WO2019004952A1 - Production of decorative and customized products using composite materials - Google Patents

Production of decorative and customized products using composite materials Download PDF

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Publication number
WO2019004952A1
WO2019004952A1 PCT/TR2017/000074 TR2017000074W WO2019004952A1 WO 2019004952 A1 WO2019004952 A1 WO 2019004952A1 TR 2017000074 W TR2017000074 W TR 2017000074W WO 2019004952 A1 WO2019004952 A1 WO 2019004952A1
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WO
WIPO (PCT)
Prior art keywords
paper
decorative
product
coating material
production
Prior art date
Application number
PCT/TR2017/000074
Other languages
French (fr)
Inventor
Coşkun KARAPINAR
Original Assignee
Karapinar Coskun
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Karapinar Coskun filed Critical Karapinar Coskun
Priority to PCT/TR2017/000074 priority Critical patent/WO2019004952A1/en
Publication of WO2019004952A1 publication Critical patent/WO2019004952A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/18—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length in the form of a mat, e.g. sheet moulding compound [SMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/253—Preform
    • B29K2105/256—Sheets, plates, blanks or films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0087—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/44—Furniture or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/44—Furniture or parts thereof
    • B29L2031/448—Tables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/722—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/048—Natural or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2479/00—Furniture

Definitions

  • the present invention relates to a method of production of decorative and customized products made using composite materials.
  • it is related to the production method of various products, such as decorative and customized tables, desks, chairs, coffee tables, cupboards, boards and laminates, in which SMC and BMC composite pastes are molded, in a single step, together with decorative papers used in lamination industry.
  • Decorative or digital papers are impregnated with a special resin, after which they are molded together with composite materials to give them a surface coating. This way, not only the surface wear resistance of the material will increase but also a pleasant appearance will be provided. Products manufactured this way will not easily catch fire, be affected from water and sunlight, and will have a long economic life. Additionally, environment-friendly products will have been manufactured due to use of no trees.
  • wood shavings There are several products manufactured from wood shavings, such as tables, desks, chairs, coffee tables, cupboards, boards and laminates.
  • the problems faced with the production from wood shavings include:
  • the production consists of a two-phase operation.
  • the wood shavings and the chemical mixture are first molded in the press, and then the decorative molding takes place.
  • Composite products may be made to have a decorative look by applying coating later or painting; however, coating applied post-production raise or become deformed before long.
  • the invention relates to a fireproof composite board material and production thereof, which contains silica as raw material, waste natural wooden material, and derivatives of formaldehyde or granulated PVC and PP elements as binding agent, to be used as an alternative to wood in the furniture industry when manufacturing tables, chairs, armchairs, cupboards and window frames, and instead of plywood molds and industrial plates in the construction sector.
  • silica as raw material
  • waste natural wooden material waste natural wooden material
  • derivatives of formaldehyde or granulated PVC and PP elements as binding agent
  • the object of the invention is to develop a production method for decorative and customized products by using composite materials, not only overcoming the problems in the available constructs but also providing lots of advantages.
  • Another object of the invention is to procure the product in a single press, and thus save from time and workmanship.
  • Another object of the invention is manufacturing products that have superior resistance to water, humidity, chemicals and atmospheric conditions.
  • Another object of the invention is manufacturing products that do not get bent or bucked or deformed otherwise.
  • Another object of the invention is to manufacture products that can easily be put out and do not spread the fire since it does not catch fire easily and melt, flow or drip, if on fire.
  • Another object of the invention is to produce products that have high resistance to wear and scratches.
  • Another object of the invention is to provide decorative products that have the desired looks, allowing for effective advertising.
