EP3286364A1 - Method for manufacturing fiber materials by photopolymerization - Google Patents
Method for manufacturing fiber materials by photopolymerizationInfo
- Publication number
- EP3286364A1 EP3286364A1 EP16726915.8A EP16726915A EP3286364A1 EP 3286364 A1 EP3286364 A1 EP 3286364A1 EP 16726915 A EP16726915 A EP 16726915A EP 3286364 A1 EP3286364 A1 EP 3286364A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- polymerization
- filament
- liquid composition
- equal
- monomers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
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- YRHRIQCWCFGUEQ-UHFFFAOYSA-N thioxanthen-9-one Chemical compound C1=CC=C2C(=O)C3=CC=CC=C3SC2=C1 YRHRIQCWCFGUEQ-UHFFFAOYSA-N 0.000 description 1
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Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/38—Formation of filaments, threads, or the like during polymerisation
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D10/00—Physical treatment of artificial filaments or the like during manufacture, i.e. during a continuous production process before the filaments have been collected
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/16—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polymers of unsaturated carboxylic acids or unsaturated organic esters, e.g. polyacrylic esters, polyvinyl acetate
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/66—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyethers
Definitions
- the invention is in the field of the manufacture of fibrous structures, in particular for textile applications.
- the invention relates to a process for producing fibrous structures, in particular fibers or filaments or multi-filaments.
- Various applications are envisaged, as well as the products resulting from this process.
- the known methods of the state of the art consist in extruding a liquid composition containing a polymer, wherein the liquid composition is made of molten polymer, which requires a constant supply of heat, or dissolved polymers. , regenerated by evaporation or coagulation of solvent, which requires an additional step of solvent extraction or coagulation.
- the current manufacturing processes for synthetic or artificial fibers involve a spinning operation (continuous stretching of polymer strands at the exit of the die).
- the production of chemical fibers is usually made from a synthetic or natural polymer.
- two processes are distinguished according to the presentation of the polymer: (i) in the molten state or (ii) in the form of dissolved polymer.
- a Third process gradually appears in industry (iii). This is a process using reactive extrusion.
- the spinning is carried out by extruding a heated polymer beyond its melting point.
- the polymer is generally in the form of fused filaments or strands, and then cooled in air pulsed to return to the solid state.
- the filaments are then joined, collected to be wound.
- a filament drawing step is generally used to orient the microstructure of the polymer and form a crystal lattice necessary for the tenacity of the filaments. This stretching is provided by a voltage differential between slightly heated drawing buckets to hold the polymer in its thermomechanical deformation zone. Texturing of the filaments can also take place directly after the collection of the filaments. This is the process used for example for the following polymers: polyester, polyamide, polypropylene, polyethylene, elastane, polylactic acid (PLA) ...
- Reactive spinning is a process that uses a chemical derivative of the polymer to solubilize it.
- the polymer is regenerated after spinning, in particular by coagulation, for example by immersion in a solution in which it is insoluble or with which it reacts to become insoluble. This is the process used for example for viscose.
- (ii-b) Dry spinning When a polymer is soluble in a low melting point solvent, a dry dissolved process is used.
- the solvents used can be, for example, acetone, dimethylformamide or dimethylacetamide.
- the polymer in the form of a filament is then regenerated by coagulation, by evaporation of the solvent. This is the process used for example for the following polymers: cellulose acetate, elastane, polyacrylonitrile, polyvinyl chloride.
- Air-gap spinning or gel Air-gap spinning or gel.
- the polymer is solubilized in a suitable solvent type sulfuric acid, NMMO, decalin ...
- the polymer filaments are regenerated by coagulation by liquid extraction of the solvent just after passage into the air-gap, that is to say the zone between the outlet of the die and the air coagulation bath. This is the process used, for example, for the following polymers: aramid, lyocell, polyethylene of very high molecular weight (UHMW-PE).
- Reactive extrusion spinning involves creating a mass polymerization reaction (living polymerization, polyaddition, anionic, radical polymerization, polycondensation) by contacting two reactive materials during extrusion.
- the initiation of the polymerization reactions begins in the extrusion system (twin-screw). This is the process used for example for the following polymers: polyetherimide, polyurethane ...
- the published patent application WO 2008/135759 A2 discloses a method of manufacturing textile filament, which comprises a step of extruding uncured silicone polymer, followed by curing by UV radiation. In this process, the polymerization of the silicone precedes the extrusion, and this type of process finds applications only for a reduced range of materials, and therefore of possible textile applications.
- the application published under the number GB 2229131 A describes a method of cable coating by extrusion of a polymer followed by curing by UV irradiation, but this extrusion / coating process is unsuitable for production. textile filaments by extrusion / spinning.
- silicones has a very unfavorable environmental balance with respect to the production of certain monomers, prepolymers or oligomers which can be used in the present invention, in particular biosourced monomers, prepolymers and oligomers.
