COATING PRODUCTION METHOD

The invention relates to a digital printed and unlimited patterned composite product, part and coating production method with different production techniques such as hand lay-up, infusion or RTM (resin transfer molding) method so as to obtain predetermined visuality in the final product.

Composite means the materials obtained by mixing different materials with one another in macroscopic levels. An object for the composite materials is to develop a new material based on the best characteristics of the materials being injected therein. To obtain these characteristics such as lighter, stronger, more durable etc. these formations can be utilized. With the development of manufacturing technology, the composite materials and the fields of their usage become widespread.

The production methods of composite materials are diverse with the most commonly used ones can be listed as follows: hand lay-up method, spray method, infusion method, RTM (resin transfer molding) light method. These can differentiate with or without gelcoat.

The hand lay-up method is the process of manual mastery in a mold. The separation layer is formed for removing on the mold, wherein it is applied by soaking the resin with a roller on the reinforced material laid in accordance with material shape and allowing it to dry. The vacuum packing method in which drying is carried out under vacuum is an advanced version of this.

In the spray method, the resin and/or the filler material is sprayed onto the reinforced material placed after providing the separation surface on the mold.

By contrast with abovementioned methods, the infusion method is developed in order to provide a homogenous and zero-touch production. In this method, the separator is placed on the mold and the reinforced material(s) are placed thereon. The resin to be used as more matrix material is impregnated into the reinforced material under a vacuum environment. For this, the vacuum bag placed on the mold is connected to the vacuum tank fed by a vacuum pump at its appropriate points. This part is called the vacuum outlet and is designed such that it can absorb the resin through the vacuum inlet. In this way, the process is completed by spreading the resin in the reinforced material from the vacuum inlet to the vacuum outlet under the vacuum.

RTM Light method is similar to the infusion technique, but it is a technique in which the resin transfer printing is produced by using a male mold. Here, the resin is also impregnated into the reinforced material under the vacuum.

These methods are called as gelcoat or without gelcoat according to whether the gelcoat is used under the reinforced material or not.

Composite properties are adjusted in accordance with the variables such as the reinforced materials used in these methods, the usage structure thereof and the resin used as a matrix material etc. The material produced in accordance with the shape of the mold is in a color according to the materials used or in visuality suitable for the laying of the composites therein.

Composite products produced by these methods cannot be produced as patterned. It can be produced in different colors with just one color. As paint is used in the abovementioned productions, processes such as repainting and polishing are needed as a result of the paint deformation, c causing addition of chemicals again and the formation of a layer on the product , so that harmful chemicals are used. Therefore, the durability of the products is at low level.

Though the visuality expectation is high in these composites used for different purposes from car parts to kitchen furniture. For this purpose, a novelty is brought to the composite production method according to the invention. Thanks to the addition of digital printed material to the method according to the invention, it is aimed to present unlimited color and pattern alternatives. As paint is not used in this production method, the paint deformation does not occur and consequently the chemical addition such as repainting and re-polishing and the formation of a layer on the product are not in question. Thus, the harmful chemicals are not used and the UV resistance of the product increases significantly. Because of its light transmittance, unlike other applications, both the application area thereof is much wider and different application options come to light. Technically, the product has more durability by comparison to other applications because a printed layer is added into the product.

In the method according to the invention comprises all types of printing placed directly in the transparent gelcoat or directly on the mold in the application without gelcoat and all fabrics reinforced or not, with or without lycra having unlimited pattern visuality (lacy fabrics, calico fabric, saxony fabric, agauzelike muslin, fresca fabric, etamin fabric, voile fabric, shantung fabric, canvas fabric, cheesecloth fabric, printed fabric, paplin fabric, tarpaulin fabric, flannel fabric, broadcloth fabric, tergal fabric, organza fabric, watered fabric, taffeta fabric, chiffon fabric, yoryochiffon fabric, alpaca fabric, blue jean fabric, dirille fabric, sayak fabric, cachet fabric, blazer fabric, gabardine fabric, tartan fabric, rubberotin fabric, cashmere fabric, velvet fabric, satin (silk) fabric, atlas fabric, chamois fabric, cassandra fabric, jessey fabric, two yarn fabric, three yarn fabric, interlock fabric, steel interlock fabric, ribana fabric, camisole fabric, pique fabric, Thessaloniki fabric, jacquard fabric, jacquard single jersey fabric, jacquard ribana fabric, ottoman fabric, quilting fabric, double face fabric, crepe mesh fabric, rayan crepe fabric, towel fabric, mesh fabric, polar fleece fabric, ringel fabric, vanize mesh fabric, nonwoven fabric, paper fabric, sequin sequin fabric), interlinings, felts, curtains, rugs / carpets and so on, wallpapers, cardboard, dekota, tarpaulins (cast tarpaulin, laminated tarpaulin, fine tarpaulin, mesk tarpaulin), foils (adhesive foils, cast foils, semi-cast foils, flat surface foils, wanweysm, bluebeck foil, canvas foil, satin foil), nylon, linoleum, natural or artificial wood coverings and sheets, metal sheets etc. are included in the product application system. Thanks to the usage of said products with or without gelcoat, light and high performance composite product, part and coat which can be produced as moisture-, chemical- and heat- resistant, high UV resistant and preferably nonflammable (flame retardant) and/or bullet-proof are obtained. After the abovementioned materials have been inserted on the mold directly after the drying of the gelcoat on the mold or without gelcoat production, fiber reinforcements are applied and the mold is finalized according to the production application.

