WO2022258710A1

WO2022258710A1 - Method for thermoforming a laminated part

Info

Publication number: WO2022258710A1
Application number: PCT/EP2022/065595
Authority: WO
Inventors: Denis MENORET; Philippe REMENIERAS
Original assignee: Plastisoft
Priority date: 2021-06-10
Filing date: 2022-06-08
Publication date: 2022-12-15
Also published as: FR3123821B1; FR3123821A1

Abstract

The invention relates to a method for producing an article, characterised in that it comprises the following steps performed in this order: providing a laminated part including at least a thermoplastic polymer layer having a density ranging from 0.5 g/cm 3 to 1.5 g/cm 3, a layer of a hot-melt adhesive with a melting temperature ranging from 60°C to 170°C, preferably from 90°C to 130°C, and a textile layer having a grammage of between 30g/m 2 and 1500 g/m 2; and thermoforming the laminated part, the thermoforming comprising a step of heating the laminated part followed by a step of vacuum forming using at least one mould, characterised in that the textile layer is in contact with the mould in the moulding step.

Description

THERMOFORMING PROCESS OF A PIECE

LAMINATE

[0001] [The invention relates to the field of thermoforming in particular for obtaining covering articles in particular for vehicles for the transport market such as for example dashboards, interior trim elements; for the building market, in particular interior fittings, furnishings; for luggage, in particular the internal surfaces of items of luggage.

More particularly, the invention relates to the manufacture of relatively rigid articles and having a surface with a particular appearance such as a soft feel conferred by a fabric or any other covering such as a coated, waterproof, washable fabric or even any material compatible with said technology. The decorative surface may have a moderate compressive strength and resilience to give it a soft and comfortable "Soft touch" in English.

[0003] Typically, such covering articles are made by injection. Indeed, this technology has the advantage of allowing the manufacture of parts of complex shape at a rapid rate, however the costs linked to the implementation of the injection processes can be prohibitive, in particular when the objective is the manufacture of elements in small or medium series.

[0004] Thermoforming is a simpler and less expensive process than injection, however the constraints linked to the implementation of thermoforming processes mean that they did not seem appropriate for shaping multilayer parts. In addition, thermoforming does not always make it possible to produce parts that are both complex and of large dimensions.

[0005] Patent application FR 3079448 A1 already describes laminated parts, however these parts do not include the same layers as the laminated parts according to the present invention, furthermore the finished articles described in this prior art document are not manufactured by a method of thermoforming said laminated piece. The document US2006/0258244 A1 describes an article formed of two parts 2a, 2b forming a cavity 4. At least the first part 2a has a multilayer structure comprising a flat material 6a laminated on a support layer of foam 3a, the layer 3a being laminated on a thermoplastic support 7a. According to certain variants, the layer 6a is made of a textile material. The method of manufacturing this article does not implement layers of hot melt adhesives as used in the present invention.

[0006] Surprisingly and advantageously, the inventors have demonstrated that a particular laminated part could be shaped very satisfactorily by the manufacturing method of the present invention.

A first object of the invention relates to a method of manufacturing an article comprising the following steps, in this order: providing a laminated part comprising at least: a layer of thermoplastic polymer with a density ranging from 0.5 g/cm ³ to 1.5 g/cm ³ ; a layer of a hot-melt adhesive with a melting temperature ranging from 60° C. to 170° C., preferably from 90° C. to 130° C.; a layer of textile having a weight of between 30 g/m ² and 1500 g/m ² ; thermoforming said laminated part, the thermoforming comprising a step of heating the laminated part followed by a step of forming under vacuum by means of at least one mold characterized in that during the step of molding the layer of textile is in contact with the mould.

Preferably, the manufacturing process is such that the laminated part comprises at least the following layers of materials, stacked in this order:

a layer of thermoplastic polymer with a density ranging from 0.5 g/cm ³ to 1.5 g/cm ³ ;

a first layer of a first hot-melt adhesive with a melting temperature ranging from 60° C. to 170° C., preferably from 90° C. to 130° C.;

a packing layer with a density ranging from 11 kg/m ³ to 200 kg/m ³ , preferably from 30 kg/m ³ to 90 kg/m ³ in a material chosen from fibrous materials and cellular materials; - a second layer of a second hot-melt adhesive with a melting temperature ranging from 60° C. to 170° C., preferably from 90° C. to 130° C.;

a layer of textile with a weight of between 30 g/m ² and 1500 g/m ² .

