Spray-on bag manufacturing process

Abstract

Method for manufacturing a bag by spraying. Method for producing a bag comprising a vat and at least one carrying element, including the following successive steps: supplying E01 a liquid composition comprising a binder and a solvent, a filler consisting of loose fibers and / or a powder, and a bulk support; forming E05 a composite layer consisting of a liquid composition and a filler on the support deposition surface by spraying E06 a liquid composition and spraying E07 a filler; drying E08 the composite layer resulting from the formation step E05; repeating E09 at least once the formation E05 and drying E08 steps of a composite layer, and forming, on the support deposition surfaces, a vat equipped with at least two extensions suitable for forming at least one carrying element; and removing E13 said vat from the support deposition surfaces. Figure to be published with the abbreviation: 1

Description

Title of the invention: Method for manufacturing a bag by spraying. TECHNICAL FIELD OF THE INVENTION

[0001] The technical field of the invention is that of the production of bags.

[0002] The present invention relates to a method for manufacturing a bag by spraying, as well as a bag obtained by this process. TECHNOLOGICAL BACKGROUND OF THE INVENTION

[0003] The bags generally include a container, which is designated as a "cauldron", and at least one carrying element, such as a shoulder strap, handle, strap, belt or grip, which is attached to the cauldron.

[0004] In the context of this invention, we are limiting ourselves to bags that are usually made of fabric, plastic, or leather, and that are generally manufactured by assembling several pieces, in particular by sewing or welding. The field of the invention preferably relates to the following bags: • Handbags, for example such as small shoulder bags, messenger bags, clutch bags, bucket bags, baguette bags and tote bags; • Carrying bags, for example such as sports bags, travel bags, backpacks, laptop bags and bicycle bags; • Professional bags, for example such as briefcases, satchels and document holders; • Utility bags, for example such as fanny packs, tote bags, shoulder bags and crossbody bags.

[0005] Nowadays, the manufacture of such bags generally requires many assembly steps, usually manual, which are costly and may require a great deal of know-how when the bag has a complex shape.

[0006] There is therefore a need to limit the number of assembly steps.

[0007] The main objective of the invention is therefore to propose an alternative method of manufacturing bags aimed at limiting the number of assembly steps.

[0008] Since there is also an urgent and growing need to reduce the environmental and ecological impact of industrial manufacturing processes, a secondary objective of the invention is also to improve bag manufacturing processes so that they are more environmentally friendly. Summary of the invention

[0009] In order to limit the number of assembly steps in the manufacture of a bag, the invention proposes to manufacture the boiler and at least two parts of a carrying element by spraying layers of composite material onto a support.

[0010] The invention offers a solution to the problem of reducing the environmental and ecological impact of bag manufacturing processes by providing a sprayable composite material that meets, as far as possible, all of the following requirements: • use environmentally friendly and ecologically sound materials; • use materials derived from renewable natural raw materials; • use non-toxic materials, especially by contact and / or inhalation; • use as little as possible of materials obtained from fossil resources; • use recyclable and / or biodegradable materials; • use recycled materials; • use locally produced materials; • use a production process that generates little waste, this waste being reusable, recyclable and / or biodegradable.

[0011] In order to meet these requirements, following numerous studies, including feasibility studies, the applicant has chosen to preferentially and predominantly use bio-based fillers in the form of powder and / or fibers, a water-soluble binder, and a water-based solvent, and to adapt the spray manufacturing process accordingly. A bio-based material is defined as a material derived from renewable, non-fossil, natural organic raw materials of plant or animal origin.

[0012] One aspect of the invention relates to a method for producing a bag comprising a cauldron and at least one carrying element, including the following successive steps: • supply E01 of a support, at least one liquid composition and at least one charge to be sprayed onto said support, this supply step E01 comprising the following sub-steps: • supply E02 of at least one liquid composition comprising a binder and a solvent in which the binder is dissolved; • supply E03 of at least one charge consisting of loose fibers and / or a powder; • supply E04 of a three-dimensional support comprising a first part having a deposition surface having the general shape of a bag cauldron and at least a second and a third part protruding from the first part and each presenting a depositional surface, each having the general shape of an extension; • Formation E05, on the deposition surface of the first part and the second and third parts of a composite layer consisting of a liquid composition and a filler resulting from the supply step E01, this formation step E05 comprising the following sub-steps: • spraying E06 onto the deposition surfaces of a liquid composition resulting from the supply step E01; and • spraying E07 onto the deposition surfaces of a charge consisting of loose fibers and / or a powder resulting from the supply step E01; • the spraying substep E07 of a charge being simultaneous with or subsequent to the spraying substep E06 of the liquid composition; • drying E08 of the resulting composite layer from the E05 formation step; • repetition E09 at least once of the formation steps E05 and drying steps E08 of a composite layer, and formation, on the substrate deposition surfaces, of a cauldron equipped with at least two extensions capable of forming at least one load-bearing element; and • removal E13 of said cauldron from the support deposition surfaces.

[0013] The expression "spraying onto a layer or surface" means spraying onto the outer face of a layer or surface.

[0014] By "loose fibers" we mean loose fibers that are not bound together, or compacted, or oriented in any way, so that when sprayed, they are randomly arranged on the surface on which they are sprayed.

[0015] The formation, on the deposition surface of the first part and the second and third parts, of several composite layers by spraying advantageously makes it possible to create a composite material shaped into a three-dimensional, one-piece mold with extensions that can then be shaped into a carrying element. This composite material is preferably a flexible material that behaves substantially like a conventional textile used for the manufacture of a bag, even in the case where said composite material contains neither yarns nor fibers.

[0016] By this process, the cauldron is manufactured in one piece with protruding elements, for example in the form of a tab, a strip, a flap or a hollow tube, in a few quick steps to implement, much easier and faster than the usual assembly steps.

[0017] It should be noted that the cauldron obtained by the process is a three-dimensional piece, and not simply a textile blank. It is a self-enclosed volumetric piece, defining a certain capacity (in the field of bags, this is referred to as volume) and having at least one opening for accessing the contents of the bag. This cauldron has at least two extensions which, after a few finishing steps, will serve as a carrying element or will serve to attach such a carrying element to the cauldron.

[0018] Spraying thin liquid layers onto or into which fibers and / or powder adhere allows for rapid drying of each layer, thus enabling the quick fabrication of a cauldron equipped with extensions. If the substeps E06 of spraying the liquid composition and E07 of spraying the filler are simultaneous, this notably reduces the process time. Spraying a filler reduces the amount of binder required to manufacture a bag and increases the mechanical strength of the resulting textile material.

[0019] If necessary, this process can be supplemented by spraying several composite layers, which makes it possible, for example, to further strengthen the mechanical resistance of the resulting composite layer and / or to make it watertight. The composition of the outer layer of the boiler can advantageously be chosen to provide good abrasion resistance.

[0020] Similarly, the spray forming of the cauldron and extensions allows for easy alternation of layers of different composition, with excellent adhesion between them, which allows for many possibilities for the bag manufacturer, including the ability to provide a bag with an appearance and / or feel that is not the same inside and outside the bag.

[0021] In addition, this process makes it possible to produce a bag locally and on demand, without requiring many manual assembly operations or very significant know-how.

[0022] In the case where a liquid composition and a filler are sprayed simultaneously, they may each be sprayed by a separate spraying unit or by the same spraying unit. In the latter case, the liquid composition and the filler may be mixed together before being introduced into the spraying unit, or be mixed within it.

[0023] If the E07 spraying substep of the filler is carried out after the E06 spraying substep of the liquid composition, this allows in particular better control of the composition of each composite layer.

[0024] According to one aspect of the invention, after the cauldron removal step E13, the process includes a finalization step El5 of at least one carrying element, this finalization step E15 comprising at least one of the following substeps: • rectification of the edges of at least one extension; • padding of at least one extension when it is hollow; • joining at least two extensions to form at least one load-bearing element.

[0025] This finalization step E15 allows, in particular, for shaping at least two extensions of the cauldron into a load-bearing element. When the two extensions are formed in a single piece by the process, they already constitute an assembly that can be used as a load-bearing element; this assembly then only needs to be modified, for example, to make it more aesthetically pleasing, more resistant, and / or more comfortable during this finalization step E15. When the two extensions are separate, they must at least be joined during this finalization step E15 to shape them into a load-bearing element. When an extension is hollow, because it was formed by spraying around a solid part, this finalization step E15 allows, for example, for it to be padded before being made into a load-bearing element in order to improve the latter's comfort.

[0026] According to another aspect of the invention, during substep E04 of supplying a support, at least one deposition surface among those of the second and third parts of the support is generally in the form of a rectangular strip, a cylinder, a rectangular prism, or a polygonal prism. This advantageously makes it possible to form an extension that can have a shape close to a carrying element or a shape that requires few operations to become a carrying element, for example, in the form of a strap or in a hollow shape suitable for padding before being sewn to form a comfortable carrying element.

[0027] According to another aspect of the invention, during substep E04 of supplying a support, at least a part of said support is detachable or removable, which makes it possible, for example, to design a support with several possible configurations, with, for example, the possibility of easily replacing one part with another. This also makes it easier to remove the cauldron and the extensions intended to remove it from the support.

[0028] According to a further aspect of the invention, during the drying step E08, the support is subjected to vibrations, which in particular improves the mechanical properties of the resulting cauldron and accelerates drying.

[0029] According to one aspect of the invention, prior to the cauldron removal step E13, the process includes a formation step E10 of a finishing layer on the layer composite resulting from the repetition step E09, this formation step E10 of a topcoat comprising the following successive sub-steps: • spraying Eli onto the deposition surfaces of a liquid composition resulting from the E02 supply step of at least one liquid composition; and • drying E12 of the liquid composition sprayed during the previous Eli spraying sub-step.

[0030] This E10 formation step of a finishing layer makes it possible in particular to cover the external face of the cauldron with binder in order to give it a smooth and uniform aesthetic appearance, to protect the lower layers and / or to provide it with good resistance to abrasion.

[0031] According to another aspect of the invention, at least one drying step E08, E12 is carried out at room temperature. "Room temperature" means the temperature of the room where the process is implemented. This temperature depends on the geographical region and the season, but it is usually between 10 and 30 °C, more commonly between 15 and 25 °C, and even more commonly between 18 and 22 °C. The process of the invention is thus designed to be carried out at a temperature at which most people are accustomed to working indoors.

[0032] According to a further aspect of the invention, at least one drying step E08, E12 is carried out at a temperature between 50 and 90 °C, which in particular accelerates drying and promotes the hardening of the binder.

[0033] According to one aspect of the invention, after a drying step E08, E12, it comprises a stabilization step E14 of the cauldron material and extensions, this stabilization step E14 comprising at least one of the following sub-steps: • a heat treatment; • plasma therapy; and / or • crosslinking by irradiation.

[0034] According to another aspect of the invention, at least a part of one of the support's deposition surfaces is textured in relief or intaglio, which makes it possible in particular to generate a texture intaglio or relief on at least a part of the face of the resulting cauldron which is in contact with the support before its removal from it.

[0035] According to a further aspect of the invention, during substep E02 of supplying at least one liquid composition comprising a binder, said binder is water-soluble and said liquid composition comprises a water-based solvent in which the binder is dissolved, and the liquid composition is such that: • the binder comprises one or more water-soluble polymers, which represent 30 to 70% by weight of the liquid composition; • The water-based solvent comprises water representing 30 to 70% by weight of the liquid composition.

[0036] In addition to being non-toxic, inexpensive, and abundant, water offers numerous and obvious environmental and ecological advantages over organic solvents. Thus, the process according to the invention has a considerably reduced environmental and ecological impact compared to previous bag production processes.

[0037] According to one aspect of the invention, during the substep of supplying E03 at least one charge consisting of loose fibers and / or a powder, at least 5% by weight of said charge is of bio-based origin, which advantageously reduces the carbon footprint of the process.

[0038] According to a further aspect of the invention, during a formation step E05 of a composite layer, the filler represents 30 to 60% by weight of said composite layer, which advantageously makes it possible to reduce the amount of binder used and therefore to reduce the environmental and ecological impact of the process.

[0039] According to one aspect of the invention, during a formation step E05 of a composite layer, the weight-to-load ratio in said composite layer is in the range of 2:1 to 1:2, which advantageously reduces the environmental and ecological impact of the process while providing a cauldron with characteristics suitable for its subsequent use. The choice of this ratio makes it possible, in particular, to adapt the flexibility and strength of the cauldron and the extensions obtained for a given final thickness, a high binder content generally favoring flexibility, while a high filler content generally favoring rigidity of the cauldron obtained.

[0040] According to another aspect of the invention, in a formation step E05 of a composite layer, a bio-based filler represents 5 to 50%, preferably 10 to 40% and more preferably 15 to 30% by weight of said composite layer, which advantageously reduces the environmental and ecological impact of the process.

[0041] According to a further aspect of the invention, during the E03 feed supply step, 5 to 70%, preferably 10 to 60% and more preferably 20 to 50% by weight of the feed is of bio-based origin.

[0042] According to one aspect of the invention, during the feed supply step E03, 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the bio-based feed consists of viscose fibers, cotton fibers, wool fibers, silk fibers, cashmere fibers, flax fibers, fur fibers, mammal hair, mycelium fibers, cellulose fibers, wood fibers, hemp fibers, mycelium powder, rice powder, wheat powder, wood powder, starch powder, alginate powder, black powder carbon, wheat flour, corn flour, millet flour, hemp flour, rapeseed flour, soybean seed hull powder, walnut shell powder, olive kernel powder, cellulose nanofiber powder, polyamide powder or fibers, polypropylene powder or fibers, polyethersulfone powder or fibers or polyurethane powder or fibers, taken alone or in mixtures, which notably helps to reduce the carbon footprint of the process.

[0043] According to another aspect of the invention, during the E03 supply step of a charge, 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the charge are made up of at least one bio-based material comprising at least 5% by weight of calcium, preferably at least 10% by weight of calcium, which in particular makes it possible to improve the tensile strength, the compressive strength and / or the water absorption capacity of the resulting cauldron.

[0044] According to a further aspect of the invention, at least one bio-based material comprising at least 5% by weight of calcium is gypsum powder, limestone powder, bone powder, calcium carbonate powder or chalk powder, which advantageously makes it possible to reduce the environmental and ecological impact of the process.

