d) applying a textile to the heated composition (A); e) cooling the mold; and f) removing the textile composite part from the mold, the textile composite part comprising an external surface that is made of the varnish layer through which the colored pattern(s) is/are visible.

2. The method according to claim 1, wherein in step b) composition (A) comprises polyvinyl chloride (PVC) and plasticizer.

3. The method according to claim 1, wherein in step b) composition (A) comprises a resin selected from the group consisting of polyvinyl chloride (PVC), a mixture of PVC and a copolymer or terpolymer of vinyl chloride and vinyl acetate, a mixture of PVC and a copolymer or terpolymer of vinyl chloride and acrylic derivative, PVC/nitrile copolymers, mono- or bicomponent polyurethanes, thermoplastic polyurethanes (TPU), thermoplastic polyetheresters, ethylene/vinyl monomer copolymers, ethylene/vinyl monomer/carbonyl terpolymers, melt-processable acrylic elastomers, polyamide and polyether block copolymers, chlorinated or chlorosulfonated polyethylenes, ethylene/alkyl (meth) acrylate polymers, MBS core-shell polymers, SBM block terpolymers, PVDF and polyamide resins.

4. The method according to claim 1, further comprising further applying on composition (A) a composition (A2) comprising at least one thermoplastic resin selected from the group consisting of copolymers or terpolymers vinyl chloride and vinyl acetate (VC/VA) or vinyl chloride and acrylic derivative (VC/AD), thermoplastic polyurethanes (TPU), thermoplastic polyetheresters, ethylene/vinyl monomer copolymers (EVA), ethylene terpolymers/vinyl monomer/carbonyl, melt-processable acrylic elastomers, polyamide and polyether block copolymer, polyetherblockamides, chlorinated or chlorosulfonated polyethylenes, ethylene/alkyl (meth) acrylate or (meth) acrylic acid polymers, MBS core-shell polymers, SBM block terpolymers, PVDF, and polyamide resins powder.

5. The method according to claim 1, wherein step a) of providing the mold further comprises the steps of: i) making or providing a scan of the mold and then processing a signal obtained of the scanned mold to provide an image; and ii) loading the image from step i) or an image in an inkjet printing assembly; and wherein at step a1) the deposition of the colored composition is carried out with the aid of the inkjet printing assembly according to the loaded image.

6. The method according to claim 2, wherein step a) of providing the mold further comprises the steps of: i) making or providing a scan of the mold and then processing a signal obtained of the scanned mold to provide an image; and ii) loading the image from step i) or an image in an inkjet printing assembly; and wherein at step a1) the deposition of the colored composition is carried out with the aid of the inkjet printing assembly according to the loaded image.

7. The method according to claim 3, wherein step a) of providing the mold further comprises the steps of: i) making or providing a scan of the mold and then processing a signal obtained of the scanned mold to provide an image; and ii) loading the image from step i) or an image in an inkjet printing assembly; and wherein at step a1) the deposition of the colored composition is carried out with the aid of the inkjet printing assembly according to the loaded image.

8. The method according to claim 4, wherein step a) of providing the mold further comprises the steps of: i) making or providing a scan of the mold and then processing a signal obtained of the scanned mold to provide an image; and ii) loading the image from step i) or an image in an inkjet printing assembly; wherein at step al) the deposition of the colored composition is carried out with the aid of the inkjet printing assembly according to the loaded image.

9. The method according to claim 1, wherein step a) of providing the mold further comprises the steps of: i) making or providing a scan of the mold and then processing a signal obtained of the scanned mold to provide an image; and ii) loading the image from step i) or an image in an inkjet printing assembly; and wherein after step a0) the mold is heated at a temperature between 20° C. and 100° C. before depositing the colored composition, the deposition of the colored composition is carried out with the aid of the inkjet printing assembly according to the loaded image.

10. The method according to claim 1, wherein the textile is selected from the group consisting of a natural textile, a synthetic textile, a textile coated with a thermoplastic resin, a luminous textile, and a textile coated with glue.

