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Innovations in coated textiles

Innovations in coated textiles. Bert Groenendaal & Bram Wydooghe Sioen Coating NV (Belgium). MATA 09 membránová a textilní architektura BRNO – April 28, 2009. Outline. Introduction to Sioen coated textiles 15 ‘ coating products and application areas

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Innovations in coated textiles

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  1. Innovations in coated textiles Bert Groenendaal & Bram Wydooghe Sioen Coating NV (Belgium) MATA 09 membránová a textilní architektura BRNO – April 28, 2009

  2. Outline • Introduction to • Sioen • coated textiles 15 ‘ • coating products and application areas • Textile architectures (TA) 15’ • Innovations in coated textiles 5’ • advanced top coats based on design polymers • incorporation of electronics • thermochromic coated textiles

  3. Sioen at a glance • Founded in 1960 • Headquarters in Ardooie, Belgium • 4 divisions: Coating, Apparel, Industrial • applications, and Chemicals • Ca. 4.500 employees • Turnover of 349 Mio EUR in 2008 • 38 subsidiaries in 13 countries • Sales in more than 80 countries • World market leader in coated textiles!

  4. We spin – extrude yans • One of the most modern spinning mills in the world • 16.000 tons of polyester and/or polyamide high-tenacity • yarns • From 245 Dtex to 6600 Dtex • High tenacity: 4 – 8 cN/Dtex • A part of the yarns is twisted in the twisting plant

  5. We weave • Two plants in Belgium (Mouscron, Kerksken) • 250 looms with airjet or rapier technology • From 150 up to 640 cm width • Standard and specialized (e.g. rashel) fabrics • High tenacity fabrics: up to 10.000N/5cm • From 28 Dtex (teabags; 20 g/m2) till 6600 Dtex yarns

  6. We colour • Production of • pigment pastes • inks • varnishes • colour dispersions

  7. We coat • Direct coating • Transfer coating • Online coating • Extrusion coating • Calendering

  8. Introduction to coated textiles • Also known as: • technical textiles • tarpaulins or tarps Coated textiles • woven or knitted • non-woven • polyester (PES) • aramide • glass • etc. • PVC/plasticizer • PU • silicone rubber • etc.

  9. Introduction to coated textiles

  10. Introduction to coated textiles

  11. Introduction to coated textiles • Example: • B6000 tarpaulin from Sioen (e.g. truck side curtains) • PVC coated PES in numerous colors • Weight: 900 g/m2 • Breaking strength: • warp/weft: 4000 N/5 cm • Tear strength: • warp 600 N • weft 500 N • Adhesion: 100 N/5 cm • Temperature resistance: -30C till +70C • Flammability: < 100 mm/min • Long life due to coating: UV resistance/ impermeability, air tightness • Easy processing by high frequency or thermal welding

  12. Products and application areas

  13. Textile architecture (TA)

  14. Criteria for TextileArchitectural PVC/polyester membranes • Low wicking fabrics • Goodweldability/processability • High tenacity PET yarns for goodmechanicalvalues • Long life • Fire resistant • Uniform opticaltransmission • Easy cleaning • Optimisedtopcoat (lacquer)

  15. LOW WICKING FABRICS • In a normal polyester yarn, water (containing dirt and fungus) can be taken up by capillary action. When this phenomenon occurs, it will lead to dark marks over the tent structure, which cannot be removed. • By a special treatment, the yarns are made “low wick”, meaning they are less prone to excessive dirt take-up and to microbial attack. • Sioen’s TA-range is produced with special low wick treated yarns.

  16. Mechanical values • Membranes have to meet the specifications of the respective TA types (type I, II, III, …) • Fabric has to possesssufficientelongationcapability (both in warp and weft) for easy processing. • Reproduciblebiaxialbehaviour is important within and betweenvarious batches.

