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Technology of coating and their applications in textile
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Coatings and their applications in textilesG. Buyle – MIICS 2012
G. Buyle - MIICS - 20120314
Textiles… various applications
G. Buyle - MIICS - 20120314
Outline
Introduction Centexbel
Basic textile coating Advanced coating techniques
Examples of applications
G. Buyle - MIICS - 20120314
Acknowledgements
Research at Centexbel on topic “smart textiles” enabled via several research projects
Acknowledgement of the funding agencies on different levels: Regional: IWT National: BELSPO European: FP6 and FP7 programmes
Acknowledgement of the numerous partners (both from academia and industry) worked with in these projects
G. Buyle - MIICS - 20120314
Outline
Introduction Centexbel Basic textile coating Advanced coating techniques
Examples of applications
G. Buyle - MIICS - 20120314
Centexbel: centre of competence
collective research and technical centre
membership organisation Belgian textile companies associated (international) member companies and
organisations
staff 140 skilled and highly educated men and women
G. Buyle - MIICS - 20120314
Research groups
Three domains: Functional thermoplastic textiles : compounding, extrusion, (bio)
polymers, nano-additives, textile reinforced composites,…
Textile functionalisation and surface modification: coating & finishing, sol gel, plasma treatment, lamination, hot melt,…
Health, safety & security : medical and bio-functional textiles, smart textiles, thermo-physiological comfort,…
G. Buyle - MIICS - 20120314
textile functionalisation and surface modification
Coating, finishing and surface modification for new and superior functional performance
textiles with multifunctional properties
modifying textile surfaces using coating, plasma functionalisation, UV curing, hot melt, sol gel,…
new sustainable technologies
G. Buyle - MIICS - 20120314
Testing laboratories
Laboratories (ISO 17025 accredited): Physical :
E.g. breathability, outdoor ageing
Chemical : E.g. chemical analysis, microscopy
Microbiological : E.g. antimicrobial effect, biodegradability
Fire : E.g. burning behaviour, smoke toxicity
Centexbel is recognized by large distribution companies, consumers’ associations, OEM’s, …
G. Buyle - MIICS - 20120314
(pre-)standardisation
Active participation/leading role in standardisation committees (CEN & ISO)
Sector operator Mirror committees Centexbel leads
WG31 “Smart Textiles”(in CEN TC248)
G. Buyle - MIICS - 20120314
Outline
Introduction Centexbel
Basic textile coating Advanced coating techniques
Examples of applications
G. Buyle - MIICS - 20120314
Vision: textile as flexible carrier foroffering specific functionalisation(s)
Fire Retardant
Breathable
Electrically conductive
Biocompatible
Antibacterial
Self cleaning
Anti abrasion
Light Reflection
Thermal insulation
Water repellencyFragrance release
Bioresponsive
G. Buyle - MIICS - 20120314
Three levels of coating fabrics
Fabriclevel
Yarnlevel
Filament/fibrelevel
Traditional coating
“Advanced”techniques e.g. plasma
coating
G. Buyle - MIICS - 20120314
Materials
Textile coating typically comprises 2 parts: Binder for durability
(washing, abrasion) Additives for functionality
Materials for binder: Polyacrylate Polyurethane Polyvinylchloride
Example nanoparticles for textile coating
NP
Matrix/binder
G. Buyle - MIICS - 20120314
Example: lamination of membrane in-between two textile fabrics
Membrane
Knitted fabric
Woven fabric
Coating
Coating
G. Buyle - MIICS - 20120314
Example: Fire Retardant coating for carpet
Coating application
G. Buyle - MIICS - 20120314
Carpet coating analysis via XRF mapping
Ti
Br
Sb
S