In a particularly advantageous manner, the invention relates to a method for manufacturing an article comprising the following steps, in this order: having a laminated part comprising at least the following layers of materials, stacked in this order:

-a first layer of a first hot-melt adhesive with a melting temperature ranging from 60° C. to 170° C., preferably from 90° C. to 130° C., said first adhesive comprising two sub-layers, one applied to the layer of thermoplastic polymer and the other applied to the filling layer,

-a packing layer with a density ranging from 11 kg/m ³ to 200 kg/m ³ , preferably from 30 kg/m ³ to 90 kg/m ³ in a material chosen from fibrous materials and cellular materials,

- a second layer of a second hot-melt adhesive with a melting temperature ranging from 60°C to 170°C, preferably from 90°C to 130°C,

-a layer of textile with a weight of between 30 g/m ² and 1500 g/m ² proceed with the thermoforming of said laminated part, the thermoforming comprising a step of heating the laminated part followed by a step of forming under vacuum by means of at least one mold characterized in that during the molding step the textile layer is in contact with the mold.

A second object of the invention relates to an article capable of being obtained by the process according to the invention and comprising:

-a layer of a hot-melt adhesive with a melting temperature ranging from 60°C to 170°C, preferably from 90°C to 130°C,

- a layer of fabric.

[0011] Preferably, the article that can be obtained by the process according to the invention comprises:

-a layer of thermoplastic polymer with a density ranging from 0.5 g/cm ³ to 1.5 g/cm ³ ;

-a first layer of a first hot-melt adhesive with a melting temperature ranging from 60°C to 170°C, preferably from 90°C to 130°C, preferably said first adhesive comprising two sub-layers, one applied on the thermoplastic polymer layer and the other applied to the packing layer;

-a packing layer of a material chosen from fibrous materials and cellular materials,

- a layer of fabric.

[0012] Preferably, the article is an element of a vehicle interior, of an article of luggage, of a furnishing article, and of any other part whose function is linked to protection, aesthetics and interior comfort.

The present invention also relates to the use of the article according to the invention in vehicles for the transport market such as, for example, dashboards, interior trim elements, for the building market, in particular the interior fittings, furnishings, for luggage storage, in particular the internal surfaces of luggage storage items.

The method according to the invention is implemented in a single thermoforming step of the entire laminated part. The method according to the invention therefore makes it possible to avoid manufacturing in several stages, for example the prior manufacture of part of the stack of layers then the assembly of the entire laminated part, it is particularly simple to put implemented. In addition, it allows parts to be obtained at a rapid rate.

[0015] During the molding step, it is generally agreed not to place the textiles in contact with the mold in order to avoid the formation of folds. However, it has been demonstrated that the method according to the invention allows very good positioning of the textile layer of the laminated part against the mold, without noticeable formation of folds. The laminated part perfectly adopts the shape of the mold during the molding step, even when the latter presents deformations in hollows or significant bumps. The laminated part and the process according to the invention make it possible to limit the risks of defects in the appearance of the final article and in particular of the face of the textile layer of this article.

The method according to the present invention allows the manufacture of an article comprising hollows and bumps and having one side entirely coated with a polymer surface and the other side entirely coated with a textile. The stacking of the layers is cohesive, with good adhesion between the layers, including in the places which have been very deformed during the thermoforming, in addition the layers have thicknesses of satisfactory homogeneity.

[0017] In particular, it has been observed that the use of two sub-layers of first adhesive, one applied to the thermoplastic polymer layer and the other applied to the packing layer, makes it possible to obtain a laminated part. whose layers do not delaminate during the thermoforming step.

[0018] The article obtained has a stable shape under normal conditions of use, in particular temperature and pressure, in particular the article is stable even when used in a vehicle interior, behind glass (windshield type). Other features and advantages of the invention will emerge clearly from the description which is given below, by way of indication and in no way limiting.

[0020] Definitions

[0021] By “laminated part” is meant an object having several layers superimposed and assembled together.