[0045] Indeed, calcium carbonate increases the tensile and compressive strength of the resulting cauldron. Magnesium sulfate increases both the tensile and compressive strength of the cauldron, as well as its water absorption capacity. Gypsum, on the other hand, only increases the tensile strength of the cauldron, while sodium sulfate increases its water absorption capacity.

[0046] According to one aspect of the invention, during the supply step E02 of at least one liquid composition, the binder comprises at least 10%, preferably at least 30% and more preferably at least 60% by weight of bio-based and / or biodegradable polymer, which in particular makes it possible to reduce the carbon footprint of the process.

[0047] According to another aspect of the invention, during the supply step E02 of at least one liquid composition, the binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of elastomer, which makes it possible in particular to produce a cauldron having elastic properties.

[0048] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition, the binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of natural latex of vegetable origin, latex of vegetable origin treated to reduce its protein content, bio-based polylactic acid, bio-based thermoplastic polyurethane, bio-based polyurethane dispersion, dispersion of rosin of vegetable origin, dispersion of terpene of vegetable origin, and acrylic polymer. bio-based or polymer matrix hydrogel, taken alone or in mixture, which advantageously reduces the environmental and ecological impact of the process.

[0049] According to one aspect of the invention, during the supply step E02 of at least one liquid composition, the binder comprises at least 10%, preferably at least 20% and more preferably at least 30% by weight of electrically conductive polymer, which notably allows the resulting cauldron to be instrumented.

[0050] According to another aspect of the invention, during the supply step E02 of at least one liquid composition, the liquid composition comprises 1 to 30% by weight of magnesium sulfate and / or sodium sulfate, which in particular improves the tensile strength, the compressive strength and / or the water absorption capacity of the resulting cauldron.

[0051] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition or during the supply step E03 of a filler consisting of loose fibers and / or a powder, the liquid composition or the filler includes a bridging agent capable of forming ionic and / or covalent bonds with the binder, which makes it possible in particular to improve or modify the physical properties of the cauldron, in particular its mechanical strength and / or its elasticity.

[0052] According to one aspect of the invention, the bridging agent mainly comprises a culture substrate containing fungal spores grown therein, fungal mycelium, silicate derivatives or magnesium chloride derivatives, taken alone or in mixture, which advantageously reduces the environmental and ecological impact of the process.

[0053] According to another aspect of the invention, during a formation step E05 of a composite layer, the weight ratio of bridging agent in said composite layer is in the range between 1:100 and 1:1, preferably between 1:10 and 1:4, and more preferably between 2:10 and 3:10, which in particular makes it possible to improve or modify the physical properties of the cauldron in a satisfactory manner.

[0054] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition, the charge includes a coalescing agent whose quantity represents from 0.1 to 10%, preferably 1 to 5% by weight of the liquid composition.

[0055] According to another aspect of the invention, the coalescing agent is 2,2,4-trimethyl-1,3-pentane diol monoisobutyrate, glycol acetate, butyl glycol, fatty acid ester, propylene glycol or ethyl acetate, taken alone or in mixture.

[0056] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition, said liquid composition comprises at least one pigment, which advantageously allows the production of a cauldron with at least one layer tinted throughout.

[0057] According to one aspect of the invention, during the supply step E02 of at least one liquid composition, said liquid composition comprises a viscosity-modifying agent, which advantageously allows the viscosity of the liquid composition to be adjusted, for example, to thicken or thin it, in particular to ensure that it adheres to the substrate without excessive dripping. Viscosity here also refers to the rheological properties of the liquid composition.

[0058] According to another aspect of the invention, the viscosity agent is polylactic acid, sugar, polysaccharide derivative, alginate, potato dextrose, agar, glucose, malt, peptone or yeast extract, taken alone or in mixture, which advantageously reduces the environmental and ecological impact of the process.

[0059] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition, said liquid composition has a dynamic viscosity between 0.1 and 10,000 mPa.s at 20 °C, which provides a wide viscosity range suitable for the different spraying conditions and the different applications envisaged.

[0060] According to one aspect of the invention, during the supply step E02 of at least one liquid composition, said liquid composition includes an adhesive agent, which notably improves the bond between the different layers of the cauldron if necessary. Indeed, the bond between layers can be achieved through the binder itself present in each layer, particularly when the binders of each layer are of the same chemical family.

[0061] According to another aspect of the invention, the adhesive agent is an aqueous dispersion of rosin and terpene, both of plant origin, which advantageously reduces the environmental and ecological impact of the process.

[0062] According to a further aspect of the invention, during a substep E06 of spraying a liquid composition, said liquid composition completely covers a charge comprising fibers, at least 80% of these fibers having a length between 3 and 7 mm, preferably between 3 and 5 mm, and more preferably between 3 and 4 mm, which in particular makes it possible to reinforce the resulting cauldron.

[0063] According to one aspect of the invention, during a substep E06 of spraying a liquid composition, said liquid composition does not completely cover a filler comprising fibers, at least 80% of these fibers having a length between 0.1 and 2 mm, preferably between 0.5 and 1.5 mm, and more preferably between 0.5 and 1 mm, which notably allows for improvement the feel of the cauldron obtained, with average counts of 1.7 Dtex for fibers of length 0.5 mm and 3.3 Dtex for fibers of length 1 mm.

[0064] Another aspect of the invention relates to a bag comprising a cauldron and at least one carrying element, which includes alternating layers of binder-based material and a filler comprising a powder and / or fibers, said bag being a product resulting from the process described above.

[0065] According to one aspect of the invention, the bag is a handbag, a tote bag, a sports bag, a travel bag, a backpack, a satchel, a schoolbag, a briefcase, a fanny pack or a shopping bag.

[0066] According to another aspect of the invention, a carrying element is a shoulder strap, a handle, a strap, a belt or a grip.

[0067] According to a further aspect of the invention, the cauldron has an average thickness of between 0.1 and 3 mm.

[0068] A further aspect of the invention relates to a spraying system for implementing the process, which comprises the following equipment: • at least one spraying unit equipped with one or more spray nozzles; • at least one fluid displacement device; • at least one tank containing: • a liquid composition comprising a binder and a solvent in which the binder is dissolved, • a powder charge, • a load in the form of loose fibers, taken alone or in blend ; • supply pipes connecting at least one reservoir to at least one fluid displacement device and to at least one spray nozzle; • at least one volume support comprising a first part having a deposition surface having the general shape of a bag cauldron and at least a second and a third part protruding from the first part and each having a deposition surface having the general shape of an extension, deposition surfaces on which a cauldron equipped with an extension can be manufactured by spraying at least one fluid contained in a reservoir and supplied by a fluid displacement device to a spraying unit.

[0069] The invention and its various applications will be better understood by reading the following description and examining the accompanying figures. BRIEF DESCRIPTION OF THE FIGURES

[0070] The figures are presented for illustrative purposes only and are in no way limiting of the invention.

[0071] [Fig-1] is a schematic representation of an example of a process according to the invention in which a liquid composition is sprayed before a charge.

[0072] [Fig.2] is a schematic representation of an example of a method according to the invention in which a liquid composition and a charge are sprayed simultaneously.

[0073] [Fig.3] is a schematic view of an example of a device comprising two spraying units each mounted on a separate robotic arm and enabling the implementation of the process according to the invention for the production of a cauldron equipped with four strip-shaped extensions to be subsequently connected in pairs to form the two handles of a tote bag.

[0074] [Fig.4] is a schematic view of an example of a cauldron made with the device of [Fig.3].

[0075] [Fig.5] is a schematic view of an example of a semi-finished tote bag made from the cauldron of [Fig.4].

[0076] [Fig.6] is a schematic view of an example of a device comprising two spraying units mounted on the same robotic arm and enabling the implementation of the process according to the invention for the production of a cauldron equipped with two band-shaped extensions suitable for being mutually connected in order to form the shoulder strap of a tote bag.

[0077] [Fig.7] is a schematic view of an example of a cauldron made with the device of [Fig.6].

[0078] [Fig.8] is a schematic view of an example of a semi-finished tote bag made from the cauldron of [Fig.7].

[0079] [Fig.9] is a schematic view of an example of a device comprising a single spraying unit mounted on a robotic arm and enabling the implementation of the process according to the invention for the production of a cauldron equipped with two tongue-shaped extensions and two hollow tubular extensions, each tongue-shaped extension being intended to be connected to a hollow tubular extension in order to form one of the two straps of a backpack.

[0080] [Fig. 10] is a schematic view of an example of a cauldron made with the device of [Fig.9].

[0081] [Fig. 11] is a schematic view of an example of a semi-finished backpack made from the cauldron of [Fig. 10].

[0082] [Fig. 12] is a schematic view of an example of a device comprising three spraying units mounted on the same robotic arm, enabling the implementation of the process according to the invention for the production of a cauldron equipped with two band-shaped extensions to be subsequently connected in pairs to form the handle of a bag. hand and equipped with a flap-shaped extension designed to form the flap closure of said handbag.

[0083] [Fig. 13] is a schematic view of an example of a cauldron made with the device of [Fig. 12],

[0084] [Fig. 14] is a schematic view of an example of a semi-finished handbag made from the cauldron of [Fig. 13]. DETAILED DESCRIPTION

[0085] Unless otherwise specified, the same element appearing on different figures has a unique reference.

[0086] The process according to the invention uses at least one liquid composition and at least one charge intended to be sprayed onto a support 4 in order to produce a cauldron 2 equipped with extensions 5.

[0087] A liquid composition according to the invention comprises a binder, preferably water-soluble, and a solvent, preferably aqueous, in which the binder is dissolved.

[0088] The aqueous solvent is preferably entirely composed of water. It represents 30 to 70% by weight of the liquid composition.

[0089] The water-soluble binder preferably comprises a water-soluble polymer representing 30 to 70% by weight of the liquid composition.

[0090] Although the binder can be supplied in the form of an aqueous solution, the percentages given here are in dry weight of binder or water-soluble polymer.

[0091] The binder preferably comprises one or more water-soluble bioplastics or one or more recyclable water-soluble polymers. Bioplastics are understood to mean polymers derived from renewable sources (bio-based polymers) and biodegradable polymers. Thus, a bioplastic may be bio-based but not biodegradable, bio-based and biodegradable, or derived from fossil resources (often petrochemicals) and yet biodegradable. Bioplastics should not be confused with biocompatible plastics.

[0092] Thus, the water-soluble binder comprises at least 10%, preferably at least 30% and more preferably at least 60% by weight of bio-based and / or biodegradable polymer.

[0093] In order to enable the production of a cauldron 2 and / or extensions 5 exhibiting elastic properties, the water-soluble binder may comprise at least 5%, preferably at least 30% and more preferably at least 70% by weight of elastomer.

[0094] According to one embodiment, the water-soluble binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of natural latex of vegetable origin, or of latex of vegetable origin treated to reduce the rate of protein, bio-based polylactic acid, bio-based thermoplastic polyurethane, bio-based polyurethane dispersion, plant-derived rosin dispersion, plant-derived terpene dispersion, bio-based acrylic polymer or polymer matrix hydrogel, taken alone or in mixture.

[0095] Natural latex of plant origin is extracted in liquid form from several plants and trees, primarily the rubber tree (Hevea brasiliensis), and forms rubber after polymerization. It is advantageous because it is bio-based, biodegradable, compostable, recyclable, and elastic. A plant-based latex treated to reduce its protein content was Vytex® from VYSTAR, which yielded excellent results with the production process of a cauldron 2 equipped with extensions 5 according to the invention.

[0096] Polylactic acid (PLA) is a homopolymer of lactic acid. It is advantageous because it is biodegradable, compostable, recyclable and can be bio-based, notably being obtained primarily from corn.

[0097] Thermoplastic polyurethanes (TPUs) are thermoplastic elastomers (TPEs) of isocyanate block polyurethane. They are advantageous in that they are recyclable and can be bio-based, biodegradable and elastic.

[0098] Very satisfactory tests were obtained with a bio-based polyurethane dispersion based on one of the following products: Impranil® DL 1545, Impranil® DL 1126, Impranil® DL 2611 / 1, Impranil® DLU, Impranil® 43031 and Impranil® DL 1380 from COVESTRO.

[0099] Very satisfactory tests were also obtained with a rosin dispersion based on Dermulsene A 7510® (Brookfield viscosity at 20 °C, 50 min-1, mPa.s: 600) and from a rosin solution based on Dermulsene TR 602® (Brookfield viscosity at 20 °C, 50 min-1, mPa.s: 800) from LES DERIVES RESINIQUES ET TERPENIQUES (DRT).

[0100] Among the bio-based water-soluble polymers that can be used, the following binders can also be mentioned: • the natural polymer, 100% bio-based and biodegradable from LACTIPS, which can provide water-soluble properties to the cauldron 2 and / or the extensions 5; • vinyl ethylene acetate (VAE), a water-soluble thermoplastic polymer that can be derived from bio-based sources; • Polyvinyl alcohol (PVA), a water-soluble polymer that can be produced from renewable raw materials; • Polyethylene glycol (PEG), also known as polyethylene oxide (PEO) and poly(oxyethylene) (POE), a polyether polymer linear water-soluble which can also be used as a thickening agent and which can be derived from renewable resources; • polyvinylpyrrolidone (PVP), a water-soluble polymer that can be used as an emulsifier and stabilizer and can be produced from bio-based sources; • ExpertGel®, a water-soluble thermogelling polymer developed by PolymerExpert, derived from natural oils; and • EstoGel® Green, a bio-sourced rheology modifier also developed by POLYMEREXPERT, a biodegradable oily gelling and shear-thinning agent, 100% of origin, which allows great versatility in terms of textures and visuals and flexibility in its use.

[0101] According to one embodiment, the water-soluble binder comprises at least 10%, preferably at least 20% and more preferably at least 30% by weight of electrically conductive polymer.

[0102] The process according to the invention also uses a filler consisting of loose fibers and / or a powder. At least 5% by weight of the filler is bio-based. Depending on the sprayed layers and the materials chosen, 5 to 70%, preferably 10 to 60%, and more preferably 20 to 50% by weight of the filler is bio-based.

[0103] The filler improves the texture and consistency of the cauldron 2 and the extensions 5, increasing their durability. It can also provide additional properties, particularly when it includes a bridging agent. When bio-based, it is environmentally friendly.

