Innovations incoated textiles

Bert Groenendaal & Bram WydoogheSioen Coating NV (Belgium)

MATA 09membránová a textilní architektura

BRNO – April 28, 2009

• 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

Outline

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!

▫ 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 spin – extrude yans

▫ 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 weave

We colour

▫ Production of ▫ pigment pastes ▫ inks ▫ varnishes ▫ colour dispersions

▫ Direct coating▫ Transfer coating▫ Online coating▫ Extrusion coating▫ Calendering

We coat

Introduction to coated textiles

Coated textiles

• PVC/plasticizer• PU• silicone rubber• etc.

• woven or knitted• non-woven

• polyester (PES)• aramide• glass• etc.

Also known as:• technical textiles• tarpaulins or tarps

Introduction to coated textiles

Introduction to coated textiles

Introduction to coated textilesExample: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 transmissionHow 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

Fabric1100 dtex

9 x 9L 1/1

1100 dtex12 x 12P 2/2

1670 dtex10,5 x 10,5

P 2/2

1670 dtex14 x 14P 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)

120 120 120 120

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

Easy cleaning surfaces for TA

PET fabric coated with • PVC• silicone rubber• PUand 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 interactivedevelopments with various chemical partners

Contex-T (EU project)

Innovations in coated textiles

Easy cleaning acceleration test

40 days at 70C

Contex-T (EU project)

•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

Innovations in coated textiles

Contex-T (EU project)

Phosphorescent coatings(glow in the dark)

Incorporation of light

LEDs EL lamps

Incorporation of light

EL lamps

Incorporation of light

EL lamps

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

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