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

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/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;

> 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/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;

> 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/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;

> 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).