[0104] In addition to adding flexibility and durability to the cauldron 2 and the extensions 5 by increasing their wear resistance, a filler made of fibers can provide a soft and pleasant texture to the cauldron 2 and the extensions 5.

[0105] According to one embodiment, 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the bio-based filler, consists of viscose fibers, cotton fibers, wool fibers, silk fibers, cashmere fibers, flax fibers, fur fibers, mammal hair, mycelium fibers, cellulose fibers, wood fibers, hemp fibers, mycelium powder, rice powder, wheat powder, wood powder, starch powder, alginate powder, carbon black powder, wheat flour, corn flour, millet flour, hemp flour, rapeseed flour, soybean hull powder, walnut hull powder, olive kernel powder, cellulose nanofiber powder, bio-based polyamide powder or fibers, or polypropylene powder or fibers. bio-based, from bio-based polyethersulfone powder or fibers or from bio-based polyurethane powder or fibers,taken alone or in mixtures.

[0106] According to one embodiment, the liquid composition and / or filler comprises a bridging agent, preferably water-soluble, capable of forming ionic and / or covalent bonds with the binder, preferably with a water-soluble polymer of the binder. Preferably, the bridging agent mainly comprises a culture substrate containing fungal spores cultured therein, fungal mycelium, silicate derivatives, or magnesium chloride derivatives, alone or in mixtures. The bridging agent preferably represents an amount such that, during a formation step E05 of a composite layer, before drying, the weight ratio of bridging agent to binder in said composite layer is in the range of 1:100 to 1:1, preferably between 1:10 and 1:4, and more preferably between 2:10 and 3:10.

[0107] For the mushroom mycelium, preferred mushroom species include the following: Pleurotus and subspecies ostratus and eryngii (king oyster mushroom), Ganoderma and subspecies lucidum (reishi) and resinceum, Trametes and subspecies versicolor (Turkish mushroom) and multicolor, Cordyceps, Lentinus, Lentinula, Agaricus (for example Agaricus bisporus, known as the button mushroom), Hericium, Schizophylium commune (saw fungus), Fomes fomentarius (birch fungus) and Lentinula edodes (shiitake).

[0108] Bridging agents in powder form are preferentially present in the feedstock, while bridging agents in liquid form are preferentially present in the liquid composition. Of course, if a feedstock is mixed with a liquid composition before spraying, a bridging agent can be added to this mixture.

[0109] According to one embodiment, 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the filler, are made of at least one bio-based material comprising at least 5% by weight of calcium, preferably at least 10% by weight of calcium. Such a material improves the rigidity and strength of the material, while being a natural product. This bio-based material comprising at least 5% by weight of calcium is preferably gypsum powder, limestone powder, bone meal, calcium carbonate powder, or chalk powder.

[0110] When the charge includes powder, this powder preferentially has a narrow particle size distribution in the range of 20 to 100 pm, with an average particle size distribution for example of about 50 pm.

[0111] A liquid composition according to the invention may also comprise from 1 to 30% by weight of an additive suitable for improving the tensile strength, compressive strength and / or water absorption capacity of the cauldron 2 and the extensions 5 obtained. This additive can, for example, be magnesium sulfate and / or sodium sulfate.

[0112] A liquid composition according to the invention may also include a coalescing agent that lowers the minimum film formation temperature (MFT) of aqueous dispersions, allowing the polymers to react more readily at lower temperatures. It acts by reducing the surface tension between the particles, thus facilitating their coalescence.

[0113] Some examples of usable coalescing agents are given in the table below, with preferred concentrations given for each as a percentage by weight relative to the total mass of the liquid composition.

[0114] [Tables 1] Coalescing Agent Operating Conditions Concentration Eastman's TEXANOL® (2,2,4-trimethyl-1,3-pentanediol monoisobutyrate) Used in water-based spray solutions. 1% to 5% Glycol Acetates Used as a coalescing agent in aqueous spray solutions. 0.1% to 10%, preferably 1% to 2% Butyl glycol Used in water-based spray solutions. 1% to 5% Fatty acid ester Used in spray solutions to reduce the minimum coating formation temperature. 2% to 4% Propylene glycol Used to improve the adhesion and durability of sprayed coatings. 1% to 3% Ethyl acetate Used in spray solutions to facilitate drying. 2% to 6%

[0115] Among preferred glycol acetates, examples include 2-hexyl-1,3-dioxolane-4-methanol, 2-hexyl-1,3-dioxane-5-ol, 2-hexyl-2-methyl-1,3-dioxolane-4-methanol, and 2-hexyl-2-methyl-1,3-dioxane-5-ol. Ethylene glycol monoethyl ether acetate is a preferred choice because of its favorable atomizing properties and its compatibility with water-based formulations.

[0116] A liquid composition according to the invention may also include at least one pigment. This pigment is preferably water-soluble. It may, for example, be an organic or inorganic pigment, for example, of chemical, mineral, or natural origin. It may also be pigments extracted from fungi or algae. Finally, it may also be disperse, azo, acid, or reactive dyes.

[0117] Some examples of usable pigments are given in the table below.

[0118] [Tables2] Pigment Type / Source Description Iron Oxide Inorganic Used to produce yellow, red, brown, black, and orange pigments. Titanium Dioxide Inorganic Common white pigment, widely used in paints, inks, and plastics. Carbon Black Inorganic Used in black printing inks, highly pigmented and lightfast. Zinc White Inorganic Solid white pigment, valued for its opacity and lightfastness. Prussian Blue Mineral Highly pigmented blue pigment, used in oil and acrylic paints. Cadmium Red Mineral Bright red pigment, known for its durability and lightfastness. Indigo Organic Blue pigment derived from the indigo plant, used for centuries for dyeing. Burnt Sienna Natural Reddish-brown pigment, used in oil and acrylic paints. Vermilion Mineral Bright red pigment, made from mercury sulfide, very opaque and luminous.Pyrrole Orange Organic Synthetic pigment offering a beautiful range of bright reds and oranges. Ganoderma lucidum Mushroom Pigment Offers natural hues, including reds, yellows, whites, blacks, and purples, and is biodegradable. Also known for its antibacterial properties. Lentinus laedodes Mushroom Pigment offering brown and beige shades. Fomes fomentarius Mushroom Pigment Known for its polysaccharides and phenolic compounds, this mushroom can be used to obtain natural dyes. Trametes versicolor Mushroom Pigment Known for its medicinal properties, this mushroom produces pigments that... can be used in textile dyes. Pigment from Schizophyllum communis (mushroom). Contains polysaccharides and proteins; this fungus can also provide natural dyes for boiler 2 and extensions 5. Phycoerythrin (red algae such as Porphyridium cruentum). Fluorescent red pigment. Phycocyanin (cyanobacteria and certain red algae). Blue pigment. Chlorophyll (algae). Green pigment. Carotenoid (algae). Yellow, orange, or red pigment.

[0119] It should be noted that other seaweed extracts can be used in the invention in combination with pigments:

[0120] Agar: Polysaccharide extracted from certain red algae such as Gelidium and Gracilaria. It can be used as a natural mordanting agent to fix dyes to cellulosic and protein fibers.

[0121] Alginates: Polysaccharides present in brown algae such as Laminaria and Macrocystis. They can serve as thickeners and binders for natural dyes in textile applications.

[0122] Carrageenans: Sulfated polysaccharides extracted from red algae such as Chondrus crispus. They improve the fixation and durability of natural dyes on fibers.

[0123] Fucoidans: Sulfated polysaccharides found in brown algae. They have properties similar to carrageenans for textile dyeing.

[0124] A liquid composition according to the invention may also include a water-soluble viscosity-modifying agent. This water-soluble viscosity-modifying agent is preferably polylactic acid, sugar, a polysaccharide derivative, alginate, potato dextrose, agar, glucose, malt, peptone, or yeast extract, taken alone or in mixture.

[0125] According to one embodiment, the liquid composition has a dynamic viscosity ranging from 0.1 mPa·s at 20 °C for very dilute solutions to several thousand mPa·s at 20 °C, for example 10,000 mPa·s at 20 °C for solutions concentrated in viscosity-enhancing agent (up to 20% or more), depending on the type of polymer used. For example, polyacrylamides and polyethylene glycols (PEGs). may have specific viscosities of up to 10 mPa.s or more in certain formulations such as 500 mPa.s or 10,000 mPa.s at 20 °C.

[0126] A liquid composition according to the invention may also include a water-soluble adhesive agent. The adhesive agent may be in the form of an aqueous dispersion of rosin and terpene, both of plant origin. Other examples of water-soluble adhesive agents are given below. Advantageously, most of them are compatible with mycelium-based materials.

[0127] [Tables3] Adhesive Agent Description Pullulan Water-soluble, biodegradable polysaccharide produced by the fermentation of tapioca starch by the fungus Aureobas idium pullulans and compatible with mycelium-based materials. Xanthan Gum Water-soluble polysaccharide produced by the fermentation of the bacterium Xanthomonas campestris and compatible with mycelium-based materials. Can be used as a thickener and stabilizer. Agar Polysaccharide extracted from algae and compatible with mycelium-based materials. Can also be used as an adhesive agent. Polyvinylpyrrolidone (PVP) Biocompatible water-soluble polymer that can be used as a binder and stabilizer. Its compatibility with mycelium-based materials still needs to be confirmed. Dextrin Polysaccharide derived from the hydrolysis of starch, used as an adhesive agent and can be used as a thickening agent. Compatible with mycelium-based materials, easily soluble in water and biodegradable..

[0128] The process according to the invention comprises several steps aimed in particular at spraying at least one liquid composition and at least one filler according to the invention onto a support 4 to form a composite layer, and repeating this operation after drying of said composite layer in order to superimpose several of them, these superimposed composite layers constituting the cauldron 2 and the extensions 5, with the extensions 5 being in one piece with the cauldron 2. It will be noted that the liquid composition and / or the filler can be identical or different for each composite layer and for the cauldron 2 and the extensions 5.

[0129] The process according to the invention therefore comprises a preliminary supply step E01 of certain essential means of the invention. This supply step E01 comprises a supply substep E02 of at least one liquid composition as described above, a supply substep E03 of a filler as described above, and a supply substep E04 of a support 4.

[0130] This support 4 is a three-dimensional part and can have any shape and dimensions. It is preferably three-dimensional and in several parts 401, 402, 403, 404, 405 which can be removable, joined together or in one piece. Each of these parts 401, 402, 403, 404, 405 has a deposition surface 411, 412, 413, 414, 415 on which composite layers will be formed by spraying according to the process of the invention, these layers then forming a cauldron 2 equipped with at least two extensions 5, 51, 52, 53, 54. Each deposition surface 411,412,413,414,415 is preferably an external surface of the parts 401,402,403,404,405 of the support 4, but it can also be an internal face of it.

[0131] The removable parts of a support 4 may, for example, be designed to be assembled by screwing. In this case, the part of the support 4 which is shaped like a cup preferably has threaded holes and the removable parts of the support 4 have threaded rods designed to be engaged by screwing into the aforementioned threaded holes.

[0132] In the case where a deposition surface 411,412,413,414,415 is a three-dimensional internal surface of one of the parts 401,402,403,404,405 of the support 4, said part may for example be in the form of a three-dimensional piece in several elements, which can be opened for the introduction and removal of one or more spray nozzles 16 inside said three-dimensional piece.

[0133] The support 4 thus comprises at least a first part 401, a deposition surface 411 of which, preferably an external surface of said first part 401, has a shape substantially similar to that of the cauldron 2 which is to be manufactured by spraying. By way of example, the first part 401 of the support 4 can be shaped into the cauldron of a tote bag (see [Fig. 3]), a shopping bag (see [Fig. 6]), a backpack (see [Fig. 9]) or a handbag (see [Fig. 12]).

[0134] The support also includes at least a second portion 402 and a third portion 403, each projecting from the first portion 401 of the support 4. The second portion 402 and the third portion 403 each have a deposition surface 412, 413 having a shape adapted for the formation of an extension 5, 51, 52, 53, 54 by spraying. At least two extensions 5, 51, 52, 53, 54 will then be used to form a carrying element 3; therefore, at least the second portion 402 and the third portion 403 are preferably in the general form of a rectangular strip. (cf. [Fig.3], [Fig.6], [Fig.9] and [Fig.12]), of a cylinder (cf. [Fig.9]), of a rectangular prism or of a polygonal prism.

[0135] A part of the rectangular plate-shaped support 4 allows in particular the formation of a flat and solid, i.e. non-hollow, extension 5 by spraying, for example in the form of a tongue 501, a longer strip 502 or a flap 504.

[0136] A portion of the support 4 in the form of a cylinder, rectangular prism or polygonal prism allows in particular the formation of a hollow extension 5 by spraying on all of its faces which extend longitudinally, the hollow extension 5 then being obtained in the form of a hollow cylindrical part or in the form of a hollow prism, for example in the form of a hollow tube 503.

[0137] At least part of one of the deposition surfaces 411,412,413,414,415 of the support 4 can be textured in relief or intaglio, for example for the formation of a cauldron 2 and / or an extension 5 with a textured face.

[0138] Indeed, although the support 4 only has a temporary support role, it is the shape of the deposition surfaces 411,412,413,414,415 on which the liquid composition and the charge according to the invention are sprayed that substantially determines the shape adopted by the cauldron 2 and the resulting extensions 5.

[0139] The various parts 401, 402, 403, 404, 405 of the support 4 are preferably rigid, but each may be at least partially flexible or elastic. They are preferably made of steel, aluminum, thermoplastic polyurethane (TPU), thermoplastic polyamide elastomer (TPA), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polycarbonate (PC), polyamide (nylon), polystyrene (PS), polypropylene (PP) or acrylonitrile butadiene styrene (ABS).

[0140] According to one variant of the invention, the support 4 is in positive relief, the layers being sprayed onto the predominantly convex external shape of the support 4.

[0141] According to another embodiment of the invention, the support 4 is in negative relief, the layers being sprayed onto the predominantly concave internal shape of the support 4, for example by introducing a spray nozzle 16 inside the support 4. In this case, the support 4 can be divided into several removable or detachable parts.

