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 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
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 N/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: N/5 cm
Tear strength:
warp 600 N
weft 500 N
Adhesion: 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 Textile Architectural PVC/polyester membranes
Low wicking fabrics
Good weldability/processability
High tenacity PET yarns for good mechanical values
Long life
Fire resistant
Uniform optical transmission
Easy cleaning
Optimised topcoat (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 possess sufficient elongation capability (both in warp and weft) for easy processing.
Reproducible biaxial behaviour is important within and between various batches.

17. PVC coating formula
PVC with low emulsifier content for good hydrophobic properties
UV stable recipe by correct pigmentation and stabilisation
Incorporation of best possible thermal stabiliser to avoid saponification and to improve weathering resistance.
Non bleeding, non hydrolysable plasticizers
No water soluble components
All components with maximum purity
Optimum whiteness degree
Fine tuning of FR properties (type dependant)

18. Light transmission
Uniformity of optical transmission is of utmost importance.
Coating formula, weight and pigmentation have to remain stable over the whole production.
Sioen uses a dedicated apparatus for light transmission and colour measurement.
This machine measures the intensity and the colour of transmitted light.
Possibility for on-line measuring (selecting identical optical properties inside one production)

19. Light and colour transmission How it should NOT be :

20. Fire resistance EN 13501-1 does NOT apply for tents and membranes.
No European legislation applies. Each country has its own FR reglementation.
Most important standards in Europe:
French NF P (TA membranes have to classify as M2)
German DIN (TA membranes have to classify as B1)

21. Easy cleaning
Special dirt repellent lacquer systems containing fluorinated polymers
High amount of fluor
(after one wipe)
No fluor
(after one wipe)

22. Lacquer Fluor is necessary for easy cleaning Drawbacks of fluor :
-transmits UV
-adhesion issues
-elasticity issues
-non weldable
too much fluor : problematic !!
Acrylic is necessary for elasticity, UV blocking, adhesion, weldability.
good formulation of lacquer is of extreme importance !!
Layer uniformity : lacquering in two stages ; different lacquering technologies
Thickness : too thick = brittle ; too thin = unsufficient protection

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 strength specifications for each type
Type I
Type II
Type III
Type IV
Fabric
1100 dtex
9 x 9
L 1/1
12 x 12
P 2/2
1670 dtex
10,5 x 10,5
14 x 14
P 3/3
Tensile warp/weft (N/5 cm)
3000/2800
4400/4000
5500/5000
7500/6500
Tear warp/weft
(N)
300/300
450/450
800/800
1000/1000
Adhesion
(N/5 cm)
120

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. Phosphorescent coatings
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