11. The method according to claim 1, wherein the textile is laminated on the heated thermoplastic resin, or is deposited with the aid of an applicator roll, or is deposited by pressing the textile on the mold.

12. The method according to claim 1, wherein the mold is a 2D mold previously etched by chemical etching, laser, machining, or wherein the mold is a 3D mold comprising steel, nickel, or silicone.

13. The method according to claim 1, wherein the method comprises a manufacturing of leather goods.

14. The method according to claim 1, wherein the varnish at step a0) comprises, by weight relative to the weight of the varnish composition: 5 to 20% of at least one thermoplastic or thermosetting resin whose particles have a size between 0.1 and 10 μm, 1 to 20% of at least one coloring agent, 5 to 20% of at least one plasticizer, and 45 to 75% of at least one organic solvent or water.

15. The method according to claim 1, wherein the colored composition comprises, by weight relative to the weight of the composition: 5 to 20% of at least one thermoplastic or thermosetting resin whose particles have a size between 0.1 and 10 μm, 1 to 20% of at least one coloring agent, 5 to 20% of at least one plasticizer, and 45 to 75% of at least one organic solvent or water.

16. The method according to claim 1, wherein the composition (A) comprises, by weight relative to the weight of the composition: from 40 to 50% by weight, of thermoplastic resin; from 25 to 40% by weight of plasticizer; from 5 to 10% by weight of solvent; from 0 to 5% by weight of pigment; from 0 to 3% by weight of additives; from 0 to 3% by weight of filler; and from 0 to 5% by weight of thermal stabilizer.

17. The method according to claim 1, wherein the composition (A) comprises, by weight relative to the weight of the composition: from 45 to 55% by weight of thermoplastic resin; from 35 to 45% by weight of plasticizer; from 0 to 3% by weight of pigment; from 0 to 3% by weight of additives; from 0 to 3% by weight of filler; and from 0 to 3% by weight of thermal stabilizer.

18. The method according to claim 1, wherein said bottom of the mold on which the varnish composition is deposited at step a0) comprises positive and/or negative etched patterns.

19. The method according to claim 18, wherein at step a1) the colored composition is deposited on the positive and/or negative etched patterns.

20. The method according to claim 1, wherein the composition (A) is applied at step b) to a thickness of between 20 and 150 μm, or 150 μm and 1.5 mm.

21. A method for manufacturing a textile composite part comprising a textile and a thermoplastic resin, the method comprising the following steps in this order: a) providing a mold having a bottom; a0) depositing a varnish composition at the bottom of the mold, heating the mold to produce a varnish layer as an external surface of the textile composite part; b) applying at least one composition (A) on the varnish layer, the at least one composition (A) comprising at least one thermoplastic resin, heating the mold, and obtaining a thermoplastic resin surface; b1) depositing a colored composition comprising at least one thermoplastic or thermosetting resin on all or a portion of the thermoplastic resin surface, providing colored pattern(s), heating the mold, and obtaining the thermoplastic resin surface having this/these colored pattern(s); c) applying at least one composition (A), comprising at least one thermoplastic resin, on the thermoplastic resin surface having the colored pattern(s) on top; d) heating the mold and the at least one composition (A); e) applying a textile to the heated at least one composition (A); f) cooling the mold; and g) removing the textile composite part from the mold, the textile composite part comprising an external surface that is made of the varnish layer through which the colored pattern(s) is/are visible.

Description

EXAMPLE OF IMPLEMENTATION OF THE METHOD ACCORDING TO THE INVENTION

(1) 1) Over the entire surface of a mold, a varnish composition (A0) according to the invention is sprayed with a gun. The weight of the deposit of the varnish composition is about 10 g/m.sup.2±5 g in dry matter. The mold is then introduced into an oven heated at 340° C. for 1 min and 30 sec (±10 sec) to reach a mold temperature of between 20 and 100° C.