[0142] The process according to the invention comprises a formation step E05 of a composite layer on the deposition surface 411, 412, 413, 414, 415 of the various parts 401, 402, 403, 404, 405 of the support 4, this composite layer being composed of a liquid composition and a filler resulting from the supply step E01. This formation step E05 comprises the following substeps: • spraying E06 onto said deposition surfaces 411, 412, 413, 414, 415 of a liquid composition resulting from the supply step E01; and • spraying E07 on said deposition surfaces 411,412,413,414,415 of a charge consisting of loose fibers and / or a powder resulting from the supply step E01; • the spraying substep E07 of a filler being simultaneous with or subsequent to the spraying substep E06 of the liquid composition.

[0143] These two spraying substeps E06, E07 can be carried out one after the other (see [Fig. 1]), or simultaneously (see [Fig. 2]). If these two substeps are carried out simultaneously, the liquid composition and the filler can be sprayed by a single spraying unit 9 in which they are in a composite mixture state, or be sprayed at the same time by a separate spraying unit 9 for each.

[0144] It will be noted that it is technically easier to spray a composite mixture with a single spraying unit 9 when the filler preferentially comprises a powder and / or very short fibers, because it is difficult to obtain a satisfactory spray quality when spraying a composite mixture comprising both a liquid composition and a filler containing long fibers.

[0145] The two spraying sub-steps E06, E07 can be carried out at a pressure between 0.5 and 100 bar.

[0146] During the spraying step E06 of a liquid composition according to the invention on the deposition surfaces 411,412,413,414,415, a thin layer of liquid composition is deposited on them.

[0147] During the spraying step E07 of a charge according to the invention on the deposition surfaces 411,412,413,414,415, a thin layer of charge is deposited on them.

[0148] For these spraying steps E06, E07, by thin layer means a layer of liquid composition having an average thickness of between 0.1 and 2 mm, preferably between 0.2 mm and 1.5 mm, and more preferably between 0.2 and 0.8 mm.

[0149] If the liquid composition and the filler are sprayed simultaneously or one after the other, the liquid composition being sprayed before the filler, the liquid composition and the filler form a composite layer.

[0150] In a composite layer, the distribution of the charge within the liquid composition is not necessarily homogeneous and may vary throughout the thickness of said composite layer. The cauldron 2 and the extensions 5 may therefore exhibit different physical and / or chemical characteristics in certain areas and / or throughout their thickness.

[0151] Masks, which can also be referred to as shields, can be used during these spraying steps E06, E07 to control the shape and dimensions of the deposition surfaces 411,412,413,414,415. The liquid composition and the charge deposited on these masks can be recovered and used in order to limit waste.

[0152] Depending on the bag's volume, before the E05 formation step of a composite layer, it may be necessary to add a mesh or seamless textile to a part of the support 4, preferably at least to the part 401 intended for the formation of a cauldron 2, in order to reinforce the structure of the bag 1 and give it better mechanical performance.

[0153] According to one embodiment, during a formation step E05 of a composite layer, the filler represents 30 to 60% by weight of said composite layer. A bio-based filler of the filler represents 5 to 50%, preferably 10 to 40% and more preferably 15 to 30% by weight of said composite layer.

[0154] According to one embodiment, the quantity of filler and the quantity of liquid composition sprayed into a composite layer are such that the weight-to-filler ratio in said composite layer is in the range between 2:1 and 1:2.

[0155] During a substep E06 of spraying a liquid composition, this spraying E06 can be arranged so that said liquid composition completely covers a filler comprising so-called long fibers, i.e., at least 80% of these fibers have a length between 3 and 7 mm, preferably between 3 and 5 mm, and more preferably between 3 and 4 mm. This has the effect of strengthening the cauldron and / or the extensions 5 obtained.

[0156] During a substep E06 of spraying a liquid composition, this spraying E06 can also be arranged so that said liquid composition does not completely cover a filler comprising so-called short fibers, i.e., at least 80% of these fibers have a length between 0.1 and 2 mm, preferably between 0.5 and 1.5 mm, and more preferably between 0.5 and 1 mm. This has the effect of improving the feel of the cauldron and / or the extensions 5 obtained.

[0157] Once these two spraying steps E06, E07 have been carried out, the process according to the invention includes a drying step E08 during which the composite layer solidifies. During this drying step E08, the solvent, preferably water-based, evaporates and the binder hardens. If the latter is a water-soluble polymer, it hardens by polymerization. Due to the thinness of the liquid composition layer, this drying can be quite rapid, for example, on the order of 1 to 10 minutes, preferably 2 to 8 minutes, and more preferably 3 to 5 minutes. Upon hardening, the binder fixes the charge, forming a cauldron-shaped textile material 2 equipped with extensions 5.

[0158] A drying step E08 can be carried out at room temperature, or with heating, for example at a temperature between 50 and 90 °C.

[0159] The drying steps are preferably carried out at atmospheric pressure.

[0160] According to one aspect of the invention, during the drying step E08, the support 4 can be subjected to vibrations, for example by means of a vibrator.

[0161] The spraying steps E06, E07, which allow obtaining a composite layer, and the drying step E08, which allows solidifying said composite layer, can be repeated at least once in order to increase the thickness of the cauldron 2 and / or the extensions 5 obtained on the deposition surfaces 411, 412, 413, 414, 415 of the support 4. The process according to the invention thus comprises at least one repetition step E09, which includes a spraying step E06 of a liquid composition and a spraying step E07 of a filler, followed by at least one drying step E08 of the composite layer obtained.

[0162] The spraying steps E06, E07 and drying step E08 are preferably repeated one to five times, more preferably twice, so as to superimpose three composite layers in total. This makes it possible, for example, to obtain a cauldron 2 equipped with extensions 5 having an average thickness of between 0.1 and 3 mm, preferably between 0.2 and 2 mm for the manufacture of most bags.

[0163] During a repetition step E09 for layering composite materials, the liquid composition and / or filler according to the invention used for each composite layer may be identical to those of the preceding composite layer or different. In the latter case, the composition of the resulting core 2 and / or extensions 5 is not homogeneous throughout its thickness. This makes it possible, in particular, to combine the characteristics of several polymers and / or fillers within the same core 2 and / or extension 5, and thus said core and / or extension 5 may have internal and external faces with a different feel and / or appearance.

[0164] Similarly, during a spraying step E06, E07, it is possible to simultaneously spray liquid compositions and / or charges according to the invention which are locally different, in different places on the deposition surfaces 411,412,413,414,415, which makes it possible to obtain a cauldron 2 and extensions 5 whose composition is not homogeneous over their entire surface.

[0165] Finally, during a spraying step E06, E07, it is possible to locally spray more liquid composition and / or more filler onto the deposition surfaces 411, 412, 413, 414, 415, or to repeat the spraying steps E06, E07 in order to spraying liquid composition and / or charge locally only on a specific part of the deposition surfaces 411,412,413,414,415. This allows in particular to vary locally the thickness of the cauldron 2 and / or the extensions 5 obtained.

[0166] After drying E08 of the various composite layers, a step E13 consists of removing the cauldron 2 equipped with the extensions 5 from the deposition surfaces 411, 412, 413, 414, 415 of the support 4. This removal step E13 of the cauldron 2 may require one or more cuts of the cauldron or of the extensions 5 with which it is equipped. However, it is generally preferred that the cauldron 2 and the extensions 5 be removed from the support 4 without cutting them. The more elastic the material of the cauldron 2 and the extensions 5, the easier it is to remove said cauldron 2 and its extensions 5 in one piece.

[0167] It should be noted that a support 4 generally rests on the ground by means of a positioning device, for example an articulated arm or a simple rigid foot. In order to be able to remove the cauldron 2 and its extensions from the support 4 without having to cut them, this positioning device is preferably fixed to the first part 401 of the support 4, at a point on said first part 401 that is not a deposition surface 411, that is to say, it is fixed to a point on the support 4 on which it is not intended to spray composite material. This is preferably a face of the support 4 that represents an open face of the cauldron 2.

[0168] Optionally, the process according to the invention may also include a formation step E10 of a topcoat provided before the removal step E13 of the cauldron 2 equipped with the extensions 5. This formation step E10 of a topcoat includes a substep of spraying Eli of a liquid composition according to the invention on the last composite layer followed by a substep of drying E12 of said liquid composition.

[0169] This drying substep E12 for hardening the binder, for example by polymerization of the water-soluble polymer by evaporation of water, has the same characteristics as the drying step E08 previously described for a composite layer resulting from the formation step E05 of a composite layer.

[0170] This E10 formation step of a topcoat makes it possible, for example, to ensure that the last charge to have been sprayed adheres well to the binder, or is even completely embedded in it.

[0171] This E10 formation step of a topcoat can also be carried out by adding glass beads, in particular of micron dimensions, to the liquid solution in addition to the usual fillers to enhance abrasion resistance, on all or part of the external surface.

[0172] The advantages provided by adding glass beads to the liquid solution are given in the table below.

[0173] [Tables4] Advantages Details Improved Abrasion Resistance Glass beads increase the surface's abrasion resistance, extending the product's lifespan. Lightweight Glass beads are lightweight, preventing added weight to the material while improving its mechanical properties. Chemical Resistance Excellent resistance to many chemicals and solvents, preserving the coating's integrity. Aesthetics Glass beads are transparent or slightly opaque, not altering the bag's appearance. Anti-slip Properties They can improve surface grip and safety, reducing the risk of slipping. Environmentally Friendly The glass bead process is environmentally friendly and recyclable. Cost-Effective Glass beads are relatively inexpensive and can be recycled multiple times (up to 30 times).

[0174] The technical characteristics of the glass beads are given in the table below.

[0175] [Tables5] Technical Specifications Details Bead Size Generally between 0.05 mm and 1 mm (depending on the possible size of spray nozzles), depending on the desired application (smaller for a smooth finish, larger for a rough texture). Shape Spherical, which allows for uniform distribution within the material and reduces localized stress points. Density Approximately 2.5 g / cm³, which is relatively light compared to other materials used for reinforcement. Wear Resistance Glass beads are wear-resistant and maintain their effectiveness over the long term. Compatibility Compatible with various types of resins and coatings, including paints and epoxy resins.

[0176] The size of the beads can be adjusted according to the specific needs of the final product: • Microbeads (0.05 mm - 0.5 mm): For a softer finish and better integration into the material. • Medium beads (0.5 mm - 1 mm): Ideal for concealing imperfections while providing texture. • Large beads (1 mm - 2 mm): Used for applications requiring a rougher texture.

[0177] With a spray pressure of up to 100 bar, it is essential that the beads are sufficiently strong so as not to break during the application process.

[0178] Optionally, the process according to the invention may also include a stabilization step E14 of one or more layers of the constituent material of the cauldron 2 and extensions 5, for example carried out after a drying step E08, E12.

[0179] This stabilization step E14 comprises at least one of the following substeps: • a heat treatment; • plasma therapy; and / or • cross-linking by UV irradiation.

[0180] This stabilization step E14 of the cauldron 2 and the extensions 5 can, in particular, render inert the organic components of the charge that are liable to mineralize or degrade over time. This step can also be used to treat a surface of the cauldron 2 and / or the extensions 5 in order to functionalize it or modify its physicochemical properties, for example to waterproof it, to activate it, to clean it, to improve its adhesion, to control its final shrinkage or to impregnate it with an odorous, coloring, antifungal, antimicrobial or other substance.

[0181] A heat treatment consists, for example, of subjecting the cauldron 2 and its extensions 5 to a temperature between 50 and 90 °C for a period of between 5 and 30 minutes, depending on the nature and thickness of the layer being treated. This allows for control of the final shrinkage of the material in order to stabilize its dimensions. Indeed, a layer of the cauldron 2 and the extensions 5 is likely to absorb moisture after its manufacture, and this heat treatment therefore aims to achieve a short drying period for the cauldron 2 and the extensions 5 to ensure that they are free of moisture before their use or packaging for the purpose of manufacturing a bag.

[0182] Plasma treatment can, for example, be carried out using an atmospheric pressure plasma or a low-pressure plasma. An atmospheric pressure plasma operates at pressures close to atmospheric pressure, allowing for rapid and efficient treatment. It is preferably used for continuous applications, while a low-pressure plasma is generally operated at pressures between 0.1 and 1 Torr offers precise control over processing conditions. It requires longer exposure times but can use higher power levels.

[0183] The power used for plasma treatment varies depending on the type of plasma and the treatment objectives. It can range from a few watts to several kilowatts depending on the equipment and application, and is adjusted according to the type of material and the desired properties. For example, it is between 10 and 200 watts for atmospheric pressure plasma and between 100 and 1000 watts for low-pressure plasma. High power can improve the cleaning and functionalization of the treated cauldron 2 and / or extension 5 surface, but it must be balanced to avoid damaging the material. Indeed, excessive power is likely to cause thermal degradation of the load.

[0184] Just as with the applied power, the duration of exposure and the type of gas used (nitrogen, argon, etc.) for plasma treatment are crucial to optimizing results.

[0185] The exposure time is for example between 10 seconds and 10 minutes, while the gas used is chosen according to the desired effect and its chemical reactivity with the material of the cauldron 2 and the extensions 5.

[0186] The gases that can be used are as follows: • Oxygen (O2): used to improve the hydrophilicity of the filler fibers (e.g. polyester fibers). • Argon (Ar): used to increase the hardness of the fibers in the filler. • a fluorinated gas (e.g. CF4): makes surfaces hydrophobic, similar to PTFE. • a mixture of ethylene and propylene: used to obtain a cauldron 2 equipped with extensions 5 which is oleophilic. • Nitrogen (N2): used for specific treatments and to create an inert atmosphere.

[0187] Plasma treatment can be combined with the incorporation of a liquid, powder, microparticles, or nanoparticles. For example, hydrophobic treatment of a surface of the cauldron 2 and / or extensions 5 can be achieved by combining plasma treatment with the addition of hydrophobic agents to create an impermeable cauldron 2 and / or extensions 5. Similarly, plasma treatment can be combined with the incorporation of nanoparticles or antimicrobial agents to enhance the antibacterial and antifungal properties of the cauldron 2 and / or extensions 5.

[0188] Plasma treatment can modify the texture of a surface of the cauldron 2 and / or extensions 5, for example to prepare said surface before printing or bonding. In this case, plasma treatment can be used to increase the specific surface area available for adhesion, thus improving the performance of the applied coatings.

[0189] Plasma treatment is advantageous because it reduces the use of water and chemicals compared to traditional methods. Indeed, plasma treatment requires little or no water and reduces the use of organic solvents, thus minimizing the environmental impact of the process.