  • Another object of the invention is to provide products that do not get stained easily and that can be cleaned quickly. Another object of the invention is to produce products that have high UV resistance, ensuring no formation of discoloration. Another object of the invention is to provide products that chemically binds to the composite structure and do not split up during use since the coats are molded and joined together with the composite during molding of the composite material. To bring about the objects of the invention, a production method has been developed for various decorative and customized products, such as tables, chairs, coffee tables, desks, covers, cupboards and boards, using composite materials.
  • FIG. 1 Block diagram drawing of a preferred representative application of the invention.
  • FIG. 1 Block diagram drawing of another preferred representative application of the invention.
  • the production method of the invention allows production of products that provide many advantages. As shown in the figures, the production method allows for production in a single step by molding (4) the main carrier composite material (1) together with at least one of the coating material craft paper (2), coating material decorative paper (3), coating material digital offset paper (5), and coating material aluminum oxide overlay paper (6).
  • the pressure of the press is set to 60 to 120 Kg/Cm 2 depending on the surface structure of the product to be manufactured and the formulation of the SMC/BMC paste to be used;
  • the molding time is calculated considering the thickest point of the product depending on the formulation of the SMC/BMC paste to be used, and said time is set to 10 to 40 sec. for every 1 mm of thickness;
  • the craft paper and decorative paper are prepared by cutting them 3 to 5 cm wider than the size of the product to be produced;
  • the SMC/BMC paste is placed in the mold making sure no paste is protruding, the craft paper is properly placed onto the paste, and the decorative paper is properly placed on the top;
  • Mold temperatures are set to 120 to 160°C depending on the formulation of the SMC/BMC paste to be used;
  • the pressure of the press is set to 60 to 120 Kg/Cm 2 depending on the surface structure of the product to be manufactured and the formulation of the SMC/BMC paste to be used;
  • the molding time is calculated considering the thickest point of the product depending on the formulation of the SMC/BMC paste to be used, and said time is set to 10 to 40 sec. for every 1 mm of thickness;
  • the craft paper, decorative paper and digital offset paper are prepared by cutting them 3 to 5 cm wider than the size of the product to be produced;
  • the SMC/BMC paste is placed in the mold making sure no paste is protruding, the craft paper is properly placed onto the paste, and the decorative paper is properly placed on the craft paper, and the digital offset paper is properly placed on the top;
  • Mold temperatures are set to 120 to 160°C depending on the formulation of the SMC/BMC paste to be used;
  • the pressure of the press is set to 60 to 120 Kg/Cm 2 depending on the surface structure of the product to be manufactured and the formulation of the SMC/BMC paste to be used;
  • the molding time is calculated considering the thickest point of the product depending on the formulation of the SMC/BMC paste to be used, and said time is set to 10 to 40 sec. for every 1 mm of thickness;
  • the craft paper and/or decorative paper and/or digital offset paper and/or aluminum oxide overlay paper are prepared by cutting them 3 to 5 cm wider than the size of the product to be produced;
  • the SMC/BMC paste is placed in the mold making sure no paste is protruding and/or the craft paper is properly placed onto the paste and/or the decorative paper is properly placed on the craft paper and/or the digital offset paper is properly placed on the decorative paper and/or the aluminum oxide overlay paper is properly placed on the top;
  • a method of production has been developed for various products, such as decorative and customized tables, desks, chairs, coffee tables, covers, cupboards, boards and laminates, in which SMC and BMC composite pastes are molded, in a single step, together with decorative papers used in lamination industry.
  • Decorative or digital papers are impregnated with a special resin, after which they are molded together with composite materials to give them a surface coating. This way, not only the surface wear resistance of the material will increase but also a pleasant appearance will be provided. Products manufactured this way will not easily catch fire, be affected from water and sunlight, and will have a long economic life. Additionally, environment-friendly products will have been manufactured due to use of no trees.
  • Decorative and customized tables, chairs, coffee tables, desks, covers, cupboards and boards are manufactured by coating the composite materials in a single step with the decorative papers used in the lamination industry.
  • the present invention relates to a method of production of decorative and customized products made using composite materials, characterized in that SMC and BMC composite pastes are molded, in a single step, together with decorative papers used in lamination industry, decorative or digital papers are impregnated with a special resin, after which they are molded together with composite materials to give them a surface coating.
  • the products are manufactured in the following steps:

Abstract

The present invention relates to a method of production of decorative and customized products made using composite materials, characterized in that the SMC and BMC composite pastes are molded, in a single step, together with decorative papers used in lamination industry, decorative or digital papers are impregnated with a special resin, after which they are molded together with composite materials to give them a surface coating.

Description

PRODUCTION OF DECORATIVE AND CUSTOMIZED PRODUCTS USING
COMPOSITE MATERIALS Field of the Invention
The present invention relates to a method of production of decorative and customized products made using composite materials. In particular, it is related to the production method of various products, such as decorative and customized tables, desks, chairs, coffee tables, cupboards, boards and laminates, in which SMC and BMC composite pastes are molded, in a single step, together with decorative papers used in lamination industry. Decorative or digital papers are impregnated with a special resin, after which they are molded together with composite materials to give them a surface coating. This way, not only the surface wear resistance of the material will increase but also a pleasant appearance will be provided. Products manufactured this way will not easily catch fire, be affected from water and sunlight, and will have a long economic life. Additionally, environment-friendly products will have been manufactured due to use of no trees.
Description of the State of the Art
Currently available decorative and customized products are manufactured via various methods.
There are several products manufactured from wood shavings, such as tables, desks, chairs, coffee tables, cupboards, boards and laminates. The problems faced with the production from wood shavings include:
· The production consists of a two-phase operation. The wood shavings and the chemical mixture are first molded in the press, and then the decorative molding takes place.
• The product manufactured is weak, not resistant to water and chemicals. • Deformations such as bends and buckling may take place in time.
• The product is combustible.
• It has low mechanical resistance.
• It is not environment-friendly due to use of trees.
There are various products manufactured only using composite materials without a coating, such as tables, desks, chairs, coffee tables, cupboards, boards and laminates. The problems faced with the production from wood shavings include:
• Uncoated composite products have low resistance to surface wear.
• Uncoated composite products have rather limited options of decorative looks.
• Surface of uncoated composite products do not allow for effective advertising.
• Uncoated composite products easily allow for formation of stains, which are difficult to clean.
• Uncoated composite products have low UV resistance, resulting in discoloration.
• Composite products may be made to have a decorative look by applying coating later or painting; however, coating applied post-production raise or become deformed before long.
In the patent application no. TR 2016/01797, the invention relates to a fireproof composite board material and production thereof, which contains silica as raw material, waste natural wooden material, and derivatives of formaldehyde or granulated PVC and PP elements as binding agent, to be used as an alternative to wood in the furniture industry when manufacturing tables, chairs, armchairs, cupboards and window frames, and instead of plywood molds and industrial plates in the construction sector. However, it does not produce any solution for the aforementioned problems.
In the presence of the problems we tried to describe above and the applications, it has become a necessity to develop a new solution. Objects of the Invention
Based on the current state of the art, the object of the invention is to develop a production method for decorative and customized products by using composite materials, not only overcoming the problems in the available constructs but also providing lots of advantages.
Another object of the invention is to procure the product in a single press, and thus save from time and workmanship.
Another object of the invention is manufacturing products that have superior resistance to water, humidity, chemicals and atmospheric conditions.
Another object of the invention is manufacturing products that do not get bent or bucked or deformed otherwise.
Another object of the invention is to manufacture products that can easily be put out and do not spread the fire since it does not catch fire easily and melt, flow or drip, if on fire.
Another object of the invention is to produce products that have high resistance to wear and scratches.
Another object of the invention is to provide decorative products that have the desired looks, allowing for effective advertising.
Another object of the invention is to provide products that do not get stained easily and that can be cleaned quickly. Another object of the invention is to produce products that have high UV resistance, ensuring no formation of discoloration. Another object of the invention is to provide products that chemically binds to the composite structure and do not split up during use since the coats are molded and joined together with the composite during molding of the composite material. To bring about the objects of the invention, a production method has been developed for various decorative and customized products, such as tables, chairs, coffee tables, desks, covers, cupboards and boards, using composite materials.
Description of the drawings
Figure-1 ; Block diagram drawing of a preferred representative application of the invention.
Figure-2; Block diagram drawing of another preferred representative application of the invention.
Figure-3; Block diagram drawing of another preferred representative application of the invention.
Description of the Reference Numbers
Figure imgf000005_0001
Detailed Description of the Invention
The production method of the invention allows production of products that provide many advantages. As shown in the figures, the production method allows for production in a single step by molding (4) the main carrier composite material (1) together with at least one of the coating material craft paper (2), coating material decorative paper (3), coating material digital offset paper (5), and coating material aluminum oxide overlay paper (6).
Description of the production methods are as follows: > Mold temperatures are set to 120 to 160°C depending on the formulation of the SMC/BMC paste to be used;
