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 Textile architectures (TA) 15’ Innovations in coated textiles 5’ advanced top coats based on design polymers incorporation of electronics thermochromic coated textiles

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!

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

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

We colour Production of pigment pastes inks varnishes colour dispersions

We coat Direct coating Transfer coating Online coating Extrusion coating Calendering

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.

Introduction to coated textiles

Introduction to coated textiles

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

Products and application areas

Textile architecture (TA)

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)

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.

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.

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)

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)

Light and colour transmission How it should NOT be :

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 92-503 (TA membranes have to classify as M2) German DIN 4102-1 (TA membranes have to classify as B1)

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

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

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

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

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

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)

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

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)

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

Incorporation of light EL lamps

Incorporation of light EL lamps

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

Incorporation of light LEDs …

Incorporation of light LEDs

Incorporation of light LEDs

Integration of photovoltaics (PV) TAPV BIPV

PV-integrated TA Powerfilm Solar Integrated FTL Solar

Thermochromic coated textiles