[0022] In the present text, the intervals are defined in an abbreviated way in order to avoid describing each of the values and all the values of this interval, however any appropriate value in the interval can be chosen as the upper value, the value lower or the terminal values of the interval. An interval defined as "between value A and value B" includes values A and B and is therefore equivalent to an interval "from value A to value B”. Further, the term "at least" includes the value set forth after, for example, "at least 5%" should be understood to also include "5%". The expression "a maximum of" includes the value stated after, for example, "a maximum of 5%" should be understood to also include "5%".

[0023] In addition, in the present text, the measurable values, such as a quantity, must be understood as including the standard deviations which can be easily determined by the person skilled in the art in the technical field of reference.

[0024] In the present text, the singular form of a word includes the plural and vice versa, unless the context clearly indicates otherwise. Thus, the references "a", "une" and "le/la" generally include the plurals of the respective terms.

[0025] Laminated parts used

In general, the laminated parts used according to the present invention have a thickness ranging from 1 mm to 30 mm.

In general, the laminated parts according to the present invention have a surface having a first side ranging from 0.05 m to 3.5 m, preferably from 0.5 m to 3.5 m and a second side ranging from 0.05 m to 2.5 m, preferably from 0.5 to 2.5 m.

[0028] Detailed Description

Other characteristics and advantages of the invention will emerge clearly from the detailed description which is given below, by way of indication and in no way limiting.

[0030] Thermoplastic polymer

The laminated part used according to the present invention comprises a layer of thermoplastic polymer with a density ranging from 0.5 g/cm ³ to 1.5 g/cm ³ .

This layer, intended to constitute the internal surface of the finished article, that is to say the side not visible when the article is assembled for its final use, makes it possible to confer its rigidity and its behavior on the part. stratified. [0033] This layer has the advantage of being able to be softened during the manufacturing step of the laminated part and then during the heating step of the thermoforming and to regain its appearance and its properties in particular of rigidity after cooling. According to a particular embodiment, the layer of thermoplastic polymer is a layer of a material chosen from acrylonitrile butadiene styrene (ABS), polystyrene (PS), poly(methyl methacrylate) (PMMA), polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC). Preferably, the layer of thermoplastic polymer is a layer of a material chosen from acrylonitrile butadiene styrene, polystyrene, polyethylene and polypropylene.

Generally the layer of thermoplastic polymer has a thickness ranging from 1 mm to 10 mm, preferably from 3 to 8 mm. [0037] Packing layer

The laminated part used according to the present invention comprises a packing layer of a material with a density of between 11 kg/m ³ and 200 kg/m ³ , preferably between 30 kg/m ³ and 90 kg/m ³ and more preferably between 50 kg/m ³ and 90 kg/m ³ chosen from fibrous materials and cellular materials.

[0039] This padding layer, also called comfort layer, provides the user with cushioning on contact and a pleasant touch. In addition, some fillings, in particular polyolefin foams, have the property of being thermo-compressible and therefore of leading to thinner layers of filling in places, this making it possible to animate the surfaces.

The filling layer is preferably made of a material chosen from polyolefin foams, in particular polyethylene, polyester fibers, cotton felts, melamine foams, polyurethane foams. [0041] According to a preferred mode, the packing layer is made of a material chosen from cross-linked polyethylene or PER foams of density ranging from 30 kg/m ³ and 90 kg/m ³ . By way of example, mention may be made of the PER foam marketed under the reference NT 2003 by the company Alvéo.

[0042] PER has a structure in which the cells forming the foam are closed, which gives the packing layer thermal insulation and airtightness properties that are particularly advantageous for the final article.

Generally the packing layer has a thickness ranging from 1 to 20 mm, preferably from 1 to 5 mm.

[0044] Textile layer

The laminated part used according to the present invention advantageously comprises a textile layer having elongations along its two main directions of between 5 and 200% regardless of the standard applied.

[0046] According to a first embodiment, the textile is a mesh fabric made of natural or synthetic yarns having elongations at 35N in its two main directions of between 10 and 200% according to ISO 13934-1 of 2013 and a weight between 50 and 500 g/m ² . By way of example, mention may be made of the Moritz knit from the company Sofileta, which comprises 56% of PET; 36% PA; 8% EA for 170 g/m ² .

According to a second embodiment, the textile is a plastic coated fabric (TEP), with or without a coating base, having elongations at 35 N in its two main directions of between 5 and 50% according to the ISO standard. 13934-1 from 2013 and a weight between 250 and ^1500g /m2.

