WO2013061254A1 - Rotational moulding method and product obtained thereby - Google Patents

Rotational moulding method and product obtained thereby Download PDF

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Publication number
WO2013061254A1
WO2013061254A1 PCT/IB2012/055839 IB2012055839W WO2013061254A1 WO 2013061254 A1 WO2013061254 A1 WO 2013061254A1 IB 2012055839 W IB2012055839 W IB 2012055839W WO 2013061254 A1 WO2013061254 A1 WO 2013061254A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
woven fabric
bag
resin
shape
Prior art date
Application number
PCT/IB2012/055839
Other languages
French (fr)
Inventor
Malte Licht
Gunnar Soren PETERSEN
Original Assignee
Alcantara S.P.A.
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 Alcantara S.P.A. filed Critical Alcantara S.P.A.
Priority to DE112012004467.3T priority Critical patent/DE112012004467B4/en
Publication of WO2013061254A1 publication Critical patent/WO2013061254A1/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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/04—Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould
    • B29C41/06—Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould about two or more axes
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/003—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor characterised by the choice of material
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/20—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. moulding inserts or for coating 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
    • B32B1/00—Layered products having a general shape other than plane
    • 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
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • 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
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/045—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyolefin or polystyrene (co-)polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/121—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds
    • D06N3/123—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds with polyesters
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/125—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyamides
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • 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
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • 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
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • 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
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • 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
    • B29K2105/0002—Condition, form or state of moulded material or of the material to be shaped monomers or prepolymers
    • 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
    • B29K2105/20—Inserts
    • 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
    • B29L2022/00—Hollow articles
    • 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
    • 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
    • B32B2260/021—Fibrous or filamentary 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • 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
    • B32B2439/00—Containers; Receptacles
    • 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 manufacture obtained using the rotational moulding technique, starting from a combination of a cross-linkable resin with a composite textile material based on polyester or polyamide microfibres immersed in a polyurethane matrix.
  • Non-woven fabrics of composite material which have the appearance of natural leather but exhibit characteristics in terms of feel, lightness, velvetiness, and resistance to light that are superior to those of natural leather are well known in the art.
  • Such non-woven fabrics include polymer microfibres, preferably polyester or polyamide microfibres immersed in a polyurethane matrix.
  • the non- woven fabric can be coated with a waterproof polymer film in order to protect the non-woven fabric during the process of covering articles obtained with the cold- injection technique.
  • the Applicant of the present patent application has surprisingly found that the above-described non-woven fabrics of composite microfibrous material, if combined with a cross-linkable resin using the rotational moulding technigue, give rise to manufactures that are rigid to the touch but visually exhibit the impression of a soft appearance.
  • said manufactures exhibit a creased (or undulated) appearance typical of a "crinkled" fabric, which in appearance gives an idea of softness associable with a fabric, but to the touch they are surprisingly rigid.
  • Manufactures thus obtained can have different shapes and sizes, for example they can have a vase shape, or else the shape of a concave container or other shapes that can be obtained with the rotational moulding technique.
  • the manufactures are mainly used for decorative purposes, for example as interior furnishings, but they can also be used as containers for objects, furnishing accessories or structural elements.
  • the non-woven fabrics of composite material used to obtain the manufactures of the invention comprise a microfibrous felt impregnated with a polyurethane or polyurea matrix.
  • the microfibrous felt is prepared starting from polyester or polyamide microfibres.
  • Polyester microfibres are, for example, microfibres of polyethylene terephthalate .
  • Polyamide microfibres are, for example, microfibres of polyamide 6, polyamide 6, 6 and polyamide 12.
  • non-woven fabric is coupled/coated with a polymer film (as described in Italian patent IT1277094), which imparts characteristics of waterproofness to the non-woven fabric and, therefore, of resistance to the penetration and consequent surface migration of the cross-linkable resin applied during preparation of the product with the rotational moulding technique .
  • a polymer film as described in Italian patent IT1277094
  • the coupling with a waterproof polymer film is achieved using techniques known in the art, such as: gluing by means of a thermo-adhesive film, applied between the first and second layers, or with a "flame" lamination technique, where the adhesive element is a thin layer of expanded material made to melt with a direct flame, or "hot melt” lamination, where the adhesive element consists of thermoplastic resins with a low melting point brought into a molten state by extrusion, or thermosetting resins subsequently distributed by means of engraved cylinders on the back of one of the two layers, preferably the microfibrous layer.
  • the coupling between the two layers is achieved by applying the above-described cohesive material (thermo- adhesive film, foam in a molten state, thermoplastic or thermosetting resins) between the two layers and subsequently calendering the two layers.
  • the waterproof polymer film of the invention is selected from among: polyurethane, polyester, co-polyesters, polyolefins, e.g. polyethylene or polypropylene, polyamides and co-polyamides .
  • the polymer film is protected by a layer of polymeric material, e.g. polyethylene, polypropylene or polyvinyl chloride, which is removed prior to production of the product.
  • a layer of polymeric material e.g. polyethylene, polypropylene or polyvinyl chloride, which is removed prior to production of the product.
  • the cross-linkable resin used in preparing the manufactures of the invention is a urethane, epoxy, epoxy-polyester or epoxy-vinyl ester resin, and is preferably a two-component urethane resin, such as, for example, Smooth-Cast® Semi-Rigid resin produced by the company Smooth-On.
  • the manufacture of the invention is obtained by means of the following process, which is based on the rotational moulding technique.
  • the process comprises the following steps:
  • step (v) it is possible to interrupt the process during step (v) , before solidification and complete crosslinking of the resin, so as to modify the shape of the product by repositioning the microfibrous non-woven fabric in the mould or modifying the shape of the bag or sack.
  • the process envisages repeating steps (iv)-(vii), wherein in the iterations of step (iv) following the first, the shape is modified.
  • the above-described process may optionally comprise a step (viii) of heating the manufacture in a kiln so as to optimise the degree of crosslinking of the resin and remove any residues of volatile compounds present in the formulation of the resin.
  • cross-linkable resin used is the one described above, which is inserted in a quantity that will depend on the size of the item, for example comprised between 50 and 1000 g for each litre of volume of . the finished manufacture, preferably between 80 and 500 g.
  • the manufacture thus obtained exhibits a soft appearance resembling that of a fabric, but to the touch it surprisingly demonstrates to have a rigid structure.
  • the manufactures of the invention can have any shape obtainable with the rotational moulding technique; for example it can have the shape of a vase, tray, concave container, etc.
  • manufactures according to the invention can be prepared for aesthetic purposes, for example as an interior furnishing, or a container for objects, but it can also be a furnishing accessory or a structural element .

