We Claim:
1. A method for producing a decorative (textured) plastic product comprising the
steps of:
a) selecting a pre-treated or non- treated thermoformable sheets having a single
5 layer or multiple layer;
b) printing a realistic graphic structure (RGS) on the thermoformable sheets by a
digital printing, a screen printing, or a combination thereof to obtain a printed
sheet;
c) coating the printed sheets obtained from step (b) with a heat resistance material
10 and then applying a bond coating on the printed sheet;
d) optionally applying a scratch-resistant, a hardness-enhancing, and an antireflective coating on the top side of the printed sheet obtained from the step (c);
e) positioning the printed sheets accurately on a tool placed in a thermoforming
or a vacuum forming machine;
15 f) simultaneously heating the printed sheets by the thermoforming or vacuum
forming under high pressure and vacuum to form a three-dimensional shape;
g) trimming an excess material from the formed sheets using a press tool or laser
cutting or while forming tool itself;
h) placing the trimmed thermoformed sheet into a pre-textured injection molding
20 cavity;
i) injecting a plastic resin into an injection molding machine to obtain the
decorative (textured) plastic product.
2. The method as claimed in claim 1, wherein the thermoformable grade sheets are
selected from Polycarbonate (PC), Polyethylene terephthalate (PET), Polyvinyl
25 chloride (PVC), Polypropylene (PP), Poly methyl methacrylate (PMMA), Acrylonitrile
butadiene styrene (ABS), or combinations thereof.
3. The method as claimed in claim 1, wherein the thermoformable grade sheets are
pre-treated by surface preparation treatment; wherein the surface preparation
treatment is selected from a corona treatment or a plasma treatment.
4. The method as claimed in claim 1, wherein the bond coating is a binder.
5. The method as claimed in claim 4, wherein the binder is selected from acrylics,
polyurethanes, polyamides, modified resins, hydrocarbon resins, or modified
cellulosic.
6. The method as claimed in claim 1, wherein the heat resistance material is selected
from acrylics, polyurethanes, polyamides, modified resins, hydrocarbon resins, and
modified cellulosic, or a combination of 1053 organic silicon resin , 9801 organic silicon
resin, 804 organic silicon resin, thermoplastic acrylic resin, alcohol-dissolving
polyurethane solution, ternary hydroxyl-modified vinyl resin copolymer, acetic acid,
ethanol, acrylonitrile butadiene rubber, and acetone.
7. The method as claimed in claim 1, wherein the plastic resin is selected from
polycarbonate (PC), polyethylene terephthalate (PET), polyvinyl chloride (PVC),
polypropylene (PP), poly methyl methacrylate (PMMA), acrylonitrile butadiene
styrene (ABS), thermoplastic polyolefins (TPOS), thermoplastic polyurethane (TPU),
15 or combination thereof.
8. The method as claimed in claim 1, wherein the thermoforming is performed at
pressure ranging from 20 to 300 bar.
9. The method as claimed in claim 1, wherein the thermoforming is performed at
temperature range of 100-350o C.
10. The method as claimed in claim 1, wherein the thermoforming is performed for
the duration of 30 seconds to 3 minutes.
11. The method as claimed in claim 1, wherein the printed sheet is functionally printed
prior to applying bond coating of step (c) .
12. The method as claimed in claim 1, wherein the functional coating and heat
25 resistance coating is carried out as a single integrated process.
13. The method as claimed in 1, wherein the method optionally comprises the steps
of:
a) injecting a plastic resin into an injection molding machine to obtain a textured
plastic product;
5 b) applying a specialty coating on the textured plastic surface and base color
coating on the top of the plastic pre textured product;
c) hydro dipping, cubic printing, aqua-printing or water transfer printing to
obtain sheet having a realistic graphic structure;
d) applying protective coatings on decorated surfaces of the realistic graphic
structure for finishing and protection.
14. A decorative (textured) plastic product obtained by a method as claimed in claims
15. The decorative (textured) plastic product as claimed in claim 13, wherein the
decorative product is equipped with touch sensors, touch switches, or other human
touch interfaces.