> The pressure of the press is set to 60 to 120 Kg/Cm2 depending on the surface structure of the product to be manufactured and the formulation of the SMC/BMC paste to be used;
> The molding time is calculated considering the thickest point of the product depending on the formulation of the SMC/BMC paste to be used, and said time is set to 10 to 40 sec. for every 1 mm of thickness;
> Insertion parts, if any, are placed in the designated points inside the mold;
> Sufficient amount of SMC/BMC paste is weighed for the product to be manufactured, cut and prepared properly for the shape and dimensions of the product;
> The craft paper and decorative paper are prepared by cutting them 3 to 5 cm wider than the size of the product to be produced;
> The SMC/BMC paste is placed in the mold making sure no paste is protruding, the craft paper is properly placed onto the paste, and the decorative paper is properly placed on the top;
> The pressing is started, and the molding is performed at the temperature and pressure values specified above;
> After the curing period is completed, the press is opened and the product is taken out to cool; weight is applied on top of the product so as to prevent bending; and
> After the product is cooled, the burrs on the edges are removed carefully and the product is packaged.
Another production method is as follows:
> Mold temperatures are set to 120 to 160°C depending on the formulation of the SMC/BMC paste to be used;
> The pressure of the press is set to 60 to 120 Kg/Cm2 depending on the surface structure of the product to be manufactured and the formulation of the SMC/BMC paste to be used; > The molding time is calculated considering the thickest point of the product depending on the formulation of the SMC/BMC paste to be used, and said time is set to 10 to 40 sec. for every 1 mm of thickness;
> Insertion parts, if any, are placed in the designated points inside the mold;
> Sufficient amount of SMC/BMC paste is weighed for the product to be manufactured, cut and prepared properly for the shape and dimensions of the product,
> The craft paper, decorative paper and digital offset paper are prepared by cutting them 3 to 5 cm wider than the size of the product to be produced;
> The SMC/BMC paste is placed in the mold making sure no paste is protruding, the craft paper is properly placed onto the paste, and the decorative paper is properly placed on the craft paper, and the digital offset paper is properly placed on the top;
> The pressing is started, and the molding is performed at the temperature and pressure values determined;
> After the curing period is completed, the press is opened and the product is taken out to cool; weight is applied on top of the product so as to prevent bending; and
> After the product is cooled, the burrs on the edges are removed carefully and the product is packaged.
Another production method is as follows:
> Mold temperatures are set to 120 to 160°C depending on the formulation of the SMC/BMC paste to be used;
> The pressure of the press is set to 60 to 120 Kg/Cm2 depending on the surface structure of the product to be manufactured and the formulation of the SMC/BMC paste to be used;
> The molding time is calculated considering the thickest point of the product depending on the formulation of the SMC/BMC paste to be used, and said time is set to 10 to 40 sec. for every 1 mm of thickness;
> Insert parts, if any, are placed in the designated points inside the mold; > Sufficient amount of SMC/BMC paste is weighed for the product to be manufactured, cut and prepared properly for the shape and dimensions of the product;
> The craft paper and/or decorative paper and/or digital offset paper and/or aluminum oxide overlay paper are prepared by cutting them 3 to 5 cm wider than the size of the product to be produced;
> The SMC/BMC paste is placed in the mold making sure no paste is protruding and/or the craft paper is properly placed onto the paste and/or the decorative paper is properly placed on the craft paper and/or the digital offset paper is properly placed on the decorative paper and/or the aluminum oxide overlay paper is properly placed on the top;
> The pressing is started at the temperature and pressure values specified above;
> After the curing period is completed, the press is opened and the product is taken out to cool; weight is applied on top of the product so as to prevent bending; and
> After the product is cooled, the burrs on the edges are removed carefully and the product is packaged.
A method of production has been developed for various products, such as decorative and customized tables, desks, chairs, coffee tables, covers, cupboards, boards and laminates, in which SMC and BMC composite pastes are molded, in a single step, together with decorative papers used in lamination industry. Decorative or digital papers are impregnated with a special resin, after which they are molded together with composite materials to give them a surface coating. This way, not only the surface wear resistance of the material will increase but also a pleasant appearance will be provided. Products manufactured this way will not easily catch fire, be affected from water and sunlight, and will have a long economic life. Additionally, environment-friendly products will have been manufactured due to use of no trees. Decorative and customized tables, chairs, coffee tables, desks, covers, cupboards and boards are manufactured by coating the composite materials in a single step with the decorative papers used in the lamination industry. The present invention relates to a method of production of decorative and customized products made using composite materials, characterized in that SMC and BMC composite pastes are molded, in a single step, together with decorative papers used in lamination industry, decorative or digital papers are impregnated with a special resin, after which they are molded together with composite materials to give them a surface coating.
The products are manufactured in the following steps:
- placing the coating material craft paper (2) onto the main carrier composite material (1),
- placing the coating material decorative paper (3) onto the coating material craft paper (2),
- placing the coating material digital offset paper (5) onto the coating material decorative paper (3) and
- placing the coating material aluminum oxide overlay paper (6) on the top, onto the coating material digital offset paper (5), after which they are molded together in a single step, allowing for production in a single step by molding (4).