Abstract

The present invention relates to a manufacture obtained by coupling a cross-linkable resin with a non-woven fabric comprising a microfibrous felt, prepared starting from polyester or polyamide microfibres and impregnated with a polyurethane or polyurea matrix. The product exhibits a soft, undulated appearance, but has a surprisingly rigid consistency to the touch. The manufacture is obtained by means of the rotational moulding technique, using a mould of the desired shape, or else without the use of a mould, by imparting a bag shape to the non-woven fabric.

Description

ROTATIONAL MOULDING METHOD AND PRODUCT OBTAINED THEREBY
DESCRIPTION
The present invention relates to a manufacture obtained using the rotational moulding technique, starting from a combination of a cross-linkable resin with a composite textile material based on polyester or polyamide microfibres immersed in a polyurethane matrix.
Non-woven fabrics of composite material which have the appearance of natural leather but exhibit characteristics in terms of feel, lightness, velvetiness, and resistance to light that are superior to those of natural leather are well known in the art. Such non-woven fabrics include polymer microfibres, preferably polyester or polyamide microfibres immersed in a polyurethane matrix.
Because of their characteristics, these non-woven fabrics are particularly valuable and have broad application in the clothing industry, in furnishings and in upholstery for the interior of automobiles, boats and other means of transport.
In the application for interior upholstery, the non- woven fabric can be coated with a waterproof polymer film in order to protect the non-woven fabric during the process of covering articles obtained with the cold- injection technique.
There remains a need in the art to use the above- described non-woven fabrics for purposes other than those known up to now, for example to make manufactures of aesthetic value or which can be used in the furniture industry or as structural elements.
The Applicant of the present patent application has surprisingly found that the above-described non-woven fabrics of composite microfibrous material, if combined with a cross-linkable resin using the rotational moulding technigue, give rise to manufactures that are rigid to the touch but visually exhibit the impression of a soft appearance. In particular, said manufactures exhibit a creased (or undulated) appearance typical of a "crinkled" fabric, which in appearance gives an idea of softness associable with a fabric, but to the touch they are surprisingly rigid.
Manufactures thus obtained can have different shapes and sizes, for example they can have a vase shape, or else the shape of a concave container or other shapes that can be obtained with the rotational moulding technique. The manufactures are mainly used for decorative purposes, for example as interior furnishings, but they can also be used as containers for objects, furnishing accessories or structural elements.
The non-woven fabrics of composite material used to obtain the manufactures of the invention comprise a microfibrous felt impregnated with a polyurethane or polyurea matrix. The microfibrous felt is prepared starting from polyester or polyamide microfibres.
Polyester microfibres are, for example, microfibres of polyethylene terephthalate . Polyamide microfibres are, for example, microfibres of polyamide 6, polyamide 6, 6 and polyamide 12.
Further details regarding the characteristics of the polyurethane or polyurea matrix and the method for obtaining the microfibrous non-woven fabric used in the invention are contained in Italian patent IT 1327162. Other microfibrous non-woven fabrics are described in Italian patents 823.055, 921.871, 839.921, 858.337, 905.222 and 873.699. Other methods of preparing the microfibrous non-woven fabric are described in Italian patent applications M192A002309, M192A001945,
M192A002944, 192A002942 and M192A001952.
The above-described non-woven fabric is coupled/coated with a polymer film (as described in Italian patent IT1277094), which imparts characteristics of waterproofness to the non-woven fabric and, therefore, of resistance to the penetration and consequent surface migration of the cross-linkable resin applied during preparation of the product with the rotational moulding technique .