Carpet structure FR additives
G. Buyle - MIICS - 20120314
Example: PVC coated polyester fabric
Textile architecture Tarpaulins for trucks
G. Buyle - MIICS - 20120314
Classical techniques:
Wet techniques: Formulation: solvent or water based Application unit: padding/ immersion,
knife coating, transfer coating, foam coating,…
Typical add-on: 20-50g/m2
Multitude of advantages: Robust Large scale Relatively simple equipment
Immersion
Mayer bar
G. Buyle - MIICS - 20120314
Classical techniques: typical coating line
Wet technique → need for ovens → energy issue
“Long” → only profitable for large batches
G. Buyle - MIICS - 20120314
Search for novel techniques because of drawbacks/limitations
Drivers: Economy:
ability to run smaller production batch sizes → “digital” reduce energy use → “dry techniques”
Performance: minimal thickness or add-on accuracy, uniformity
Ecology: more healthy products (e.g. prevention of phthalates) use of bio-based and/or bio-degradable
G. Buyle - MIICS - 20120314
Hot melt: basics
Hot melt: 100% system
(granulates, blocks,…) Melting of the polymer Application as melt Solidifying → Coating Materials: PE, PP, PES, PA,
EVA, TPU, silicone
Two main groups (curing based): Thermoplastic hot melts:
Solidifying via cooling Reactive hot melts:
Solidifying via cooling + drying or UV irradiation
Source: www.robatech.com
G. Buyle - MIICS - 20120314
UV curable coatings
UV
IR
Coating application
IR sourceUV source
Curing
Textile substrate
G. Buyle - MIICS - 20120314
Polyolefine-coatings (1/2) POD = po lyolefine dispersion in water, suitable
for “standard” application techniques
Source: Dow
G. Buyle - MIICS - 20120314
Polyolefine-coatings (2/2)
PODs have unique advantages: Solvent-free solution High solid content (typically 40 to 55 wt%) Functionalisation possible
Functionalisation: Possible to mix in active components Examples: FR, antimicrobial, conductive
Goal: replace some of the PVC applications (prevention of phthalates)
G. Buyle - MIICS - 20120314
Outline
Introduction Centexbel
Basic textile coating
Advanced coating techniques Examples of applications
G. Buyle - MIICS - 20120314
Advanced coating techniques
ALD Evaporation Magnetron sputtering
Atmospheric Plasma coating
G. Buyle - MIICS - 20120314
Deposition via ALD: Atomic Layer Deposition Process at low pressures
(in vacuum chamber)
→ highly conformal coatings
Advantages for textile: Example: ALD deposition on cotton fibres
→ Extremely high conformality→ Possibility to have anti-corrosion layer
Cross section: cotton fibre with ALD coating
Source: Hyde et al.
ALD technique - introduction
ALD technique
Standard technique
G. Buyle - MIICS - 20120314
ALD deposition into non woven substrate
Outside
Inside
Deposition is uniform throughout the sample
Example*: ALD deposition on non woven (NW): Al-oxide (Al2O3) deposition PES NW cube dimensions: side = 3.5cm XPS analysis: penetration of coating ?
* TMMETACEL, in collaboration with UGent - www.ald.ugent.be
G. Buyle - MIICS - 20120314
Advanced coating techniques
ALD
Evaporation Magnetron sputtering
Atmospheric Plasma coating
G. Buyle - MIICS - 20120314
Evaporation for textiles
Evaporation is feasible on textile Use of existing (large scale)
equipment Offered via toll manufacturing Applications:
UV and/ or IR reflection layers Conductive layers Antimicrobial layers …
Source: Alupa
G. Buyle - MIICS - 20120314
Advanced coating techniques
ALD
Evaporation
Magnetron sputtering Atmospheric Plasma coating
G. Buyle - MIICS - 20120314
Magnetron sputtering on textile
Bron: Tersuisse Multifils
Commercially available: silvercoated PA monofilament
Use: Textile electrodes Antimicrobial textile
But… cost factor !!!
G. Buyle - MIICS - 20120314
“Most Luxurious Necktie Ever ? ...”