- the inventors have identified that radiation polymerization, in particular by UV and / or visible radiation, makes it possible to develop new methods for producing filaments, and in particular textile filaments, from a solution of monomers or of pre-polymers, by associating such a polymerization step immediately after the extrusion step.
- the method of the invention is simple to implement, requiring only simple modifications of existing extrusion devices, and makes it possible to optimally control the composition of the reactive mixture, this mixing being carried out independently of the step of extrusion. Finally, the energy consumption is reduced compared to existing processes.
- the invention relates to a method of manufacturing fibrous structures, by polymerization of liquid composition, said polymerization being initiated during or immediately after extrusion by irradiation of the extrudate, characterized in that the liquid composition essentially comprises monomers reactive oligomers and / or prepolymers, and optionally an initiator and / or other non-reactive additives.
- the polymerization is a photopolymerization.
- the process developed here is different from other fiber production processes, in particular because the raw material is a polymerizable formulation based on single monomers, reactive oligomers or prepolymers.
- the formation of a macro-molecular network constituting the fiber structure is triggered in the liquid being extruded, more particularly in the extrudate, under the effect of exposure to radiation, and in particular to radiation. UV and / or visible.
- the invention therefore relates in particular to the creation of a new generation of fibers implemented by an innovative extrusion / spinning process coupled to a photopolymerization under UV radiation.
- the photopolymerization is carried out on the liquid extrudate of varied viscosity so as to form a solid filament, in particular by radical and / or cationic reaction initiated by the photon absorption by a photoinitiator system as a function of the wavelength. and the intensity of the radiation emitted by the UV source.
- the polymerization is a radical reaction.
- the polymerization is an ionic reaction, in particular cationic.
- the polymerization is associated with both radical reactions and ionic reactions, in particular cationic reactions.
- the subject of the invention is a process for the production of fibrous structures, in particular of fibers or filaments, and in particular from a composition of biosourced and / or petrochemical monomers / oligomers / pre-polymers of low viscosity.
- the initiation of the UV (or UV / visible) photopolymerization reaction during spinning can be carried out thanks to the radiations emitted by mono or poly chromatic UV sources such as LEDs or bulb lamps whose wavelength may be between 230 and 600 nm, and preferably between 365 and 410 nm.
- the subject of the application is in particular the transformation by UV radiation of the liquid extrudate of varied viscosity into a solid filament after photopolymerization of the raw material during extrusion / spinning.
- the rheological properties of the photopolymerizable composition in particular its viscosity, typically between 1 and 4 Pa.s and the rapidity of its solidification triggered by a short-term exposure to light at the exit of the die (from 10 ms to 10 s) , are key factors in extrusion at room temperature.
- the reactivity of the photopolymerizable composition is in particular dependent on (i) intrinsic factors such as the efficiency of production of active centers by the initiator or the rate of polymerization which is accompanied by the formation of a solidified polymer network and (ii) ) external factors such as the characteristics of the light source (radiation intensity, emission spectrum, geometry of the light beam, continuous or pulsed nature of the latter, temperature within the exposure zone at the exit of the die).
- intrinsic factors such as the efficiency of production of active centers by the initiator or the rate of polymerization which is accompanied by the formation of a solidified polymer network
- external factors such as the characteristics of the light source (radiation intensity, emission spectrum, geometry of the light beam, continuous or pulsed nature of the latter, temperature within the exposure zone at the exit of the die).
- the indicators of the reactivity of a processed formulation under given lighting and ambient conditions are in particular quantifiable quantities (i) relating to the process chemical, such as the rate of polymerization, the exposure dose inducing gelation, the degree of conversion of the monomer functions obtained in fine or (ii) characteristics of the properties of the fibrous materials obtained (toughness, tackiness). These different quantities can be measured at the end of the process to adjust said parameters.
- the liquid composition is stable at room temperature.
- the liquid composition does not comprise any non-reactive solvent, in particular the liquid composition is not an aqueous or alcoholic solution and / or contains no organic solvent.
- the elemental composition of the liquid composition is not, or not significantly, modified during extrusion and / or polymerization.
- no reagent, additive and / or solvent is added to the liquid composition just before or during extrusion and / or polymerization.
- the viscosity of the liquid composition is 0.5 to 4 Pa.s or is between 0.5 and 10 Pa.s, in particular between 1 and 4 Pa.s (inclusive).
- the liquid composition consists of or essentially comprises epoxy monomers, oligomers and / or prepolymers.
- the reagents belong to the family of epoxides.
- the reagents, in particular the monomers, oligomers and / or epoxy prepolymers, are bio-sourced.
- the extrusion / spinning process of the monomers and / or oligomer or prepolymer formulations has the advantage of allowing operation with liquid compositions of lower viscosity at room temperature without solvent application. .