As an example, we can cite the Nappa fabric from the Continental company.

According to a third embodiment, the textile is a nonwoven having elongations in its two main directions of between 5 and 100% according to the ISO 9073-3 standard of December 1992 and a weight of between 30 and 500 g /m ² . By way of example, mention may be made of the product Aquadim BK40 from the company Fibertex. Generally the textile layer has a thickness ranging from 0.4 mm to 3 mm.

[0050] Hot melt adhesive

The laminated part used according to the present invention comprises at least two layers of hot-melt adhesive with a melting temperature ranging from 60° C. to 170° C., preferably ranging from 80° C. to 150° C., preferably from 90°C to 130°C.

The first layer of a first hot-melt adhesive, with a melting temperature ranging from 60° C. to 170° C., preferably ranging from 80° C. to 150° C., preferably from 90° C. to 130° C. , is located between the thermoplastic polymer layer and the packing layer.

The first hot-melt adhesive is advantageously non-crosslinkable. Non-curing hot melt adhesives are non-reactive.

[0054] Indeed, it has been observed that crosslinkable hot-melt adhesives do not allow good sliding of the layers, in particular of the thermoplastic polymer layer and the packing layer, relative to each other during the thermoforming step.

Preferably, the first hot-melt adhesive is chosen from (co)polyamides, (co)polyesters, polyurethanes (PU), polyethylenes, ethylene vinyl acetate (EVA) and mixtures thereof, preferably from (co)polyamides, polyethylenes, ethylene vinyl acetate (EVA) and mixtures thereof, and preferably from (co)polyamides.

The second layer of a second hot-melt adhesive, with a melting temperature ranging from 60° C. to 170° C., preferably ranging from 80° C. to 150° C., preferably from 90° C. to 130° C. , is located between the filling layer and the textile layer.

Preferably, the second hot-melt adhesive is chosen from (co)polyamides, (co)polyesters, polyurethanes (PU), polyethylenes, ethylene vinyl acetate (EVA) and mixtures thereof, preferably it is chosen among the (co)polyamides. Advantageously, the second hot-melt adhesive is non-crosslinkable.

The first and second adhesives can be identical or different.

As thermofusible (co)polyamides, mention may be made of the following commercial products: web COPA 178D20 from the company Protechnic and Film TC 204 from the company Prochimir.

As thermofusible polyurethanes, mention may be made of 6C8D30 from the company Protechnic.

According to a particular and preferred variant, the first adhesive comprises two sub-layers, identical or different, one applied to the thermoplastic polymer layer and the other applied to the packing layer. The nature of these underlayers depends in particular on the resistance required by the end use. In particular when the final article is intended for interior furnishings, the resistance requirements are lower than for an article intended for vehicles which is subjected to greater stresses such as temperature variations, exposure to UV rays.

By “identical sub-layers” is meant that the sub-layers consist of the same hot-melt adhesive, this adhesive possibly corresponding to a single product or a mixture; “different undercoats” means that the undercoats are made of different hot melt adhesives.

For a furnishing article, it is possible to use, as first adhesive, an adhesive comprising two sub-layers, a (co)polyamide sub-layer applied to the thermoplastic polymer layer and a polyurethane sub-layer applied to the filling layer.

For an article intended for vehicles, it is possible to use, as first adhesive, an adhesive comprising two sub-layers, one sub-layer of (co)polyamide applied to the layer of thermoplastic polymer and another sub-layer of (co)polyamide. )polyamide, identical or different, applied to the filling layer.

[0066] It has been observed that the use of two sub-layers of first hot-melt adhesive allows good holding of the laminated part during thermoforming and obtaining a stable article, without delamination or degradation of the layers over time, in particular without delamination between the thermoplastic polymer layer and the packing layer.

[0067] Hot-melt adhesives, when they are applied, can be in the form of veils or in the form of films.

[0068] Advantageously, hot-melt adhesives in the form of a veil or cobweb, also called Web in English, are preferred. By way of example, mention may be made of the CoPA 178D20 product from Protechnic.

As a hot-melt adhesive in the form of a film, mention may be made of the product Film TC 204 from the company Prochimir.