[0190] UV irradiation crosslinking consists of irradiating a layer with ultraviolet rays. This crosslinking can, for example, be achieved by free radicals or by cationic means. In both cases, UV protection is necessary to protect the skin and eyes.

[0191] Free radical crosslinking is based on the decomposition of a photoinitiator, releasing free radicals. It allows for a very rapid polymerization rate, on the order of a few seconds, but is sensitive to inhibition by oxygen. It generally promotes good adhesion of the treated layer, but its effectiveness depends on the composition of the photoinitiator and can be limited by the thickness of the layer. Thus, longer exposure times are necessary for thick materials. Free radical crosslinking uses a UV radiation power preferably between 200 and 400 mW / cm², for a duration preferably between 1 and 10 seconds, depending on the formulation and the thickness of the treated layer.

[0192] Cationic crosslinking is based on the formation of positive ions by UV irradiation. It allows for a polymerization rate that is slightly slower than free radical crosslinking, on the order of a few minutes, but is less sensitive to inhibition by oxygen. It generally promotes good chemical and thermal resistance of the treated layer, and its effectiveness is less affected by thickness than free radical crosslinking. Cationic crosslinking uses a UV radiation power preferably between 100 and 300 mW / cm², for a duration preferably between 10 and 60 seconds, depending on the formulation and thickness of the treated layer.

[0193] In the process according to the invention, crosslinking by free radicals is preferred because it is faster and suitable for the small thicknesses of the layers obtained during each spraying step.

[0194] Optionally, the method according to the invention may also include a step of applying pressure to the material of the boiler 2 and / or the extensions 5, for example before the stabilization step E14, to increase the mechanical properties of the composite layers and prevent their delamination. This pressure may, for example, be applied to the material of the boiler 2 and / or the extensions 5 by means of a counter-mold closely following the shape of support 4, while respecting the surface design of the part.

[0195] Optionally, after the removal step E13 of the cauldron 2 equipped with extensions, the process according to the invention may also include a finalization step E15 of at least one carrying element 3. This finalization step E15 aims to convert at least two extensions 5, 51, 52, 53, 54 into a carrying element 3 usable as such, preferably aesthetically finished and finalized.

[0196] The finalization step E15 comprises at least one of the following substeps: • rectification of the edges of at least one extension 5,51,52,53,54, in particular when it is in the form of a tab 501, a strip 502 or a flap 504; • padding of at least one extension 5,51,52,53,54 when it is hollow; • joining of at least two extensions 5,51,52,53,54 to form a carrying element 3.

[0197] If a flat extension 5 is obtained by spraying onto a rectangular strip-shaped portion of the support 4 during the finalization step El5 of at least one carrying element 3, said flat extension 5 can, for example, be formed into a carrying element 3, either immediately after its formation by spraying if the second part 402 and the third part 403 are connected together, or subsequently by connecting it to another extension 5, either directly or via another element, for example, a strap, a clip, an adjustment buckle, a belt buckle, a fastener, a clamp, a slide, a ring, etc. A flat extension 5 can be formed into a flat carrying element 3, for example, after grinding its lateral edges. It can also be formed into a cylindrical or prism-shaped carrying element 3 by rolling it up on itself at least once.However, it is simpler to manufacture it cylindrically directly by spraying. The edges of an extension 5, 51, 52, 53, 54 can, for example, be rectified by cutting and / or forming a hem.

[0198] If a hollow extension 5 is obtained by spraying onto the longitudinal faces (i.e., the faces other than the end faces) of a portion of the cylindrical, rectangular prism, or polygonal prism-shaped support 4 during the finalization step E15 of at least one carrying element 3, said hollow extension 5 may also be ground to remove any unwanted areas of material and / or be connected to another extension 5. During the finalization step E15, the hollow extension 5 may advantageously be padded with a padding material, for example, to form a more comfortable carrying element 3. The padding material may, for example, be foam, wadding, or fibers. recycled or not, a gel, a recycled or not textile, neoprene or a 3D printed structure. Once padded, a hollow extension 5 can for example be shaped by sewing, welding or gluing to give it a section whose shape is for example adapted to a shoulder strap 302, a handle 304, a strap 303, a belt or a grip 301.

[0199] The invention also relates to the cauldron 2 equipped with extensions 5 and obtained by the process, as well as the bag 1 obtained from this cauldron 2. This cauldron 2 equipped with extensions 5 and this bag 1 are particularly distinguished in that they comprise an alternation of layers of binder-based and filler material.

[0200] Depending on the nature of the liquid compositions used, these different layers of matter may be more or less bound to each other. They may also form a substantially homogeneous whole such that it is not possible to distinguish them.

[0201] The invention also relates to a method for producing a bag from the cauldron 2 equipped with extensions 5 obtained at the end of the preceding process. This method thus comprises a general step of finalizing a cauldron 2 equipped with extensions 5 to make it into a bag as such. This manufacturing step, which includes modifying a cauldron 2 equipped with extensions 5, notably includes a substep E15 of finalizing at least one carrying element 3 as described above. It may also include at least one of the following substeps involving the cauldron 2 equipped with extensions 5, preferably several: • assembly with another piece of textile, for example to create a compartment or a pocket; • assembly of a part of the cauldron 2 onto itself; • integration of an accessory; • cutting; • flocking; and • rectification of one or more edges.

[0202] The assembly substep according to the invention is preferably carried out by sewing, welding, or gluing. For gluing, the adhesive is preferably the same binder as that of the bonded coating in order to ensure chemical compatibility and recyclability.

[0203] Indeed, when the binder is thermoplastic, it is possible to assemble a part of the cauldron 2 onto itself or with another piece of textile by applying heat locally in an area where they overlap, for example at a temperature slightly above the melting temperature of the binder or by adding molten material between said parts.

[0204] Similarly, it is possible to use known sewing techniques or to use an adhesive suitable for the composite material of the cauldron 2 and the extensions 5 to assemble them, although the use of an adhesive comprising one of the sprayed binders is preferable.

[0205] It is also possible to assemble two pieces of sprayed composite material by connecting them mutually to a third piece of textile or composite material serving as a joining piece.

[0206] These assembly techniques can also be used to assemble a cauldron 2 equipped with extensions 5 onto itself.

[0207] It should be noted that the substeps of the modification step are not necessarily carried out in the order given above, and each may be carried out once, several times, or not at all. They are preferably carried out after the removal step El3 of the boiler 2 equipped with extensions 5 from the support 4 or, where appropriate, after the stabilization step E14 of the material of the part of the boiler 2 and the extensions 5. However, they may also be carried out before this step, in particular with regard to the substep of integrating an accessory, the cutting substep and the flocking substep.

[0208] The aforementioned sub-steps can be carried out in any order, therefore they are not illustrated in the form of a flowchart in the figures.

[0209] At the end of the production process of a cauldron 2 equipped with extensions 5, the latter can vary in shape, material, and dimensions depending on the desired end bag. However, it is preferably three-dimensional. The cauldron 2 can thus have a highly variable volume, for example, from 1 to 85 liters. In the case of a cauldron 2 for a backpack, its volume is, for example, approximately 10 liters.

[0210] At the end of said process, the cauldron 2 may already be a semi-finished bag 1, that is to say, a cauldron 2 equipped with extensions 5 which is already shaped into a bag but which requires some modifications, including rectification operations and possibly the addition of some accessories, at least one piece of textile or other elements, some cutting or other sub-steps before it can be a finished bag 1 and usable as such. Indeed, by semi-finished bag 1, we mean here a cauldron 2 equipped with extensions 5 which is in the general shape of a bag, but which requires finishing in order to be truly usable for marketing as a ready-to-use bag 1.

[0211] Examples of semi-finished bags 1 are illustrated in [Fig.4], [Fig.7], [Fig.10] and [Fig.13].

[0212] Modifications to a semi-finished bag 1 may include, in particular, a finalization substep E15 in which at least two extensions 5 are converted into a carrying element 3. Examples of semi-finished bags in which 5 extensions are converted into a 3-porting element, illustrated in [Fig.5], [Fig.8], [Fig.11] and [Fig.14].

[0213] Modifications to a semi-finished bag 1 may also include a substep of integrating an accessory onto a cauldron 2 or onto a semi-finished bag 1. This accessory may be a button, a hook, a zipper, a ribbon, a lace, an elastic band, a lining, a pocket, a flap, a decorative accessory, or any other element that may normally be present on a bag 1.

[0214] This substep of integrating an accessory can be carried out conventionally by sewing, but if technically possible, it is preferably carried out by covering at least part of said accessory between two composite layers during the manufacture of the cauldron 2 equipped with extensions 5. Indeed, this technique has many advantages over sewing, in particular that it is faster, more economical, more aesthetic, does not alter the sealing of the bag 1, facilitates final recycling and does not require any additional manual operation after the integration of an accessory by spraying.

[0215] The method for producing a bag 1 according to the invention may also include one or more sub-steps of cutting a cauldron 2 equipped with extensions 5 or a semi-finished bag 1, for example to form a buttonhole, a pocket, a slit, a vent or any other similar element of a bag 1 requiring the creation of an opening.

[0216] The method for producing a bag 1 according to the invention may also include one or more sub-steps of flocking a cauldron 2 equipped with extensions 5 or a semi-finished bag 20, for example in order to produce a side of the bag which is soft to the touch and which, depending on the length of the fibers, offers better heat and / or moisture management.

[0217] Similarly, one face of the bag 1 can be made so as to be waterproof, for example by a forming step E10 of a waterproof finishing layer.

[0218] In the case where it is desired that an external part of the bag 1 has satisfactory abrasion resistance, the composite layer of the latter may have a quantity of fibers and / or a thickness greater than those of the other layers.

[0219] It should be noted that in the case where bag 1 is produced upside down, its outer face is the first composite layer of the bag, while its inner face is the last sprayed composite layer.

[0220] The cauldron 2 and the extensions 5 obtained by spraying may have irregular edges and / or edges with a thickness that decreases towards the outside. The process for producing a bag according to the invention may therefore include one or more substeps of rectifying one or more edges of a cauldron 2 and / or the extensions 5.

[0221] Such a substep of rectifying an edge can, for example, be carried out by cutting said edge and / or by forming a hem in said edge. Such a hem can be sewn, welded or glued.

[0222] Finally, the invention relates to a bag 1 obtained by the process of producing a bag 1 according to the invention, which comprises at least one cauldron 2 equipped with a carrying element integrating two extensions 5 and comprising an alternation of layers of binder-based and filler material.

[0223] This bag 1 can also integrate various bag parts and accessories.

[0224] Because of the countless possible variations and the fact that a person skilled in the art knows what it looks like, no finished bag 1 is illustrated.

[0225] The implementation of the method for producing a cauldron 2 equipped with extensions 5 by spraying of the invention requires in particular the use of at least one spraying system 8, comprising one or more spraying units 9. Any suitable spraying system 8 can be used within the framework of the present invention.

[0226] For spraying a liquid composition and / or a charge comprising powder and / or loose fibers according to the invention onto the support 4, a suitable spraying unit 9 may include, but is not limited to, an air-based, airless or electrostatic-based sprayer, and may be, for example, in the form of a spray gun.

[0227] Besides the spraying unit 9, the spraying system 8 may also include one or more fluid displacement devices 10, tanks 11, flow and / or pressure regulators 12, supply pipes 13 and other components known in the art for spraying liquid products or bulk fibers.

[0228] A fluid displacement device 10 allows a liquid, powder, fibers, or composite material to be conveyed from a reservoir 11 to a spraying unit 9. In the case of a liquid or composite material, this is preferably a pump. In the case of a powder or fibers, this is preferably a compressor.

[0229] Each spray unit 9 is preferably variable flow to allow the creation of thicker bands or layers of product in the desired locations.

[0230] A spraying system 8 comprising several spraying units 9 makes it possible in particular to spray the desired quantities of product more quickly and / or to spray different products simultaneously.

[0231] Support 4 can be fixed or mobile.

[0232] The spraying system 8 may also include one or more positioning devices 14, for example in the form of a fixed, mobile and / or articulated foot, a robotic arm, a cobot 14a or any other suitable device known, allowing a spray unit 9 and / or the support 4 to be moved and oriented in space in a controlled and precise manner. If masks are used, each mask can also be associated with a positioning device 14.

[0233] The spraying system 8 may also include a controller 15 which adjusts, in particular, the position relationship between each spraying unit 9 and the support 4, and which adjusts in real time the flow rate of each spraying unit 9, notably in order to precisely control the position, arrangement, and thickness of the sprayed layers. An increase in thickness can be achieved by repeating the spraying on specific areas, by slowing down the movement on specific areas, or by increasing the flow rate of the sprayed product on specific areas.

[0234] The controller 15 can thus control each spraying unit 9, each fluid displacement device 10, each flow and / or pressure regulator 12, each positioning device 14 by means of control lines 17. It can also be connected to a probe provided in each of the tanks 11 in order to measure the quantity of material in each tank 11, and can in particular be provided to warn the operator when this quantity becomes low.

[0235] The controller 15 can also control the mask positioning device 14 if necessary.

[0236] In general, the controller 15 can be provided so as to automate or assist all or part of the production process of a cauldron 2 equipped with extensions 5 by spraying.

[0237] The controller 15 can be a computer, a terminal, a control cabinet, a workstation or any other electronic device, preferably programmable, capable of controlling each device of the spraying system 8, for example individually and in a particular sequence.

[0238] Each spraying unit 9 may include a single spray nozzle 16 (see [Fig. 3] and [Fig. 9]) or several (see [Fig. 6] and [Fig. 12]), the latter being oriented in the same direction or in different directions, for example converging towards a point located at an ideal spraying distance. Each spray nozzle 16 may spray the same material or different materials.

[0239] Each spray nozzle 16 can be provided to spray a liquid composition, fibers, a powder or a composite mixture according to the invention, each spray nozzle 16 being in particular connected to a suitable product reservoir 11 via a supply pipe 13.