Gold coated silk
Source: www.ecouterre.com
“Retailing at 7,500 Swiss francs (or roughly $8,450) apiece, each tie will comprise 8 grams of 24-karat gold,…”
G. Buyle - MIICS - 20120314
Advanced coating techniques
ALD
Evaporation Magnetron sputtering
Atmospheric Plasma coating
G. Buyle - MIICS - 20120314
Atmospheric plasma coating
Plasma source
Plasma
Textile substrate
Plasma + Precursor (chosen according to the desired properties) Coating possible → permanent change of the surface properties Crucial: interaction between precursor, substrate and plasma
Precursor
G. Buyle - MIICS - 20120314
Atmospheric plasma coating equipment*
Key properties: For wide substrates (up to 40 cm) Corona + possibility to add liquid precursor
* Available through cooperation with Univ. College Ghent
G. Buyle - MIICS - 20120314
Example: surface analysisantimicrobial coating
XPS and ToF-SIMS → chemical composition
Untreated Uniformly treated“Badly” treated
Size = 5x5mm2, color = specific for chemical group, PES fabric
G. Buyle - MIICS - 20120314
Outline
Introduction Centexbel
Basic textile coating Advanced coating techniques
Examples of applications
G. Buyle - MIICS - 20120314
Electrical conductivity: integration of carbon nanotubes in textile coatings
0
100020003000
4000
50006000
70008000
0 2 4 6 8 10wt % CNT
Res
istiv
ity (O
hm)
Acrylic based coating with increasing CNT content: Highly flexible textile coatings Conductivity starts at 4 wt% CNT, resistivity down to 60 Ω (!)
G. Buyle - MIICS - 20120314
SEM pictures: coated fibre with well distributed CNT network
G. Buyle - MIICS - 20120314
Application: Integration of solar cells in textile Solar cells require
(highly) conductive layers
Potential application: directly coating on textile materials e.g. tents, screens,
backpacks, garments
Coated fabric
Flexible textile solar cell
G. Buyle - MIICS - 20120314
Application: conductive yarn via CNT, used in antistatic fabrics
Patent pending(EP2011002735)
Antistatic fabric
G. Buyle - MIICS - 20120314
Self Healing properties
Several principles exist for reaching self-healing (mixing of substances when crack/scratch appears)
Own development for textile:Freshly scratched After self-healing
G. Buyle - MIICS - 20120314
Abrasion resistance via sol-gel chemistry for textiles
Characteristics: Existing technology for coating on
glass surfaces Sustainable layers of eg. Si-O-Si
(~glass) Adapted to textiles
(lower curing temperature) Nano-porous surface,
thickness ca. 100nm
→ Superior abrasion properties !
Abrasion test
Reference
Sol gel
G. Buyle - MIICS - 20120314
Bioresponsive coatings Smart dressings for burn wounds: the wound dressing
releases antimicrobials when needed and signals an (upcoming) infection via dye release
Stabilised nanocapsules containing "switched off"
dye and antimicrobial
Pathogenic bacteria release toxins and
enzymes → opening of nanocapsules shell
Nanocapsules release signaling molecules and antimicrobials
1. 2. 3.
G. Buyle - MIICS - 20120314
Development of PV cells and batteries at fibre level
G. Buyle - MIICS - 20120314
Summary
(Coated) Textiles have a broad range of application s. Both for garments and for technical textiles Coating enables textile as “flexible functionality carrier”
The classical techniques dominate. Relatively simple, reliable, large scale
Continuous search for novel methods, materials and applications. Methods: energy consumption ↓, accuracy ↑ Materials: “bio-…”, “nano-…” Applications: electrical conductive, bioresponsive, …
G. Buyle - MIICS - 20120314
Contact
Contact info:
Guy Buyle
CentexbelTechnologiepark 7
9052 ZwijnaardeBELGIUM
www.centexbel.be
Tel: +32 9 220 41 51Fax: +32 9 220 49 55