[0070] Process for preparing the laminated part used

The method for manufacturing the laminated part used according to the invention implements at least two bonding steps using at least one hot-melt adhesive with a melting temperature ranging from 60° C. to 170° C., preferably from 90°C to 130°C.

The steps for bonding the different layers are carried out by depositing/anchoring the hot-melt adhesive on one of the surfaces of a layer of a material then application of one of the surfaces of a layer of another material. According to one embodiment, the process for manufacturing the laminated part used comprises at least the following steps:

-a step of bonding, by means of the first hot-melt adhesive, of the first face of the layer of packing material on one face of the layer of thermoplastic polymer, -a step of bonding, by means of the second hot-melt adhesive, of a face of the textile layer on the second face of the layer of filling material.

Preferably, the step of bonding the layer of packing material to the layer of thermoplastic polymer is carried out according to the following steps:

-a step of depositing the first hot-melt adhesive on one face of the thermoplastic polymer layer,

a step of depositing a first hot-melt adhesive on the first face of the layer of packing material;

-these two steps being followed by a step of bringing the hot-melt adhesive deposited on the layer of thermoplastic polymer into contact with the hot-melt adhesive deposited on the layer of packing material.

The method of manufacturing the laminated part used is implemented by means of any suitable device for producing an assembly of the layers by pressing them together while heating simultaneously. [0076] The laminated piece is advantageously flat.

According to a particular method for manufacturing the laminated part, a continuous flatbed gluing press, of the MEYER type, can be used, in particular a roller press equipped with heating means, in particular equipped with high and low belts and several systems. of two parallel and counter-rotating rollers where two layers are superimposed, compressed and heated. This pressing is also called rolling, it is further done by applying a heating temperature higher than the melting temperature of the adhesive. The heating can be provided by a heating device placed close to the layer to be heated or it can be provided by heating rollers.

[0078] Process for thermoforming the laminated part

[0079] Steaming

According to a preferred embodiment, the thermoforming process according to the invention is preceded by a step of curing the laminated part at a temperature below the melting temperature of the hot-melt adhesive(s).

The steaming step can be carried out for 12 to 72 hours at a temperature ranging from 50 to 90°C.

[0082] Thermoforming

[0083] Heating [0084] Thermoforming conventionally comprises the steps of heating and molding, that is to say the deformation of the part to be treated to give it the desired 3D shape.

The method according to the present invention comprises a step of heating the laminated part followed by a step of forming said part under vacuum by means of at least one shaping mold in such a way that the textile layer either in contact with the mould.

[0086] The mold can be chosen from bump molds for obtaining articles with a hollow face covered with textile and hollow molds for obtaining bump articles with a face covered with textile.

The heating step makes it possible to soften the laminated part and to use its ductility to shape it in a mould. The part is heated at least to the higher temperature between the glass transition temperature of the thermoplastic polymer layer and the melting temperature of the adhesive.

[0088] The determination of this temperature falls within the competence of a person skilled in the art

The heating is carried out by means of at least one heating element allowing the temperature to be raised to make the laminated part malleable. Preferably said heating element is ceramic. The ceramic elements, due to their inertia properties, allow a rise in temperature / regular and gradual heating.

The heating time depends on the materials used and in particular on the nature of the textiles and the thickness of the thermoplastic layer. The determination of the heating time is within the competence of a person skilled in the art. Preferably, the duration of the heating step the heating step ranges from 200 seconds to 500 seconds.

Preferably, the heating step is carried out by means of two heating means, also called “heaters”, the first located in contact with the thermoplastic polymer layer and the second located in contact with the textile layer. [0092] Preferably, the heating temperature in contact with the textile layer is between 80 and 220°C.

[0093] Preferably, the heating temperature in contact with the layer of thermoplastic polymer is between 380 and 420°C.

Preferably, during the heating step, the part is heated to a temperature of between 100 and 250°C, preferably between 150 and 220°C and even more preferably between 170 and 200°C.

This temperature corresponds to the temperature at the heart of the laminated part recorded by thermolabel.

At the end of the heating step, the heating element(s) are removed.

[0097] Molding

The molding or forming corresponds to the shaping of the softened laminated part in the mold with a view to giving it its final three-dimensional shape.