[0240] In [Fig. 3], given by way of example, two spraying units 9, each comprising a single spray nozzle 16, are provided on either side of a support 4 shaped for the production of a tote bag 1. This support 4 comprises a first part 401 with a parallelepiped-shaped deposition surface 411 for the The formation of a parallelepiped-shaped cauldron 2, and four other rectangular strip parts 402, 403, 404, 405 with a deposition surface 412, 413, 414, 415 for the formation of extensions 5 in the form of strips 502 (see [Fig. 4]), these strips 502 being intended to be subsequently assembled in pairs to form the handles 301 of a semi-finished tote bag 1, 101 (see [Fig. 5]). In this example, the support 4 is mounted on a positioning device 14 articulated and rotatable about a vertical axis so that the two spraying units 9, themselves each mounted on an articulated positioning device 14, can spray their respective product onto the entirety of the deposition surfaces 411, 412, 413, 414, 415.In this example, having two spraying units 9 allows, for example, the spraying of two different products, either at the same time or one after the other, these two products each being a liquid composition, a filler, or a composite mixture of the two.

[0241] In [Fig. 6], also given by way of example, a single spraying unit 9 comprising two spray nozzles 16 is provided near a support 4 shaped for the production of a tote bag 1, each spray nozzle 16 being connected to its own reservoir 11. The support 4 comprises a first part 401 with a deposition surface 411 substantially cylindrical oval right for the formation of a cylindrical oval right, and two other parallel parts 402, 403 with a deposition surface 412, 413 for the formation of strip-shaped extensions 502 (see [Fig. 7]), the strips 502 being intended to be subsequently joined together and finished to form the shoulder strap 302 of a semi-finished tote bag 1, 102 (see [Fig. 8]). The support 4 and the spraying unit 9 are each mounted on an articulated positioning device 14.In this example, having two spray nozzles 16 allows, for example, two different products to be sprayed with a single spray unit 9, either at the same time or one after the other, these two products each being a liquid composition, a filler, or a composite mixture of the two.

[0242] In the example illustrated in [Fig.9], a single spraying unit 9 comprising a single spray nozzle 16 is provided near a support 4 shaped for the production of a backpack-type bag 1. This support 4 comprises a first part 401 with a right circular cylindrical deposition surface 411 for forming a right circular cylindrical cauldron 2, and four other parts 402, 403, 404, 405, of which two rectangular strip parts 402, 403 have a deposition surface 412, 413 for forming first and second extensions 5, 51, 52 in the form of tabs 501, and two right circular cylindrical parts 404, 405 have a deposition surface 414, 415 for forming third and fourth extensions 5, 53, 54 in the form of hollow tubes 503 (see [Fig. 10]), these tabs 501 and hollow tubes 503 being intended to be subsequently assembled in pairs to form the Two shoulder straps 303 of a semi-finished backpack 1,103 (see [Fig. 11]). The support 4 and the spray unit 9 are each mounted on an articulated positioning device 14. This assembly, having only one spray nozzle 16, is preferably intended for spraying a composite mixture comprising a liquid composition and a filler.

[0243] Finally, in the example illustrated in [Fig. 12], a single spraying unit 9 comprising three spray nozzles 16 is provided near a support 4 shaped for the production of a flap-type handbag 1. This support 4 comprises a first part 401 with an oval cylindrical deposition surface 411 for the formation of an oval cylindrical cauldron 2, and three other parts 402, 403, 404, of which two parts 402, 403 are rectangular strips with a deposition surface 412, 413 for the formation of a first and second extensions 5, 51, 52 in the form of strips 502 and a part 404 in the form of a domed plate with an approximately convex rectangular deposition surface 414 for the formation of a third extension 53 in the form of a flap 504 (see [Fig. 13]). The 502 strips are intended to be joined together to form a handle 304 and the flap 504 is intended to form the flap 6 of a semi-finished handbag 1,104 (cf. [Fig.14]).The support 4 and the spraying unit 9 are each mounted on an articulated positioning device 14. This assembly, having only one spray nozzle 16, is preferably intended for spraying a composite mixture comprising a liquid composition and a filler.

[0244] The example illustrated on [Fig. 12] will be described in greater detail later in an example of implementation of the method of the invention.

[0245] It should be noted that the examples illustrated in [Fig. 3] to [Fig. 14] are highly schematic and do not necessarily represent reality. In the examples illustrated in [Fig. 3], [Fig. 6], and [Fig. 9], each spray nozzle 16 is connected to a single, dedicated reservoir 11. It is also possible to provide several reservoirs 11, each containing, for example, a different liquid composition and / or charge, which can be connected as needed to the same spray nozzle 16 by means of a quick-connect system. Each spray nozzle 16 can also be connected to several reservoirs 11, for example, via a multiport valve 18, as illustrated in [Fig. 12].

[0246] In order to control the air quality, ambient temperature and humidity, the means of the invention, in particular the spraying system 8 and the support 4, can be housed in an enclosure 19. Due to the possible presence of robot(s), access to this enclosure 19 can be secured. EXAMPLES OF ACHIEVEMENTS

[0247] Examples of liquid compositions

[0248] Six examples of liquid compositions according to the invention are given in the table below. The percentage of each component is given by weight relative to the total mass of the liquid composition.

[0249] [Tableauxô] % by weight LIQ1 LIQ2 LIQ3 LIQ4 LIQ5 LIQ6 Binder: Bio-based polylactic acid 13% 45% 40% Binder: Natural plant-based latex 30% 40% 45% 40% Additive: Magnesium sulfate 1% 5% 1% 24% 2% 1% Bridging agent 10% 10% 24% Pigment: Azorubine dye El32 2% 5% 2% 1% 3% 5% Viscosity agent: Potato dextrose 25% Adhesive agent: α-1,4-α-α,6-glucan (pullulan) 22% Aqueous solvent: Water 44% 40% 30% 30% 30% 30% Total 100% 100% 100% 100% 100% 100%

[0250] Examples of loads

[0251] Six examples of loads according to the invention are given in the table below. The percentage of each component is given by weight relative to the total mass of the load.

[0252] [Tables?] % by weight CH1 CH2 CH3 CH4 CH5 CH6 Fur fibers (bio-based) 30% 55% 35% 40% 15% Limestone powder (bio-based) 40% 60% 30% 30% 35% Synthetic polyurethane fibers 30% 40% 45% 35% 30% 50% Total 100% 100% 100% 100% 100% 100%

[0253] Examples of composite layers

[0254] Six generic examples of composition for a composite layer according to the invention are given in the table below. The percentage of each component is given by weight relative to the total mass of the composite layer before it dries.

[0255] [Tables8] % by weight CCG1 CCG2 CCG3 CCG4 CCG5 CCG6 Non-bio-based binder 15% 30% 10% 40% 10% Bio-based binder 15% 10% 32% 33% 5% 37% Non-bio-based filler 15% 18% 10% 13% 18% 24% Bio-based filler 15% 12% 20% 21% 12% 6% Coalescing agent 1% 0.1% 5% 3% 0.1% 2% Water 39% 29.9% 23% 30% 29.9% 21% Total 100% 100% 100% 100% 100% 100%

[0256] Three specific examples of compositions for a composite layer according to the invention are given in the table below. The percentage of each component is given by weight relative to the total mass of the composite layer before it dries.

[0257] [Tables9] % by weight CCI CC2 CC3 Bio-based binder: Vytex® 20% 20% Bio-based binder: Impranil® 2611 / 1 30% Bio-based binder: Impranil® DLU 40% 35% Non-bio-based filler: synthetic polyurethane fibers 13% Bio-based filler: calcium carbonate powder 3% 2% 15% Bio-based filler: Agaricus bisporus mycelium powder 18% Coalescing agent: ethylene glycol monoethyl ether acetate 7% 2% 5% Water 30% 30% 30% Total 100% 100% 100%

[0258] In this table, the CCI example relates to a first mixed layer intended to be an inner layer of the cauldron 2 and extensions 5, not comprising fibers, but comprising both Vytex® and Impranil® DLU in order to be pleasant to the touch and breathable for comfort when carrying.

[0259] Example CC2 relates to a second layer intended to be an intermediate layer between the cauldron 2 and the extensions 5, comprising Impranil® DLU, mycelium powder, and polyurethane fibers to act as a shock-absorbing layer, protecting the contents of bag 1 while being durable and compatible with the other layers CCI and CC3 to prevent delamination due to chemical incompatibility. The mycelium powder provides an ecological dimension, while the synthetic polyurethane fibers add strength.

[0260] Finally, example CC3 concerns a third layer which is of the rubber + filler type composed of Impranil® DL 2611, Vytex® and calcium carbonate in order to be weather-resistant while offering flexibility and comfort. The calcium carbonate reinforces the structure while maintaining a light weight.

[0261] Using the device illustrated in [Fig. 12], these three layers are sprayed in the order above to directly form a three-dimensional casing 2 equipped with two extensions 5, which can be used to manufacture a flap-type handbag 1 after a final assembly step comprising various modification steps for attaching the straps, buckles, and options. The composite layers CCI, CC2, and CC3 contain bio-based fillers to reduce environmental impact, while ensuring the expected performance properties of a bag, such as weather resistance, flexibility, and comfort.

[0262] The parameters for the formation of these three layers are given in the table below.

[0263] [TableauxlO] CCI parameter CC2 CC3 Spraying time 2x2 minutes 2x2+1 minutes 2x2 minutes Spraying pressure 70 bar 80 bar 70 bar Thickness 0.5 mm 0.5 mm 0.5 mm Drying temperature 90 °C 90 °C 90 °C Drying time 2 to 5 minutes 2 to 5 minutes 2 to 5 minutes

[0264] Example of implementation of the process

[0265] An example of implementing the method of the invention according to the invention is given below for the manufacture of a three-dimensional cauldron 2 equipped with extensions 5 which can be used for the manufacture of a bag 1 of the flap handbag type.

[0266] A complete cleaning of the equipment used is carried out beforehand, in particular the spraying systems 8. The working environment must be clean to guarantee the quality of spraying (no fibers, clean surfaces, controlled and filtered air quality to eliminate foreign particles).

[0267] Temperature and humidity are controlled at 20°C and 80% respectively.

[0268] The equipment used is housed in an enclosure 19. It consists of the following equipment. Its number is also indicated in parentheses. • 19" enclosure measuring 4.10 x 5.40 x 2.40 m including lighting, security door and window, camera, security sensors and door closing contact (xl). • Enclosure air filtration devices (x4). • Air conditioning and humidity control device for the enclosure (xl). • 9 spray units (x3) • Spray nozzles 16 (x3) equipping the spray unit 9, comprising two nozzles 16a, 16b adapted for spraying a composite mixture and one nozzle 16c adapted for spraying loose fibers. • Tanks 11 (x3), including two tanks 1 la,l 1b for liquid composite mixture and one tank 1 le for loose fibers. • Multi-way valve 18, in the form of a mixing solenoid valve, suitable for connecting each spray nozzle 16a, 16b, 16c to one of the tanks 11a, 11b, 11c. • Fluid displacement device 10 (x3) each associated with one of the reservoirs 11 to supply the multi-way valve 18 with fluid, two fluid displacement devices 10a, 10b being pumps connected to the reservoirs 11a, 11b for composite mixture, while the last fluid displacement device 10c is a compressor connected to the reservoir 1 for fibers. • Flow and / or pressure regulators 12 (x3) in the form of solenoid valves 12a, 12b, 12c each associated with one of the fluid supply lines of the multi-way valve 18 from the tanks 1 la, l lb, l le. • Polymer supply pipes 13 (x3) each connecting the multi-way valve 18 to a spray nozzle. • Polymer supply pipes 13 (x3) each connecting a tank 11, to the multiport valve 18, as well as to the flow and / or pressure regulator 12 and the associated fluid displacement device 10. • Positioning device 14 (xl) for the spraying unit 9 in the form of a cobot 14a. • Support 4 (xl) comprising a part 401 for the formation of an oval cylindrical cauldron 2, two parts 402,403 in rectangular strip for the formation of strips 502 and a part 404 in the form of a plate for the formation of a flap 504. • Positioning device 14 (xl) for support 4 in the form of an articulated arm 14b. • Drying system (xl). • Plasma processing unit (xl). • Controller 15 (xl), in the form of a control cabinet for the spray units 9, the multi-way valve 18, the solenoid valves 12a, 12b, 12c, the fluid pumps 10a, 10b, the compressor 10c, the cobot 14a and the articulated arm 14b with a touch screen, synchronizing in particular the articulated arm 14b and the cobot 14a. • Electrical cabinet (xl) and electrical cables to supply the various devices with electricity.

[0269] For clarity of figures, only part of this equipment is illustrated schematically and in a simplified manner on [Fig. 12].

[0270] As a reminder, a cobot, or collaborative robot, is a robot designed for direct human-robot interaction within a space where humans and robots are in close proximity.

[0271] To prepare a three-dimensional cauldron 2 equipped with two extensions 5, three composite layers CCI, CC2, and CC3 are required, as well as a volumetric support 4 to receive the prepared solutions. The composition of these three composite layers CCI, CC2, and CC3 is given in the preceding Table 9. The support 4 is, for example, such as the one illustrated in [Fig. 12] and described previously.

[0272] In this example, the support 4 is mounted on an articulated arm 14b, while the spraying unit 9 is mounted on a cobot 14a. The cobot 14a and the articulated arm 14b are synchronized so that all movements of the support 4 and the spray nozzles 16a, 16b, 16c are perfectly coordinated.

[0273] The support 4 is made of TPU using 3D printing, which offers versatility and responsiveness for testing numerous design and size options. This also provides control over the overall cost and weight of the cauldron 2 and extensions 5, which are lighter than if they were made using injection molding. The head and arms are removable. The support 4 is coated with silicone to facilitate demolding of the cauldron 2 and extensions 5 after the various spraying processes.

[0274] In this example, we assumed that five liters of composite material (liquid composition + filler) for spraying would be required. To facilitate the start-up of the installation and to achieve the required pressure and homogeneous spraying conditions, 10 liters of composite material were produced. Indeed, to ensure a constant supply pressure to the spraying units, it is important to have enough solution to prevent the pumps from cavitating.