The coupling with a waterproof polymer film is achieved using techniques known in the art, such as: gluing by means of a thermo-adhesive film, applied between the first and second layers, or with a "flame" lamination technique, where the adhesive element is a thin layer of expanded material made to melt with a direct flame, or "hot melt" lamination, where the adhesive element consists of thermoplastic resins with a low melting point brought into a molten state by extrusion, or thermosetting resins subsequently distributed by means of engraved cylinders on the back of one of the two layers, preferably the microfibrous layer.
The coupling between the two layers is achieved by applying the above-described cohesive material (thermo- adhesive film, foam in a molten state, thermoplastic or thermosetting resins) between the two layers and subsequently calendering the two layers. The waterproof polymer film of the invention is selected from among: polyurethane, polyester, co-polyesters, polyolefins, e.g. polyethylene or polypropylene, polyamides and co-polyamides .
According to a preferred embodiment, the polymer film is protected by a layer of polymeric material, e.g. polyethylene, polypropylene or polyvinyl chloride, which is removed prior to production of the product.
The cross-linkable resin used in preparing the manufactures of the invention is a urethane, epoxy, epoxy-polyester or epoxy-vinyl ester resin, and is preferably a two-component urethane resin, such as, for example, Smooth-Cast® Semi-Rigid resin produced by the company Smooth-On.
The manufacture of the invention is obtained by means of the following process, which is based on the rotational moulding technique.
The process comprises the following steps:
(i) inserting the coupled/coated microfibrous non-woven fabric in a mould having a desired shape, causing the non-woven fabric to adhere to the walls of the mould by means of a removable adhesive or by means of mechanical blocking devices, or shaping the microfibrous non-woven fabric into the form of a bag or sack;
(ii) inserting a cross-linkable resin in the mould or the bag or sack of microfibrous non-woven fabric;
(iii) closing the mould, or closing the open end of the bag or sack by gluing or heat-welding;
(iv) inserting the mould or the bag or sack in the machine for rotational moulding;
(v) rotating along two axes for a time comprised between 3 minutes and 2 hours, preferably between 5 minutes and 1 hour, at a temperature comprised between 30 °C and 100 °C, preferably between 40 °C and 70 °C;
(vi) cooling the mould or the bag or sack;
(vii) opening the mould and removing the product, or cutting the glued end of the bag or sack to obtain a manufacture, preferably concave in shape.
In one embodiment of the process it is possible to interrupt the process during step (v) , before solidification and complete crosslinking of the resin, so as to modify the shape of the product by repositioning the microfibrous non-woven fabric in the mould or modifying the shape of the bag or sack.
In such a case, the process envisages repeating steps (iv)-(vii), wherein in the iterations of step (iv) following the first, the shape is modified.
The above-described process may optionally comprise a step (viii) of heating the manufacture in a kiln so as to optimise the degree of crosslinking of the resin and remove any residues of volatile compounds present in the formulation of the resin.
The cross-linkable resin used is the one described above, which is inserted in a quantity that will depend on the size of the item, for example comprised between 50 and 1000 g for each litre of volume of . the finished manufacture, preferably between 80 and 500 g.
The manufacture thus obtained exhibits a soft appearance resembling that of a fabric, but to the touch it surprisingly demonstrates to have a rigid structure. By positioning the non-woven fabric in the mould and rotating along the two axes of the machine it is possible to obtain a manufacture of undoubted aesthetic value, in which the creases typical of a fabric are "immortalised" in a rigid form through the application and crosslinking of the resin.
The manufactures of the invention can have any shape obtainable with the rotational moulding technique; for example it can have the shape of a vase, tray, concave container, etc.
The manufactures according to the invention can be prepared for aesthetic purposes, for example as an interior furnishing, or a container for objects, but it can also be a furnishing accessory or a structural element .