According to the invention, the forming step is carried out under vacuum by means of at least one mold generally comprising suction holes allowing the evacuation of the air between the textile and the mold in order to give to the article its final three-dimensional shape.

[0100] The pressure forces are created by a source of depression and holes made in the mold. The vacuum can range from 15% to 100%. The molding step is very fast, its duration is generally a few seconds.

[0101] During vacuum molding, the laminated part matches the shape of the mould, in particular the layer of textile covered with a layer of hot-melt adhesive, matches the shape of the mold without noticeable formation of folds.

[0102] The layer(s) of hot-melt adhesives allow the layers to move between them without deformation of the overall geometry of the part, or significant crushing of the packing layer if present.

[0103] Furthermore, the process according to the invention does not lead to the impregnation of the textile layer by capillarity. [0104] According to a particular embodiment, a counter mold can be applied to the opposite face of the laminated part, that is to say in contact with the layer of thermoplastic polymer. The counter mold is generally applied with low pressure so as not to crush the part.

[0105] At the end of the molding, the article obtained is generally cooled by means of a forced air system applied to the mold in order to freeze the article in its final shape. The mold temperature control system by pyrometric analysis is 60°C.

[0106] At the end of the thermoforming process, the article, corresponding to the shape of the mould, is unmolded.

[0107] Machining

[0108] Preferably, the thermoforming is followed by a step of cutting and/or machining the thermoformed laminated part, preferably by means of a multi-axis numerical control machine, in particular 5 axes,

The following examples illustrate the invention without limiting its scope.

[0110] EXAMPLES

Examples 1 to 3 below were implemented using a roller press according to the following 3 steps named A, B and C.

[01121 Step A:

[0113] During this step, the layers of the following materials in rolls were used:

-on the one hand, at the top, the lining layer and a web of hot-melt adhesive corresponding to a sub-layer of first hot-melt adhesive according to the present invention, on the lining layer, at this stage, the first hot-melt adhesive is anchored on the packing layer, it is then used for bonding during step C;

-on the other hand, at the bottom, the textile layer and a veil of hot-melt adhesive corresponding to the second hot-melt adhesive according to the present invention, on the textile layer.

During this step A, the materials were unrolled and the following stack was formed: textile layer/second hot-melt adhesive/layer filling/a part (under layer a) of the layer of the first hot-melt adhesive.

[01151 Step B:

During this step, the layers of the following materials were used:

-on the one hand, at the top, a veil of hot-melt adhesive in roll form corresponding to the first hot-melt adhesive according to the present invention.

-on the other hand, at the bottom, the layer of thermoplastic polymer plate.

During this step B, the following stack was formed: layer of thermoplastic polymer/a part (sub-layer b) of the layer of the first hot-melt adhesive.

[01181 Step C:

During this step, the stack formed in step A was unrolled at the top on the stack formed in step B by bringing the two parts (sub-layers a and b) of the layer into contact. of the first hot melt adhesive.

During this step C, by heating, the following stack was formed: textile layer/second hot-melt adhesive/filling layer/(under layers a and b) of the layer of the first hot-melt adhesive/thermoplastic polymer layer .

In the following tables, the materials have been named "top material" and "bottom material", and the heating devices intended to heat the "top material" and "bottom material" respectively have been named "top heater" and “low heat”.

[0122] The laminated parts of Examples 1 to 3 were made with the materials presented respectively in Tables 1 to 3. In the laminated parts of Examples 1 to 3, the first hot-melt adhesive comprises two sub-layers

[01231 Example 1

[0124] Example 1 was produced with a layer of ABS as the thermoplastic polymer, a PER as the filling and a mesh fabric. [0125] [Table 1]

[01261 Example 2

Example 2 was produced with a layer of ABS as the thermoplastic polymer, a PER as the filling and a TEP fabric. [0128] [Table 2]

[01291 Example 3

[0130] Example 3 was produced with a layer of PS as the thermoplastic polymer, a PER as the filling and a mesh fabric.

[0131] [Table 3]

[01321 Example 4

Example 4 was produced with a layer of ABS as the thermoplastic polymer, a PER as the filling and a mesh fabric with a single pass. [0134] [Table 4]

For each of these examples, all of the layers of the laminated part obtained are cohesive, the surface condition of the textile layer shows no deformation: the elongation of the textile allows a conformal deformation of the laminated part. [01361 Thermoforming of laminated parts

The thermoforming of the laminated parts of Examples 1 to 4 was carried out in a Geiss-type device.

