Presentation on theme: "Innovations in coated textiles"— Presentation transcript:
1Innovations in coated textiles Bert Groenendaal & Bram WydoogheSioen Coating NV (Belgium)MATA 09membránová a textilní architekturaBRNO – April 28, 2009
2Outline Introduction to Sioen coated textiles 15 ‘ coating products and application areasTextile architectures (TA) 15’Innovations in coated textiles 5’advanced top coats based on design polymersincorporation of electronicsthermochromic coated textiles
3Sioen at a glance Founded in 1960 Headquarters in Ardooie, Belgium 4 divisions: Coating, Apparel, Industrialapplications, and ChemicalsCa employeesTurnover of 349 Mio EUR in 200838 subsidiaries in 13 countriesSales in more than 80 countriesWorld market leader in coated textiles!
4We spin – extrude yansOne of the most modern spinning mills in the worldtons of polyester and/or polyamide high-tenacityyarnsFrom 245 Dtex to 6600 DtexHigh tenacity: 4 – 8 cN/DtexA part of the yarns is twisted in the twisting plant
5We weave Two plants in Belgium (Mouscron, Kerksken) 250 looms with airjet or rapier technologyFrom 150 up to 640 cm widthStandard and specialized (e.g. rashel) fabricsHigh tenacity fabrics: up to N/5cmFrom 28 Dtex (teabags; 20 g/m2) till 6600 Dtex yarns
6We colour Production of pigment pastes inks varnishes colour dispersions
7We coat Direct coating Transfer coating Online coating Extrusion coatingCalendering
8Introduction to coated textiles Also known as:technical textilestarpaulins or tarpsCoated textileswoven or knittednon-wovenpolyester (PES)aramideglassetc.PVC/plasticizerPUsilicone rubberetc.
11Introduction to coated textiles Example:B6000 tarpaulin from Sioen (e.g. truck side curtains)PVC coated PES in numerous colorsWeight: 900 g/m2Breaking strength:warp/weft: N/5 cmTear strength:warp 600 Nweft 500 NAdhesion: N/5 cmTemperature resistance: -30C till +70CFlammability: < 100 mm/minLong life due to coating: UV resistance/ impermeability, air tightnessEasy processing by high frequency or thermal welding
14Criteria for Textile Architectural PVC/polyester membranes Low wicking fabricsGood weldability/processabilityHigh tenacity PET yarns for good mechanical valuesLong lifeFire resistantUniform optical transmissionEasy cleaningOptimised topcoat (lacquer)
15LOW WICKING FABRICSIn 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.
16Mechanical valuesMembranes 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.
17PVC coating formulaPVC with low emulsifier content for good hydrophobic propertiesUV stable recipe by correct pigmentation and stabilisationIncorporation of best possible thermal stabiliser to avoid saponification and to improve weathering resistance.Non bleeding, non hydrolysable plasticizersNo water soluble componentsAll components with maximum purityOptimum whiteness degreeFine tuning of FR properties (type dependant)
18Light transmissionUniformity 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)
19Light and colour transmission How it should NOT be :
20Fire 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)
21Easy cleaningSpecial dirt repellent lacquer systems containing fluorinated polymersHigh amount of fluor(after one wipe)No fluor(after one wipe)
22Lacquer Fluor is necessary for easy cleaning Drawbacks of fluor : -transmits UV-adhesion issues-elasticity issues-non weldabletoo 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 technologiesThickness : too thick = brittle ; too thin = unsufficient protection
23Lacquer systems Pure acrylic : excellent overall properties Siofluo (standard TA lacquer) : small amount of fluor for dirt repellent effectFluomax : 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
24Minimum strength specifications for each type Type IType IIType IIIType IVFabric1100 dtex9 x 9L 1/112 x 12P 2/21670 dtex10,5 x 10,514 x 14P 3/3Tensile warp/weft (N/5 cm)3000/28004400/40005500/50007500/6500Tear warp/weft(N)300/300450/450800/8001000/1000Adhesion(N/5 cm)120
25Type II special construction : reinforced concrete domes Inflation of the PVC membraneSpraying PU insulation foam to the internal structure, embedding of tabs in the foamFixation of steel reinforcements along the wall.Spray application of concrete along the steel gridOnce the concrete has dried, the inflation fans can be turned off and openings (doors, windows) can be cut into the structure
26Innovations in coated textiles Easy cleaning surfaces for TAPET fabric coated withPVCsilicone rubberPUand subsequent top coat material (1K and 2K systems based on PU, acrylates, fluoropolymers, etc.)Dozens of products have been testedSioen easy cleaning testDesign polymers with advanced top coat properties via interactivedevelopments with various chemical partnersContex-T (EU project)
27Easy cleaning acceleration test 40 days at 70CContex-T (EU project)
28Innovations in coated textiles Top coat materials with easy cleaning propertiesTop coat materials with anti-graffiti propertiesTop coat materials with excellent UV blocking properties (liquidlaminates) => ROLACOATContex-T (EU project)
29Phosphorescent coatings Incorporation of lightLEDsEL lampsPhosphorescent coatings(glow in the dark)
32Incorporation of light LEDsIn contrast to electroluminescent lamps, LEDs require much less powerVarious types: single color LEDs, RGB LEDsLEDs 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