Claims

1. A process for preparing a product, characterised by a soft appearance and a rigid structure, comprising the steps of:
(i) inserting a non-woven fabric comprising a microfibrous felt, prepared starting from polyester or polyamide microfibres, impregnated with a polyurethane or polyurea matrix, said non-woven fabric being coupled/coated with a polymer film, in a mould having a desired shape, causing the non-woven fabric to adhere to the walls of the mould by means of a removable adhesive or by means of mechanical blocking devices, or shaping the microfibrous non-woven fabric in a form of a bag or sack;
(ii) inserting a cross-linkable resin in the mould or the bag or sack of microfibrous non-woven fabric;
(iii) closing the mould, or closing the open end of the bag or sack by gluing or heat-welding;
(iv) inserting the mould or the bag or sack in the machine for rotational moulding;
(v) rotating along two axes for a time comprised between 3 minutes and 2 hours, preferably between 5 minutes and 1 hour, at a temperature comprised between 30°C and 100°C, preferably between 40°C and 70°C;
(vi) cooling the mould or the bag or sack;
(vii) opening the mould and removing the product, or cutting the glued end of the bag.
2. The process of claim 1, wherein said polyester microfibres are fibres of polyethylene terephthalate.
3. The process of claim 1, wherein said polyamide microfibres are selected from polyamide 6, polyamide 6, 6 and polyamide 12.
4. The process of any one of claims 1 to 3, wherein said polymer film is a waterproof polymer film selected from polyurethane, polyester, co-polyesters, polyolefins, polyamides and co-polyamides .
5. The process of any one of claims 1 to 4, wherein said cross-linkable resin is selected from a urethane, epoxy, epoxy-polyester and epoxy-vinyl ester resin, and is preferably a two-component urethane resin.
6. The process of any one of claims 1 to 5, wherein said cross-linkable resin is used in a quantity comprised between 50 and 1000 g for each litre volume of the finished product, preferably between 80 and 500 g.
7. The process of any one of claims 1 to 6, wherein said process is interrupted during step (v) , before solidification and complete crosslinking of the resin, such as to modify the shape of the product by repositioning the microfibrous non-woven fabric in the mould or modifying the shape of the bag or sack.
8. The process of claim 7, wherein the steps (iv)-(vii) are repeated and wherein in the iterations of step (iv) following the first, said shape of the product is modified.
9. The process of any one of claims 1 to 8, further comprising a step (viii) of heating the manufacture in a oven to optimise the crosslinking degree of the resin and to remove any residues of volatile compounds present in the resin formulation.
10. A manufacture obtainable by the process of any one of claims 1 to 9, characterised in that it exhibits a soft/undulated/crinkled appearance and a rigid structure .
11. The manufacture of claim 10, having a vase-shape, a tray-shape or a concave container shape.
12. Use of the manufacture of claim 10 or 11, as an internal furnishing or as a container for objects, or as a finishing for furnishing, or as a structural element.
PCT/IB2012/055839 2011-10-26 2012-10-24 Rotational moulding method and product obtained thereby WO2013061254A1 (en)

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Citations (4)

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DE1246225B (en) * 1962-11-06 1967-08-03 Ernst Wehncke Fa Method for producing an inflatable play ball
US4104357A (en) * 1973-01-10 1978-08-01 Monster Molding, Inc. Method of rotational molding about plural axes at low rotational speeds
EP0786333A1 (en) * 1995-12-18 1997-07-30 ALCANTARA S.p.A. Composite product consisting of a leather-like microfibrous material and polymer film, useful for coating cold injection molding manufactured articles
WO2005007452A2 (en) * 2003-07-11 2005-01-27 Collins & Aikman Products Co. Cloth texture cover material

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Publication number Priority date Publication date Assignee Title
US4258917A (en) 1979-12-03 1981-03-31 The B. F. Goodrich Company Rotocasting process for producing rubbery reinforced articles
DE202010002032U1 (en) 2010-02-08 2010-08-19 Iris Sitta und Thorsten Helwig this-design GbR (vertretungsberechtigte Gesellschafter: Herr Thorsten Helwig Textile vase

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1246225B (en) * 1962-11-06 1967-08-03 Ernst Wehncke Fa Method for producing an inflatable play ball
US4104357A (en) * 1973-01-10 1978-08-01 Monster Molding, Inc. Method of rotational molding about plural axes at low rotational speeds
EP0786333A1 (en) * 1995-12-18 1997-07-30 ALCANTARA S.p.A. Composite product consisting of a leather-like microfibrous material and polymer film, useful for coating cold injection molding manufactured articles
IT1277094B1 (en) 1995-12-18 1997-11-04 Alcantara Spa COMPOSITE MATERIAL INCLUDING A MICROFIBROSE PRODUCT ITS PREPARATION METHOD AND ITS USE FOR THE COATING OF PRODUCTS OBTAINED
WO2005007452A2 (en) * 2003-07-11 2005-01-27 Collins & Aikman Products Co. Cloth texture cover material

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