Claims

1. The present invention relates to a method of production of decorative and customized products made using composite materials; characterized in that
- SMC and BMC composite pastes are molded, in a single step, together with decorative papers used in lamination industry, and
- decorative or digital papers are impregnated with a special resin, after which they are molded together with composite materials to give them a surface coating.
2. Method of production according to Claim 1 , characterized in that
- mold temperatures are set to 120 to 160°C depending on the formulation of the SMC/BMC paste to be used;
- the pressure of the press is set to 60 to 120 Kg/Cm2 depending on the surface structure of the product to be manufactured and the formulation of the SMC/BMC paste to be used;
- the molding time is calculated considering the thickest point of the product depending on the formulation of the SMC/BMC paste to be used, and said time is set to 10 to 40 sec. for every 1 mm of thickness;
- insertion parts, if any, are placed in the designated points inside the mold;
- sufficient amount of SMC/BMC paste is weighed for the product to be manufactured, cut and prepared properly for the shape and dimensions of the product;
- the craft paper and/or decorative paper and/or digital offset paper and/or aluminum oxide overlay paper are prepared by cutting them 3 to 5 cm wider than the size of the product to be produced;
- the SMC/BMC paste is placed in the mold making sure no paste is protruding and/or the craft paper is properly placed onto the paste and/or the decorative paper is properly placed on the craft paper and/or the digital offset paper is properly placed on the decorative paper and/or the aluminum oxide overlay paper is properly placed on the top;
- the pressing is started at the temperature and pressure values specified above;
- after the curing period is completed, the press is opened and the product is taken out to cool; weight is applied on top of the product so as to prevent bending; and
- after the product is cooled, the burrs on the edges are removed carefully and the product is packaged.
3. Method of production according to Claim 1, characterized in that
- decorative and customized tables, chairs, coffee tables, desks, covers, cupboards and boards are manufactured by coating the composite materials in a single step with the decorative papers used in the lamination industry.
4. Method of production according to Claim 1 , characterized in that
- the production method comprises production in a single step by molding (4) the main carrier composite material (1) together with at least one of the coating material craft paper (2), coating material decorative paper (3), coating material digital offset paper (5), and coating material aluminum oxide overlay paper (6).
5. Method of production according to Claim 1 , characterized in that
- the production method includes placing the coating material craft paper (2) onto the main carrier composite material (1),
- placing the coating material decorative paper (3) onto the coating material craft paper (2),
- placing the coating material digital offset paper (5) onto the coating material decorative paper (3) and
- placing the coating material aluminum oxide overlay paper (6) on the top, onto the coating material digital offset paper (5), after which they are molded together in a single step, allowing for production in a single step by molding (4).
PCT/TR2017/000074 2017-06-29 2017-06-29 Production of decorative and customized products using composite materials WO2019004952A1 (en)

Priority Applications (1)

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Application Number Priority Date Filing Date Title
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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0760911A (en) * 1993-08-26 1995-03-07 Dainippon Printing Co Ltd Thermosetting resin decorative panel and production thereof
JPH08127036A (en) * 1994-10-31 1996-05-21 Sekisui Chem Co Ltd Manufacture of decorative molded product and sheet for decorative molded product
JPH10202680A (en) * 1997-01-20 1998-08-04 Sekisui Chem Co Ltd Decorative molding sheet and manufacture of decorative molded product
JPH11309731A (en) * 1998-04-28 1999-11-09 Sekisui Chem Co Ltd Production of decorative molded product
US20060141260A1 (en) * 2004-12-29 2006-06-29 Enamul Haque Sandwich composite material using an air-laid process and wet glass
DE102007062941A1 (en) * 2007-12-21 2009-06-25 Akzenta Paneele + Profile Gmbh Process for producing a laminate
GB2464541A (en) * 2008-10-20 2010-04-28 Acell Group Ltd Laminate of porous material, curable material and veneer
TR201601797A2 (en) 2016-02-11 2016-02-11 Can Ulusoy Deniz FIREPROOF COMPOSITE PANEL MATERIAL AND PRODUCTION METHOD

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0760911A (en) * 1993-08-26 1995-03-07 Dainippon Printing Co Ltd Thermosetting resin decorative panel and production thereof
JPH08127036A (en) * 1994-10-31 1996-05-21 Sekisui Chem Co Ltd Manufacture of decorative molded product and sheet for decorative molded product
JPH10202680A (en) * 1997-01-20 1998-08-04 Sekisui Chem Co Ltd Decorative molding sheet and manufacture of decorative molded product
JPH11309731A (en) * 1998-04-28 1999-11-09 Sekisui Chem Co Ltd Production of decorative molded product
US20060141260A1 (en) * 2004-12-29 2006-06-29 Enamul Haque Sandwich composite material using an air-laid process and wet glass
DE102007062941A1 (en) * 2007-12-21 2009-06-25 Akzenta Paneele + Profile Gmbh Process for producing a laminate
GB2464541A (en) * 2008-10-20 2010-04-28 Acell Group Ltd Laminate of porous material, curable material and veneer
TR201601797A2 (en) 2016-02-11 2016-02-11 Can Ulusoy Deniz FIREPROOF COMPOSITE PANEL MATERIAL AND PRODUCTION METHOD

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