[0275] The composition by weight (Kg) for each layer is given in the table below

[0276] [Tableauxll] Weight in kg CCI CC2 CC3 Bio-based binder: Vytex® 2.00 2.00 Bio-based binder: Impranil® 2611 / 1 3.00 Bio-based binder: Impranil® DLU 4.00 3.50 Non-bio-based filler: synthetic polyurethane fibers 1.30 Bio-based filler: calcium carbonate powder 0.30 0.20 1.50 Bio-based filler: Agaricus bisporus mycelium powder 1.80 Coalescing agent: ethylene glycol monoethyl ether acetate 0.70 0.20 0.50 Water 3.00 3.00 3.00 Total 10.00 10.00 10.00

[0277] The preparation of the mixtures for the first CCI composite layer, which is the layer that will be sprayed first (inside the bag), is carried out by the following steps: • draining and cleaning of the three tanks 1 la, l lb, l le, of the pumps 10a, 10b, of the compressor 10c and of the spraying unit 9, in particular of the three spray nozzles 16a, 16b, 16c, although only one will be used here, namely the first spray nozzle 16a suitable for spraying a composite mixture; • weighing of the two binders, i.e. 2 kg of Vytex® and 4 kg of Impranil® DLU respectively; • weighing of the water, divided into two equal volumes, i.e. 1.5 kg each; • weighing of the bio-based feed (calcium carbonate powder) divided into two equal volumes, i.e. 0.15 kg each; • weighing of the coalescing agent (ethylene glycol monoethyl ether acetate) divided into two equal volumes, i.e. 0.35 kg each; • mixture of 2 kg of Vytex® with 1.5 kg of water, 0.35 kg of coalescing agent, and 0.15 kg of bio-based filler, i.e.: 2 + 1.5 + 0.35 + 0.15 = 4 kg of a first mixture designated as Ml; • mixture of 4 kg of Impranil® DLU 1.5 kg of water, 0.35 kg of coalescing agent, and 0.15 kg of bio-based filler, i.e.: 4 + 1.5 + 0.35 + 0.15 = 6 kg of a second mixture designated as M2; • filling the first tank 1 with 4 kg of the Ml mixture; and • filling the second tank 11b with the 6 kg of mixture M2.

[0278] The contents of the two reservoirs 1a,l 1b are summarized in the table below:

[0279] [Tables 12] Weight in kg CCI Tank lia Tank 11b Bio-based binder: Vytex® 2.00 2.00 Bio-based binder: Impranil® 2611 / 1 Bio-based binder: Impranil® DLU 4.00 4.00 Bio-based filler: calcium carbonate powder 0.30 0.15 0.15 Coalescing agent: ethylene glycol monoethyl ether acetate 0.70 0.35 0.35 Water 3.00 1.50 1.50 Total 10.00 4.00 6.00

[0280] The different parts 401, 402, 403 of the support 4 are assembled, the part 401 for the formation of a cauldron 2 being fixed to the free end of the arm of the cobot 14a, while the two parts 402, 403 in rectangular strip for the formation of tabs 501 and the part 404 in the form of a plate for the formation of a flap 504 are screwed onto the part 401 for the formation of a cauldron 2.

[0281] A trial adjustment of the spraying system is then carried out. For this purpose, the two pumps 10a, 10b connected to the first and second tanks 11a, 11b are started up, the spraying unit is first supplied with compressed air at 4 bar to ensure that the first and second spray nozzles 16a, 16b are not obstructed so that with the settings of the spraying unit 9, there are no impacts on homogeneity when the spraying unit 9 is moved by the cobot 14a from one surface to be sprayed to another, whether it is in volume or not.

[0282] After this, the work program of the spraying unit is defined for a first pass. With the support 4 positioned, the collaborative work function of the cobot is used. The spraying unit is positioned on the cobot arm. The operator's experience allows for the definition of a trajectory suitable for spraying the composite mixture all around part 401 to form a cauldron 2 and on parts 402,403 in rectangular strip for the formation of tabs 501 and part 404 in the form of a plate for the formation of a flap 504.

[0283] To do this, the operator manually moves the spray unit 9 in the space all around part 401 to form a cauldron 2, while also passing over the other parts 402, 403, 404 of the support 4. When this step is completed, the trajectory is recorded. One step consists of verifying this trajectory by running the cobot without a load until an OK signal is obtained. This OK is confirmed by adding compressed air to the spray nozzles 16a, 16b, 16c to ensure the correct distance of each nozzle from the different deposition surfaces 411, 412, 413, 414. Flour, previously deposited using a fine mesh sieve (120 mesh nylon filter), is used on the surfaces to be sprayed to observe, as the spray unit 9 passes over them with compressed air, whether the flour is properly cleaned, area by area. As long as this is not the case, the trajectory is optimized directly within the program.

[0284] To continue, the work program of the spray unit 9 is defined for a second pass at 90° to the first pass, in order to achieve an isotropic effect. The support remains in the same position as before. The spray unit 9 is positioned on the arm of the cobot 14a, oriented at 90° to its previous orientation. The operator's experience allows them to define a trajectory suitable for spraying the composite mixture. To do this, the operator manually moves the spray unit 9 in space to cover all the deposition surfaces 411, 412, 413, 414 to be sprayed. When this step is completed, the trajectory is recorded. One step consists of verifying this trajectory by running the cobot 14a without a load until an OK signal is obtained.This OK is confirmed by adding compressed air to the spray nozzles 16a, 16b, 16c to ensure the correct distance between the spray nozzles and the deposition surfaces 411, 412, 413, 414. Flour, previously deposited using a fine mesh sieve (120 mesh nylon filter), is applied to the surfaces to be sprayed. When the spray unit 9 passes over the surfaces with compressed air, it is observed whether the flour is properly cleaned. If this is not the case, the trajectory is optimized directly in the program.

[0285] The following table summarizes the parameters of the experiments carried out and the results obtained:

[0286] [Tables 13] Spray power (W) Nozzle diameter (mm) Spray flow rate (ml / min) 410-600 0.5 100-150 600-800 0.8 200-300 800-1200 1 to 2 300-500 Spray distance (cm) Spray duration (min) Number of passes 20-30 10-15 3-4 15-20 5-10 2-3 10-15 3-5 1-2

[0287] Spray power: pump power, which influences flow rate and pressure, affecting spray quality.

[0288] Spray nozzle diameter: a smaller diameter allows for finer spraying, while a larger diameter increases flow rate and coverage.

[0289] Spray flow rate: measured in ml / min, it indicates the quantity of composite mixture sprayed per minute.

[0290] Spraying distance: distance between the spray nozzle and the deposition surfaces, generally between 10 and 30 cm depending on the type of application.

[0291] Spraying time: time required to cover the deposit surfaces, depending on the flow rate and the number of passes.

[0292] Number of passes: number of layers required to obtain uniform coverage, often recommended between 1 and 3 depending on the type of composite mixture sprayed and the condition of the deposition surfaces.

[0293] In this example, the composite mixture is quite viscous and the parameters chosen for the two passes are as follows: • Spraying power: 1200 Watts • Nozzle diameter: 1 mm • Spray rate: 500 ml / min • Spraying distance: 15 cm • Spraying time: 2 minutes per pass • Number of passes: 2

[0294] At that time, we therefore have two prepared composite mixtures M1 and M2 contained respectively in the first tank 11a and in the second tank 11b, the support 4 positioned, two trajectories validated in empty and validated spraying parameters.

[0295] The pumps 10a, 10b and the solenoid valves 12a, 12b associated with them are suitable for supplying the first nozzle 16a with the two mixtures M1,M2, the first nozzle 16a being adapted for spraying the CCI layer, that is to say that the diameter of the first nozzle 16a as well as the pressure are chosen as specified above.

[0296] With the prepared composite mixtures M1 and M2 mixed in the multiport valve 18, spray tests are then carried out via the first nozzle 16a onto an adjacent surface to prime the pumps 10a, 10b and ensure that the flow rate is constant. The solenoid valves 12a, 12b and the pumps 10a, 10b are controlled to guarantee a homogeneous mixture. It is also verified that the composite mixtures M1 and M2 are available for spraying.

[0297] The spraying program is now initiated with two spray passes using the M1+M2 mixtures through the first nozzle 16a to cover all the deposition surfaces 411, 412, 413, 414, in two opposite directions. For each spray of the CCI layer, the spraying time is 2 minutes per pass, with a spraying pressure of 70 bar.

[0298] This spray program is followed by drying the CCI layer at 90 °C with hot circulating air for 2 minutes.

[0299] The first composite layer CCI of a cauldron 2 equipped with two tabs 501 and a flap 504 is then available, and the second composite layer CC2 is deposited. To do this, the material is prepared as indicated below.

[0300] The preparation of the mixtures for the second composite layer CC2, which is the intermediate layer, is carried out by the following steps: • draining and cleaning of the first and second tanks 1a,l 1b, of the two pumps 5a,5b and of the spraying unit 9, in particular of the two nozzles 16a, 16b adapted for spraying a composite mixture, even if only one will be used here, as well as the nozzle 16c adapted for spraying loose fibers which has already been cleaned; • weighing of the binder, i.e. 3.5 kg of Impranil® DLU divided into two equal volumes i.e. 1.75 kg each; • weighing of the water, divided into two equal volumes, i.e. 1.5 kg each; • Weighing of the bio-based feedstock (0.2 kg of calcium carbonate powder) and 1.8 kg of Agaricus bisporus mycelium powder) divided into two equal volumes, i.e. 1 kg each; • weighing of the non-bio-based charge (1.3 kg of synthetic polyurethane fibers); • weighing of the coalescing agent (ethylene glycol monoethyl ether acetate) divided into two equal volumes, i.e. 0.1 kg each; • mixture of 1.75 kg of Impranil® DLU with 1.5 kg of water, 0.1 kg of coalescing agent and 1 kg of bio-based filler, i.e.: 1.75 + 1.5 + 0.1 + 1 = 4.35 kg of a first mixture designated as M3; • mixture of 1.75 kg of Impranil® DLU with 1.5 kg of water, 0.1 kg of coalescing agent and 1 kg of bio-based filler, i.e.: 1.75 + 1.5 + 0.1 + 1 = 4.35 kg of a second mixture designated as M4; • filling the first tank 1 with 4.35 kg of mixture M3; • filling the second tank 11b with 4.35 kg of M4 mixture; and • filling the third tank 1 with the 1.3 kg of synthetic polyurethane fibers.

[0301] The contents of the three tanks 1 la, l lb, l le are summarized in the table below:

[0302] [Tables 14] Weight in kg CC2 Tank 11b Tank 11c Bio-based binder: Impranil® DLU 3.50 1.75 1.75 Non-bio-based filler: synthetic polyurethane fibers 1.30 1.30 Bio-based filler: calcium carbonate powder 0.20 0.10 0.10 Bio-based filler: Agaricus bisporus mycelium powder 1.80 0.90 0.90 Coalescing agent: ethylene glycol monoethyl ether acetate 0.20 0.10 0.10 Water 3.00 1.50 1.50 Total 10.00 4.35 4.35 1.30

[0303] A trial adjustment of the spraying system is then performed with the second nozzle 16b, adapted for spraying the second composite mixture M3+M4. For this purpose, the pumps 10a, 10b connected to the two reservoirs 1a, 1b are started, and the spraying unit 9 is initially supplied with compressed air at 4 bar to ensure that the second nozzle 16b is not obstructed. The support 4 and all its parts 401, 402, 403, 404 remain in the position they were in for spraying the first CCI layer.

[0304] For the first pass, the same working program of the spraying unit is used as for the first CCI coat.

[0305] Similarly, for the second 90° pass, the same spray unit work program is used as for the first CCI coat.

[0306] The parameters chosen for the two passes are as follows: • Spraying power: 1000 Watts • Nozzle diameter: 2 mm • Spray rate: 400 ml / min • Spraying distance: 15 cm • Spraying time: 2 minutes per pass • Number of passes: 2

[0307] At that time, we therefore have two prepared composite mixtures M3 and M4, a non-bio-based filler in the form of synthetic polyurethane fibers, a support 4 whose deposition surfaces 411,412,413,414 are covered with the CCI layer, two validated trajectories in a vacuum and validated spraying parameters.

[0308] With the prepared composite mixtures M3 and M4 mixed in the multiport valve 18, spray tests are then carried out via the second nozzle 16b on an adjacent surface to prime the pumps 10a, 10b and ensure that the flow rate is constant. The solenoid valves 12a, 12b and the pumps 10a, 10b are controlled to guarantee a homogeneous mixture. Spray tests are also carried out with the synthetic polyurethane fibers via the third nozzle 11 on an adjacent surface to prime the compressor 5c and ensure that the flow rate is constant. Finally, it is verified that the composite mixtures M3 and M4 are available for spraying.

[0309] The CC2 layer spraying program is now launched. It begins with two spray passes using the M3+M4 mixture through the second nozzle 16b to cover all the deposition surfaces 411, 412, 413, and 414 in two opposite directions, thus creating the first layer of the CC2 layer. Next, a spray pass using the synthetic polyurethane fibers through the third nozzle 16c covers the first layer of the CC2 layer, creating the second layer. Finally, two more spray passes using the M3+M4 mixture through the second nozzle 16b cover the second layer of the CC2 layer, creating the final layer of the CC2 layer.

[0310] For each spraying, the spraying time is 1 minute per pass for the first layer, then 1 minute for the second layer and finally 1 minute per pass for the last layer, i.e. a total of 2xl + l + 2xl = 5 minutes, with a spraying pressure of 80 bars.

[0311] This spray program is followed by drying the CC2 layer at 90°C with hot circulating air for 2 minutes.

[0312] This step is completed by a stabilization treatment using an atmospheric plasma at 200 Watts for 1 minute. The gas used is oxygen O2 for improve the hydrophilicity of the filler fibers and ensure better adhesion to the polymer matrix.

[0313] The first and second composite layers CCI and CC2 of a cauldron 2 equipped with two tabs 501 and a flap 504 are then available, and the third and final composite layer CC3 is deposited. To do this, the material is prepared as indicated below.

[0314] The preparation of the mixtures for the third and final CC3 composite layer is carried out by the following steps: • draining and cleaning of all tanks 1 la, l lb, l le, of the three pumps 10a, 10b, 10c and of the spraying unit 9, in particular of the three spray nozzles 16a, 16b, 16c, although only one will be used here, namely the first spray nozzle 16a suitable for spraying a composite mixture; • weighing of the two binders, i.e. 2 kg of Vytex® and 3 kg of Impranil® DL 2611 / 1 respectively; • weighing of the water, divided into two equal volumes, i.e. 1.5 kg each; • weighing of the bio-based load, i.e. 1.5 kg of carbonate powder calcium, divided into two equal volumes, i.e. 0.75 kg each; • weighing of the coalescing agent (ethylene glycol monoethyl ether acetate) divided into two equal volumes, i.e. 0.25 kg each; • mixture of 2 kg of Vytex® with 1.5 kg of water, 0.25 kg of coalescing agent and 0.75 kg of bio-based filler, i.e.: 2 + 1.5 + 0.25 + 0.75 = 4.5 kg of a first mixture designated as M5; • mixture of 3 kg of Impranil® 2611 / 1 with 1.5 kg of water, 0.25 kg of coalescing agent and 0.75 kg of bio-based filler, i.e.: 3 + 1.5 + 0.25 + 0.75 = 5.5 kg of a second mixture designated as M6; • filling the first tank 1 with 4.5 kg of M5 mixture; and • filling the second tank 11b with 5.5 kg of M6 mixture.