  17. PVC coating formula • PVC with low emulsifier content for goodhydrophobicproperties • UV stablerecipeby correct pigmentation and stabilisation • Incorporation of best possiblethermalstabiliser to avoidsaponification and to improveweatheringresistance. • Non bleeding, non hydrolysableplasticizers • No water solublecomponents • All componentswith maximum purity • Optimum whitenessdegree • Fine tuning of FR properties (type dependant)

  18. Light transmission • Uniformity of opticaltransmission is of utmost importance. • Coatingformula, weight and pigmentation have to remainstable over the wholeproduction. • Sioenuses a dedicatedapparatus for lighttransmission and colour measurement. • This machine measures the intensityand the colour of transmittedlight. • Possibility for on-linemeasuring (selectingidenticalopticalpropertiesinsideoneproduction)

  19. Light and colour transmissionHow it should NOT be :

  20. Fire resistance • EN 13501-1 does NOT apply for tents and membranes. • No Europeanlegislationapplies. Each country has itsown FR reglementation. • Most important standards in Europe: • French NF P 92-503 (TA membranes have to classify as M2) • German DIN 4102-1 (TA membranes have to classify as B1)

  21. Easy cleaning • Special dirtrepellentlacquersystemscontainingfluorinatedpolymers High amount of fluor (afteronewipe) No fluor (afteronewipe)

  22. Lacquer • Fluor is necessary for easy cleaning • Drawbacks of fluor : • -transmits UV • -adhesion issues • -elasticity issues • -non weldable • toomuch fluor : problematic !! • Acrylic is necessary for elasticity, UV blocking, adhesion, weldability. • goodformulation of lacquer is of extreme importance !! • Layeruniformity : lacquering in two stages ; different lacqueringtechnologies • Thickness : toothick = brittle ; toothin = unsufficientprotection

  23. Lacquer systems • Pure acrylic : excellent overall properties • Siofluo (standard TA lacquer) : small amount of fluor for dirt repellent effect • Fluomax : highly fluorinated binder system, with good long-term properties AND weldable. Sioen does not promote 100% fluorinated lacquer systems. These systems show excellent performance (dirt repellency) at first, but may have disadvantageous effects upon ageing

  24. Minimum strengthspecifications for each type

  25. Type II special construction : reinforced concrete domes • Inflation of the PVC membrane • Spraying PU insulation foam to the internal structure, embedding of tabs in the foam • Fixation of steel reinforcements along the wall. • Spray application of concrete along the steel grid • Once the concrete has dried, the inflation fans can be turned off and openings (doors, windows) can be cut into the structure

  26. Innovations in coated textiles • Easy cleaning surfaces for TA • PET fabric coated with • PVC • silicone rubber • PU • and subsequent top coat material (1K and 2K systems based on PU, acrylates, fluoropolymers, etc.) • Dozens of products have been tested • Sioen easy cleaning test Design polymers with advanced top coat properties via interactive developments with various chemical partners Contex-T (EU project)

  27. Easy cleaning acceleration test 40 days at 70C Contex-T (EU project)

  28. Innovations in coated textiles • Top coat materials with easy cleaning properties • Top coat materials with anti-graffiti properties • Top coat materials with excellent UV blocking properties (liquid • laminates) => ROLACOAT Contex-T (EU project)

  29. Incorporation of light LEDs EL lamps Phosphorescent coatings (glow in the dark)

  30. Incorporation of light EL lamps

  31. Incorporation of light EL lamps

  32. Incorporation of light • LEDs • In contrast to electroluminescent lamps, LEDs require much less power • Various types: single color LEDs, RGB LEDs • LEDs integrated textiles have been developed => Lumalive (Philips) • Problems: humidity, not wash resistant, etc. • Question: can the LED integrated textile survive the PVC coating process? RGB LEDs integrated in textile

  33. Incorporation of light • LEDs • … • …

  34. Incorporation of light LEDs

  35. Incorporation of light LEDs

  36. Integration of photovoltaics (PV) TAPV BIPV

  37. PV-integrated TA Powerfilm Solar Integrated FTL Solar

  38. Thermochromic coated textiles

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