(2) 2) An image is created via software or scanned. The mold surface is scanned to place the created or scanned image exactly where desired. The print head allows the deposition of the composition (B) at the exact location chosen to print the image.

(3) 3) A PVC composition (A1) according to the invention is then sprayed onto the mold obtained in 2) with the aid of a spray gun. The deposition weight of this composition (A1) is about 150 g/m.sup.2±30 g/m.sup.2.

(4) The mold is then heated for 5 min±30 sec at 340° C. to achieve a mold temperature of between 150 and 360° C. During this step the composition (A1) is gelled.

(5) 4) The mold obtained in step 3) is coupled to a powder tank comprising the PVC composition (A2) according to the invention in powder form. The assembly rotates for about 30 seconds in order to obtain a thickness of the vinyl product of about 0.6 mm. The mold is then re-introduced to an oven at 340° C. for 1 minute to effect the post-gelation operation and reach a mold temperature of between 70 and 300° C. This is a step to gel all the PVC material.

(6) 5) At the end of step 4) a textile is applied directly to the outlet of the oven, pressure is applied to obtain a mechanical anchoring of the fabric and thus have a good adhesion.

(7) 6) The assembly is then cooled either by water or by air, and after demolding a printed debossed/embossed fabric is obtained.

EXAMPLE OF IMPLEMENTATION OF THE METHOD ACCORDING TO THE INVENTION

(8) 1) A varnish composition (A0) according to the invention is sprayed with a gun over the entire surface of a mold. The weight of the deposit of the varnish composition is about 10 g/m.sup.2±5 g in dry matter. The mold is then introduced into an oven heated at 340° C. for 1 min and 30 sec (±10 sec) to reach a mold temperature of between 20 and 100° C.

(9) 2) An image is created via software. The print head allows the deposition of the composition (B) at the exact location chosen to print the image.

(10) 3) A PVC composition (A1) according to the invention is then scraped on the mold obtained in 2) using a doctor blade. The deposition weight of this composition (A1) is about 650/m.sup.2±50 g/m.sup.2. The mold is then heated for 5 min±30 sec at 340° C. to achieve a mold temperature of between 150 and 360° C. During this step the composition (A1) will gel.

(11) 4) At the end of step 3), a textile is applied directly to the outlet of the oven, pressure is applied to obtain mechanical anchoring of the fabric and thus provide good adhesion.

(12) 5) The assembly is then cooled either by water or by air, and after demolding a debossed printed embossed fabric is obtained.

EXAMPLE OF IMPLEMENTATION OF THE METHOD ACCORDING TO THE INVENTION

(13) 1) A varnish composition (A0) according to the invention is sprayed with a gun over the entire surface of a mold. The weight of the deposit of the varnish composition is about 10 g/m.sup.2±5 g in dry matter. The mold is then introduced into an oven heated at 340° C. for 1 min and 30 sec (±10 sec) to reach a mold temperature of between 20 and 100° C.

(14) 2) A PVC composition (A1) according to the invention is then scraped on the mold obtained in 2) using a doctor blade. The deposition weight of this composition (A1) is about 650/m.sup.2±50 g/m.sup.2. The mold is then heated for 1 min±30 sec at 340° C. to reach a mold temperature of between 50 and 150° C. During this step the composition (A1) is pregelled

(15) 3) An image is created via software. The print head allows the deposition of the composition (B) at the exact location chosen to print the image on the pre-gelled composition A1.

(16) 4) The mold is then reheated for 5 minutes±30 sec at 340° C. to achieve a mold temperature of between 150 and 360° C. During this step the composition (A1) will gel.

(17) 5) At the end of step 4) a textile is applied directly at the outlet of the oven, a pressure is applied to obtain mechanical anchoring of the fabric to provide good adhesion.

(18) 6) The assembly is then cooled either by water or by air, and after demolding a debossed/embossed printed fabric is obtained.