[0315] The contents of the first and second reservoirs 1la, 11b are summarized in the table below:

[0316] [Tables 15] Weight in kg CC3 Tank 11a Tank 11b Bio-based binder: Vytex® 2.00 2.00 Bio-based binder: Impranil® 2611 / 1 3.00 3.00 Bio-based filler: calcium carbonate powder 1.50 0.75 0.75 Coalescing agent: ethylene glycol monoethyl ether acetate 0.50 0.25 0.25 Water 3.00 1.50 1.50 Total 10.00 4.50 5.50

[0317] A trial adjustment of the spraying system is then carried out. For this purpose, the two pumps 5a, 5b connected to the first and second reservoirs 1a, 1b are started, and the spraying unit is initially supplied with compressed air at 4 bar to ensure that the first and second spray nozzles 16a, 16b are not obstructed. The support 4 and all its parts 401, 402, 403, 404 remain in the position they were in for the spraying of the two previous coats C1 and CC2.

[0318] For the first pass, the same working program of the spraying unit is used as for the two previous coats CCI and CC2.

[0319] Similarly, for the second 90° pass, the same work program of the spraying unit is used as for the two previous coats CCI and CC2.

[0320] The parameters chosen for the two passes are as follows: • Spraying power: 1200 Watts • Nozzle diameter: 2 mm • Spray rate: 500 ml / min • Spraying distance: 15 cm • Spraying time: 2 minutes per pass • Number of passes: 2

[0321] At that point, we therefore have two prepared composite mixtures M5 and M6, of a support 4 whose deposition surfaces 411,412,413,414 are covered with the CCI and CC2 layers, of two validated trajectories in empty and of validated spraying parameters.

[0322] The pumps 5a, 5b and the associated solenoid valves 12a, 7b are suitable for supply the first nozzle 16a with the two mixtures M5,M6, the first nozzle 16a being adapted to spray the CC3 layer, that is to say that the diameter of the first nozzle 16a as well as the pressure are adjusted as specified above.

[0323] With the prepared composite mixtures M5 and M6 mixed in the mixing solenoid valve 13, spray tests are then carried out via the first nozzle 16a onto an adjacent surface to prime the pumps 5a, 5b and ensure that the flow rate is constant. The solenoid valves 12a, 7b and the pumps 5a, 5b are controlled to guarantee a homogeneous mixture. It is also verified that the composite mixtures M5 and M6 are available for spraying.

[0324] The spraying program is now launched with two spraying passes with the M5+M6 mixtures through the first nozzle 16a to cover all the volumes to be sprayed, in two opposite directions.

[0325] For each spraying of the CC3 layer, the spraying time is 2 minutes per pass, with a spraying pressure of 70 bar.

[0326] This spray program is followed by drying at 90 °C with circulating hot air for 2 minutes.

[0327] This step is completed by a stabilization treatment of the third composite layer CC3 once it is dry, using an atmospheric plasma at 200 Watts for 1 minute. The gas used is fluorinated gas CF4 to make the external surface more hydrophobic.

[0328] After drying and stabilization treatment, the cauldron 2 equipped with two tabs 501 and a flap 504 resulting from the superposition of the sprayed layers is demolded from the support 4. To do this, the two rectangular strip parts 402, 403 for the formation of strips 502 and the part 404 in the form of a domed plate for the formation of a flap 504 are unscrewed to remove them from the part 401 of the support 4 intended for the formation of a cauldron 2, then the cauldron 2 equipped with the extensions 5 is removed from the top of the part 401 of the support 4.

[0329] Various modification operations to the cauldron 2, equipped with two bands 502 and a flap 504, are necessary after these steps, including reinforcement and finishing steps. Thus, the two bands 502 are joined at their free ends by sewing, and their lateral edges are trimmed by hemming to form a handle 304. Similarly, the free edges of the flap 504 are trimmed by hemming to form a flap 6. A female magnetic button is sewn onto an external face of the cauldron 2, and a male magnetic button is sewn onto the internal face of the flap 504, so that the flap 6 can be locked onto the cauldron 2 when the latter is closed by said flap 6. The bottom of the cauldron 2, opposite its opening, is reinforced by bias tape sewn to the cauldron all around its bottom.Finally, a pouch is added to an external face of cauldron 2 by ultrasonic welding, said pouch being made from the same materials as those of cauldron 2 to guarantee perfect assembly compatibility.

[0330] The bag 1 thus obtained is then stored in the open air. Quality checks (dimensions, volume, weight) are carried out. It is then ready for sale.

[0331] Although described through a number of examples, variants and embodiments, the methods according to the invention include various variants, modifications and improvements which will be obvious to a person skilled in the art, it being understood that these variants, modifications and improvements form part of the scope of the invention.

Claims

1. Demands A method for producing a bag (1) comprising a cauldron (2) and at least one carrying element (3) comprising the following successive steps: supply (E01) of a support (4), of at least one liquid composition and of at least one charge to be sprayed onto said support (4), this supply step (E01) comprising the following sub-steps: • supply (E02) of at least one liquid composition comprising a binder and a solvent in which the binder is dissolved; • supply (E03) of at least one charge consisting of loose fibres and / or a powder; • supply (E04) of a support (4) in volume comprising a first part (401) having a deposit surface (411) having the general shape of a bag cauldron and at least a second and a third part (402,403) projecting from the first part (401) and each having a deposit surface (412,413) each having the general shape of an extension; formation (E05), on the deposition surface (411,412,413) of the first part (401) and of the second and third parts (402,403), of a composite layer consisting of a liquid composition and a filler resulting from the supply step (E01), this formation step (E05) comprising the following sub-steps: • spraying (E06) onto the deposition surfaces (411, 412, 413) of a liquid composition resulting from the supply step (E01); and • spraying (E07) onto the deposition surfaces (411,412,413) of a charge consisting of loose fibers and / or a powder resulting from the supply step (E01); • the spraying substep (E07) of a charge being simultaneous with or subsequent to the spraying substep (E06) of the liquid composition; drying (E08) of the resulting composite layer from the formation step (E05); - repetition (E09) at least once of the formation (E05) and drying (E08) steps of a composite layer, and formation, on the deposition surfaces (411,412,413) of the support (4), of a cauldron (2) equipped with at least two extensions (5,51,52) capable of forming at least one carrying element (3); and - removal (E13) of said cauldron (2) from the deposition surfaces (411,412,413) of the support (4).

2. A method according to claim 1, characterized in that, after the step of removing (El3) the cauldron (2), it comprises a finalization step (E15) of at least one carrying element (3), this finalization step (El5) comprising at least one of the following substeps: - rectification of the edges of at least one extension (5,51,52); - padding of at least one extension (5,51,52) when it is hollow; - joining of at least two extensions (5,51,52) to form at least one carrying element (3).

3. A method according to claim 1 or 2, characterized in that, during the substep of supplying (E04) a support (4), at least one deposition surface (412,413) among those of the second and third parts (402,403) of the support (4) is in the general form of a rectangular strip, a cylinder, a rectangular prism or a polygonal prism.

4. A method according to any one of the preceding claims, characterized in that, during the substep of supplying (E04) a support (4), at least a part (401,402,403) of said support (4) is demountable or removable.

5. A method according to any one of the preceding claims, characterized in that, during the drying step (E08), the support (4) is subjected to vibrations.

6. A method according to any one of the preceding claims, characterized in that, before the step of removing the cauldron (2) (E13), it comprises a step of forming (E10) a finishing layer on the composite layer resulting from the repetition step (E09), this formation step (E10) of a topcoat comprising the following successive substeps: - spraying (Eli) onto the deposition surfaces (411,412,413) of a liquid composition resulting from the supply step (E02) of at least one liquid composition; and - drying (E12) of the liquid composition sprayed during the previous spraying substep (Eli).

7. A method according to any one of the preceding claims, characterized in that at least one drying step (E08, E12) is carried out at room temperature.

8. A process according to any one of the preceding claims, characterized in that at least one drying step (E08, E12) is carried out at a temperature between 50 and 90 °C.

9. A process according to any one of the preceding claims, characterized in that after a drying step (E08, E12), it comprises a stabilization step (E14) of the cauldron material (2) and extensions (5), this stabilization step (E14) comprising at least one of the following substeps: - a heat treatment; - a plasma treatment; and / or - a crosslinking by irradiation.

10. A method according to any one of the preceding claims, characterized in that at least a part of one of the deposition surfaces (411,412,413) of the support (4) is textured in relief or intaglio.

11. A process according to any one of the preceding claims, characterized in that, during the supply substep (E02) of at least one liquid composition comprising a binder, said binder is water-soluble and said liquid composition comprises a water-based solvent in which the binder is dissolved, and the liquid composition is such that: - the binder comprises one or more water-soluble polymers, which represent 30 to 70% by weight of the liquid composition; - the water-based solvent comprises water representing 30 to 70% by weight of the liquid composition.

12. A process according to any one of the preceding claims, characterized in that, during the substep of supplying (E03) at least one charge consisting of loose fibers and / or a powder, at least 5% by weight of said charge is of bio-based origin.

13. A method according to any one of the preceding claims, characterized in that, during a formation step (E05) of a composite layer, the filler represents 30 to 60% by weight of said composite layer.

14. A method according to any one of the preceding claims, characterized in that, during a formation step (E05) of a composite layer, the weight-loading ratio in said composite layer is in the range between 2:1 and 1:

2.

15. A method according to any one of the preceding claims, characterized in that, during a formation step (E05) of a composite layer, a bio-based filler represents 5 to 50%, preferably 10 to 40% and more preferably 15 to 30% by weight of said composite layer.

16. A process according to any one of the preceding claims, characterized in that during the feed supply step (E03), 5 to 70%, preferably 10 to 60% and more preferably 20 to 50% by weight of the feed is of bio-based origin.

17. A process according to any one of the preceding claims, characterized in that during the feed supply step (E03), 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the bio-based feed consists of viscose fibers, cotton fibers, wool fibers, silk fibers, cashmere fibers, flax fibers, fur fibers, mammal hair, mycelium fibers, cellulose fibers, wood fibers, hemp fibers, mycelium powder, rice powder, wheat powder, wood powder, starch powder, alginate powder, carbon black powder, wheat flour, corn flour, millet flour, hemp flour, rapeseed flour, soybean hull powder, walnut hull powder, olive kernel powder, and soybean hull powder. cellulose nanofiber, polyamide powder or fibers, polypropylene powder or fibers,of polyethersulfone powder or fibers or polyurethane powder or fibers, taken alone or in mixtures.

18. A method according to any one of the preceding claims, characterized in that during the feed supply step (E03), 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the feed are made up of at least one bio-based material comprising at least 5% by weight of calcium, preferably at least 10% by weight of calcium.

19. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the binder comprises at least 10%, preferably at least 30% and more preferably at least 60% by weight of bio-based and / or biodegradable polymer.

20. A method according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of elastomer.

21. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of natural latex of vegetable origin, latex of vegetable origin treated to reduce its protein content, bio-based polylactic acid, bio-based thermoplastic polyurethane, bio-based polyurethane dispersion, rosin dispersion of vegetable origin, terpene dispersion of vegetable origin, bio-based acrylic polymer or polymer matrix hydrogel, taken alone or in mixture.

22. A method according to any one of the preceding claims, characterized in that, during the supply step (E02) of at least one liquid composition or during the supply step (E03) of a filler consisting of loose fibers and / or a powder, the liquid composition or the filler comprises a bridging agent capable of forming ionic and / or covalent bonds with binder.

23. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the feed comprises a coalescing agent whose quantity represents from 0.1 to 10%, preferably 1 to 5% by weight of the liquid composition.

24. A method according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, said liquid composition comprises at least one pigment.

25. A method according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, said liquid composition comprises a viscosity agent.

26. A method according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, said liquid composition has a dynamic viscosity between 0.1 and 10,000 rnPa.s at 20 °C.

27. ​​A method according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, said liquid composition comprises an adhesive agent.

28. Bag (1) comprising a cauldron (2) and at least one carrying element (3), characterized in that it comprises an alternation of layers of binder-based material and a filler comprising a powder and / or fibers, said bag (1) being a product resulting from the process according to any one of the preceding claims.

29. Bag (1) according to claim 28, characterized in that it is a handbag, a tote bag, a sports bag, a travel bag, a backpack, a satchel, a schoolbag, a briefcase, a fanny pack or a shopping bag.

30. Bag (1) according to claim 28 or 29, characterized in that a carrying element is a shoulder strap (302), a handle (304), a strap (303), a belt or a handle (301).

31. Bag (1) according to any one of claims 28 to 30, characterized in that the cauldron (2) has an average thickness of between 0.1 and 3 mm.

32. Spraying system (3) for carrying out the process according to any one of claims 1 to 27, characterized in that it comprises the following equipment: at least one spraying unit (4) equipped with one or more spray nozzles (11); at least fluid displacement device (5); at least one reservoir (6) containing: • a liquid composition comprising a binder and a solvent in which the binder is dissolved, • a powder charge, • a load in the form of loose fibers, taken alone or in mixtures; supply pipes (8) connecting at least one reservoir (6) to at least one fluid displacement device (5) and to at least one spray nozzle (11); at least one support (4) in volume comprising a first part (401) having a deposition surface (411) having the general shape of a bag cauldron and at least a second and a third part (402,403) projecting from the first part (401) and each having a deposition surface (412,413) each having the general shape of an extension, deposition surfaces (411,412,413) on which a cauldron (2) equipped with an extension (5) can be manufactured by spraying at least one fluid contained in a reservoir (6) and supplied by a fluid displacement device (5) to a spraying unit (4).

Images