In order to obtain the aim of novelty in the composite production method according to the invention, the system is explained below with reference to the attached figures. The figures are as follows:

Figure 1 - The view of the digital printed and unlimited patterned composite product, part that are obtained by means of infusion method with gelcoat and coating production method.

Figure 2 - The view of the digital printed and unlimited patterned composite product, part that are obtained by means of infusion method without gelcoat and coating production method.

Figure 3 - The view of the digital printed and unlimited patterned composite product, part that are obtained by means of rtm light method with gelcoat and coating production method.

Figure 4 - The view of the digital printed and unlimited patterned composite product, part that are obtained by means of rtm light method without gelcoat and coating production method.

Figure 5 - The view of the digital printed and unlimited patterned composite product, part that are obtained by means of hand lay -up method with gelcoat and coating production method.

Figure 6 - The view of the digital printed and unlimited patterned composite product, part that are obtained by means of hand lay -up method without gelcoat and coating production method.

The parts in the figures are numbered individually and the corresponding parts of these numbers are described below:

1- Composite product, part and coating production method 1.1- Mold

1.2- Double-sided tape

1.3- Gelcoat

1.4- Visual surface

1.5- Reinforced material

1.6- Resin

1.7- Vacuum inlet (resin inlet)

1.8- Vacuum outlet

1.9- Vacuum tank

1.10- Vacuum pump

1.11- Spiral pipes

1.12- Male mold

The invention relates to composite product, part and coating production method (1), wherein it comprises at least one of mold (1.1), double-sided tape (1.2), gelcoat (1.3), visual surface (1.4), reinforced material (1.5), resin (1.6), vacuum inlet (1.7), vacuum outlet (1.8), vacuum tank (1.9), vacuum pump (1.10), spiral pipes (1.11) and male mold (1.12) in accordance with the production technique.

Composite product, part and coating production method (1) includes mold (1.1) designed in accordance with the shape of the material to be produced as the main element. It is the basis of the composite material production to spread the reinforced material (1.5) and to soak the resin (1.6) over this mold. This production technique maybe in different forms as it is pointed out in the figures.

Figure 1 shows the application details on composite product, part and coating production method (1) in case the infusion technique is used. Here, the mold (1.1) and, if any, the separable surface, gelcoat (1.3), visual surface (1.4) and reinforced materials (1.5) are laid thereon. The double-sided tape (1.2) is then used to fix the vacuum bag to work under vacuum. The vacuum formed in the vacuum pump (1.10) and vacuum tank (1.9) is connected to the vacuum outlet (1.8) by means of a connection. Besides, the vacuum inlet (1.7) is connected to the resin (1.6). Thus, the process is completed by passing the resin (1.6) into the vacuum inlet (1.7) through the reinforced material (1.5) laid onto the mold towards the vacuum outlet (1.8), providing a homogenous distribution. In this infusion technique, in the case of gelcoat (1.3) usage under the visual surface (1.4), infusion production technique without gelcoat arises as seen in Figure 2.

The RTM Light production technique is used for the composite product, part and coating production method (1) according to the invention as seen in Figure 3 with gelcoat or in Figure 4 without gelcoat. This method includes the mold (1.1), if used separator surface, gelcoat (1.3), visual surface (1.4) and reinforced material (1.5). The male mold (1.12) which provides the material to be produced to take shape by fitting mold (1.1) is located on them. As in the infusion method, the vacuum effect formed by the vacuum pump (1.10) and the vacuum tank (1.9) reaches between the two molds and the vacuum outlet (1.8) and the resin (1.6) is absorbed through the vacuum inlet (1.7).

Figure 5 illustrates the hand lay-up method with gelcoat while Figure 6 illustrates the hand lay-up method without gelcoat. Here, the gelcoat (1.3), the visual surface (1.4) and the reinforced material (1.5) are laid on the mold (1.1). The resin (1.6) is rubbed into the reinforced material by spreading it by means of a roller manually. This process is repeated in layers.

Thanks to the composite product, part and coating production method (1) according to the invention, it is supplied that the material produced has a predetermined visuality by using a visual surface (1.5) between the mold (1.1) and the reinforced material (1.5) in the abovementioned composite production methods or other methods.

Thermoplastics, thermosets, elastomers are used as resins (1.6).

The mold (1.1) and the male mold (1.12) are made of glass, composite, wood, silicon, iron, steel and similar materials. The visual surface (1.4) used for the composite product, part and coating production method (1) according to the invention may be materials for different visual and aesthetic purposes such as digital print patterned lycra fabric, patterned plastic material, printed fabric or papers and thin wood surfaces. It is obvious that elements such as gelcoat (1.3), separating surface, double-sided tape (1.2) can be used in different order with the fixed idea of using the visual surface (1.4) between the mold (1.1) and the reinforced material (1.5). These are also within the scope of the invention. It is obvious that modification to the figures can be made, the parts used can be replaced and the number of the parts used can be changed in the invention independently from the material and size. These are all within the scope of the invention.

It is evident that those skilled in the art can put into practice the novelty disclosed in the invention using similar embodiments and/or can also apply this embodiment to other fields with similar purpose used in the related art. It is therefore evident that such embodiments would lack the criterion of novelty and in particular inventive step.