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. Method for manufacturing a textile composite part/thermoplastic resin comprising the following steps: a) Provide a mold; b) Apply at least one composition (A), comprising at least one thermoplastic resin, at the bottom of the mold; c) Heat the mold obtained in the previous step; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

2. Method according to claim 1 further comprising a step a0), before step b), deposition of a varnish composition (A0) at the bottom of the mold.

3. Method according to claim 1, further comprising a step a1), before step b), after step b) or during step b) or, if appropriate, after step a0), deposition of a colored composition (B) comprising at least one thermoplastic or thermosetting resin on all or part of the surface of the mold.

4. Method according to claim 1, comprising the following steps: a) Provide a mold; b) Apply a composition (Al) comprising at least one thermoplastic resin; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

5. Method according to claim 1, comprising the following steps: a) Provide a mold; b) Heat the mold and apply a composition (A2) comprising at least one thermoplastic resin; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

6. Method according to claim 1, comprising the steps of: a) Provide a mold; b) Optionally heat the mold and apply a composition (A1) comprising at least one thermoplastic resin at the bottom of the mold; b1) Heat and apply a composition (A2) comprising at least one thermoplastic resin; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

7. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; a1) Heat the mold of step a) or a0) and deposit the composition (B) with the aid of the inkjet printing assembly according to the loaded image; b) Optionally heat and apply at least one composition (A) comprising at least one thermoplastic resin; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

8. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; a1) Heat the mold of step a) or a0) and deposit the composition (B) with the aid of the inkjet printing assembly according to the loaded image; b) Optionally heat and apply a composition (A1) comprising at least one thermoplastic resin; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

9. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; a1) Heat the mold of step a) or a0) and deposit the composition (B) with the aid of the ink jet printing assembly according to the loaded image; b) Heat the mold and then apply a composition (A2) comprising at least one thermoplastic resin; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

10. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; a1) Heat the mold of step a) or a0) and deposit the composition (B) with the aid of the inkjet printing assembly as a function of the loaded image; b) Optionally apply a composition (A1) comprising at least one thermoplastic resin; b1) Heat the mold and apply a composition (A2) comprising at least one thermoplastic resin; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

11. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; a) Optionally heat and apply at least one composition (A) comprising at least one thermoplastic resin; a1) Heat and deposit the composition (B) using the inkjet printing assembly as a function of the loaded image; b) Heat the mold; c) Apply the textile to the heated thermoplastic resin; d) Cool the mold; e) Turn.

12. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; b) Optionally heat the mold and apply a composition (A1) comprising at least one thermoplastic resin; a1) Heat the mold and depositing a composition (B) using the inkjet printing assembly as a function of the loaded image; c) Apply the textile to the heated thermoplastic resin; d) Cool the mold; e) Turn.

13. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; b) Heat the mold and then apply a composition (A2) comprising at least one thermoplastic resin; b2) Cool the mold at a temperature between 20 and 100 C., preferably between 50 and 100 C., and deposit the composition (B) using the inkjet printing assembly as a function of the loaded image; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

14. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; b) Optionally heat and apply a composition (A1) comprising at least one thermoplastic resin; a1) Heat the mold and deposit the composition (B) with the inkjet printing assembly according to the loaded image; b1) Heat the mold and apply a composition (A2) comprising at least one thermoplastic resin; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

15. Method according to claim 1, comprising the steps of: a) Provide a mold; i) Optionally make a scan of the mold and then process the signal obtained to give an image; ii) Load the image from step i) or an image in an inkjet printing assembly; a0) Optionally deposit a layer of composition (A0) at the bottom of the mold; b) Optionally heat the mold and apply a composition (A1) comprising at least one thermoplastic resin; b1) Heat the mold and apply a composition (A2) comprising at least one thermoplastic resin; b2) Cool the mold at a temperature between 20 and 100 C., preferably between 50 and 100 C., and deposit the composition (B) using the printing assembly as a function of the loaded image; c) Heat the mold; d) Apply the textile to the heated thermoplastic resin; e) Cool the mold; f) Remove mold.

16. Method according to claim 1, wherein the textile is a natural or synthetic textile or a mixture optionally coated with a thermoplastic resin or is a luminous textile or is a textile coated with glue.

17. Method according to claim 1, wherein the textile is deposited by rolling, for example with the aid of an applicator roll, by simply depositing the textile on the mold, or by pressing.

18. Method according to claim 1, wherein the mold is a 2D mold previously etched for example by chemical etching, laser, machining, or a 3D mold, preferably a steel, nickel or silicone mold.

19. Method according to claim 1 for the manufacture of leather goods, for example purses, travel bags, public and private furnishings such as sofas, armchairs, of articles for the covering of a seat, particularly in the automobile, aeronautical, nautical and railway sectors; in the automotive field, these composite parts may be intended for the manufacture of headrests, gearshift, armrest, door panel, dashboard liner and cabinetry parts.

Description

EXAMPLE OF IMPLEMENTATION OF THE METHOD ACCORDING TO THE INVENTION

[0470] 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.25 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.

[0471] 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.

[0472] 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.230 g/m.sup.2.

[0473] The mold is then heated for 5 min30 sec at 340 C. to achieve a mold temperature of between 150 and 360 C. During this step the composition (A1) is gelled.

[0474] 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.

[0475] 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.

[0476] 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

[0477] 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.25 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.

[0478] 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.

[0479] 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.250 g/m.sup.2. The mold is then heated for 5 min30 sec at 340 C. to achieve a mold temperature of between 150 and 360 C. During this step the composition (A1) will gel.

[0480] 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.

[0481] 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

[0482] 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.25 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.

[0483] 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.250 g/m.sup.2. The mold is then heated for 1 min30 sec at 340 C. to reach a mold temperature of between 50 and 150 C. During this step the composition (A1) is pregelled

[0484] 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.

[0485] 4) The mold is then reheated for 5 minutes30 sec at 340 C. to achieve a mold temperature of between 150 and 360 C. During this step the composition (A1) will gel.

[0486] 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.

[0487] 6) The assembly is then cooled either by water or by air, and after demolding a debossed/embossed printed fabric is obtained.