The heating steps were carried out according to the temperature and time operating conditions presented in Table 5 below. Then the moldings were made with a hollow mould, under vacuum (100%).

[0140] The thermoformed parts were then cooled by a forced air system and by bringing the mold to 60°C (thermal regulation circuit)

[0141] [Table 5]

0142] The results obtained with the parts of examples 1 to 3 are satisfactory: the articles obtained by thermoforming are cohesive, without delamination. The packing layer appears to be of homogeneous thickness without significant crushing. The textile surface appears unaltered, with no noticeable creases.

On the other hand, during thermoforming, the thermoplastic polymer and packing layers of Example 4 separate. [0144] Example 1 was also reproduced with vacuum molding at

15%, slower, and the result was unchanged j

Claims

[Claim 1] [Process for manufacturing an article characterized in that it comprises the following steps, in this order: providing a laminated part comprising at least the following layers of materials, stacked in this order:

- a layer of thermoplastic polymer with a density ranging from 0.5 g/cm ³ to 1.5 g/cm ³ ; a layer of a hot-melt adhesive with a melting temperature ranging from 60° C. to 170° C., preferably from 90° C. to 130° C., a layer of textile having a weight of between 30 g/m ² and 1500 g/m ² ; thermoforming said laminated part, the thermoforming comprising a step of heating the laminated part followed by a step of forming under vacuum by means of at least one mold characterized in that during the step of molding the layer of textile is in contact with the mould.

[Claim 2] A method of manufacturing an article according to claim 1 wherein the laminated part comprises at least the following layers of materials, stacked in this order:

-a first layer of a first hot-melt adhesive with a melting temperature ranging from 60°C to 170°C, preferably from 90°C to 130°C,

a layer of textile with a weight of between 30 g/m ² and 1500 g/m ² .

[Claim 3] A method of manufacturing an article according to claim 1 or 2 comprising the following steps, in this order: providing a laminated part comprising at least the following layers of materials, stacked in this order:

-a first layer of a first hot-melt adhesive with a melting temperature ranging from 60° C. to 170° C., preferably from 90° C. to 130° C., said first adhesive comprising two sub-layers, one applied to the layer of thermoplastic polymer and the other applied to the packing layer, -a packing layer with a density ranging from 11 kg/m ³ to 200 kg/m ³ , preferably from 30 kg/m ³ to 90 kg/m ³ in a material chosen from fibrous materials and cellular materials,

[Claim 4] A method according to claim 3 wherein said first adhesive comprises an underlayer of (co)polyamide applied to the layer of thermoplastic polymer and an undercoat of polyurethane applied to the filler layer.

[Claim 5] A method according to claim 3 wherein said first adhesive comprises an underlayer of (co)polyamide applied to the layer of thermoplastic polymer and another underlayer of (co)polyamide, identical or different, applied to the layer of filling.

[Claim 6] Process according to any one of the preceding claims, in which the step of heating the laminated part is carried out by means of two heating means, the first located in contact with the layer of thermoplastic polymer and the second located in contact of the textile layer.

[Claim 7] A method according to any preceding claim wherein the duration of the heating step is from 200 seconds to 500 seconds.

[Claim 8] Process according to any one of the preceding claims, in which the thermoforming is preceded by a steaming step of the laminated part at a temperature below the melting temperature of the hot melt adhesive(s).

[Claim 9] Process according to any one of the preceding claims, in which the thermoforming is followed by a step of cutting and/or machining the thermoformed laminated part, preferably by means of a multi-axis numerically controlled machine.

[Claim 10] Article obtainable by the process according to any one of claims 3 to 9 comprising:

-a first layer of a first hot-melt adhesive with a melting temperature ranging from 60°C to 170°C, preferably from 90°C to 130°C, preferably said first adhesive comprising two parts or sub-layers, one applied to the thermoplastic polymer layer and the other applied to the packing layer,

- a layer of fabric.

[Claim 11] Use of the article according to claim 10 in vehicles for the transport market such as, for example, dashboards, interior trim elements, for the building market, in particular interior fittings, furnishing, for luggage, in particular the internal surfaces of items of luggage.