- the initially liquid extrudate is transformed into a solid of regular geometry which forms a manipulable filament.
- interpenetrating networks can be obtained by applying the process to mixtures of monomers polymerizing by mechanisms involving separate active centers, for example radical and cationic.
- Semi-interpenetrating networks can be obtained by applying the process to mixtures of mono- and difunctional monomers polymerizing by mechanisms involving separate active centers, for example radical and cationic.
- Filaments of composite materials - and multifilaments, fibers, etc. - can be obtained by photopolymerization of photopolymerizable compositions comprising solid additives, such as micronized fillers or nanoparticles.
- bio-sourced resin ensures a high renewable carbon content in the raw materials, facilitating market acceptance of the products, this characteristic in line with sustainable development prospects. be promoted by "organic” and / or “green” marketing. This is particularly the case when formulations based on epoxidized vegetable oils are used.
- the photo-polymerization reaction during spinning to provide cohesion or consolidation of the filament is allowed by the choice of the parameters relating to UV dose pairs and reactivity of the formulation, which is a factor critical in the development of this photo-filament.
- the wavelengths, the irradiation power of the UV sources, the irradiation time, the transparency of the formulation at the chosen wavelengths are therefore all parameters to be considered in order to guarantee the triggering of the photo-polymerization reactions or crosslinking photo.
- the main technological, environmental and industrial advantages expected from the invention using the photo-polymerization are among others: overall reduction of the energy consumption of up to 67%; increase in production rates; limited pollution especially by reduction of chemical waste, compact systems; reduction of production cycles and consequently of waste generated by start-up / shutdown; possibility of small series for niche markets.
- the method of the present invention allows the manufacture of filaments, fibers and other fibrous structures with novel properties which form an integral part of the invention, in particular of polymeric filaments or fibers obtained from biosourced epoxy monomers, in particular particular of filaments or fibers consisting of epoxidized vegetable oil polymers, more particularly epoxidized linseed oil, and optionally another epoxide monomer and / or a viscosifying additive and / or a monomer of epoxidized epoxy acrylate.
- the present invention provides filaments or fibers and epoxy polymer having a density of less than 0.6 and particularly such filaments or fibers having a diameter of 210 to 300 ⁇ and / or a toughness of 2 to 3 cN / Tex.
- the invention relates to a method of manufacturing fibrous structure, in particular fiber or filament.
- a fibrous structure in the present application, denotes any material consisting of one or more fibers, of one or more filaments, or of a network, in particular a planar network, of fibers or fibrillar structures. .
- the fibers or filaments may be in homogeneous form or not within the material.
- the fibrous structure obtained (and / or the fibers or filament which constitute it) has a viscoelastic behavior.
- fibrous structure thus includes any structure commonly referred to by the generic term filament, and its derivatives (fibers, nanofibres, microfibers monofilament, multi-filament, multi-strand, single strand, rush, fibrils, micro-fibrils, nano fibrils , son) and any structure using these materials, linear (warp and weft, braid, ...) or nonlinear (fabric, fabric, knit, nonwoven ).
- the definition of fibrous structure also includes any type of non-woven fabric and more particularly nonwovens resulting from the bursting of polymers in fibrils such as spunlace (non-woven meltblown or spunbond melts), electrospinning or spinning force.
- a fiber in the present invention denotes a unitary formation whose aspect ratio (ratio of lengths from the largest to the smallest dimension) is greater than 1000 and whose length is relatively limited.
- unitary structure is meant a continuous solid, formed in particular of a single covalent macro molecular network, including an interpenetrating polymer macromolecular network, or a semi-interpenetrating polymer macromolecular network.
- a fiber has a maximum length of 1 m.
- a fiber has a minimum length of 1 cm.
- a fiber has a maximum length of 5, 7, 10 or 15 cm.
- the length of a fiber is between 1 cm or 2 cm and 10 cm or 15 cm (inclusive).
- a filament in the present application, refers, in a fiber-like manner, to a unitary aspect ratio formation greater than 1000, but whose length is not particularly limited, in particular is indefinite (e.g. in the case of a filament being extruded and / or wound). To determine that the aspect ratio is in accordance with the definition, it will suffice if the length measured over a finite fraction of the filament leads to a ratio greater than 1000.
- the diameter of the fiber or filament, or its length in the largest dimension of its section (perpendicular to the length), is in particular less than or equal to 1 cm, at 5, 3 or 1 mm, and in particular it (it) is included (e) in the intervals 500 ⁇ at 1mm, 0 to 500 ⁇ , 0 to 300 ⁇ , 0 to 200 ⁇ , 0 to 100 ⁇ , 0 to 50 ⁇ , 25 to 500 ⁇ , 25 to 300 ⁇ , 25 to 200 ⁇ , 25 to 100 ⁇ , 25 to 50 ⁇ , 50 to 500 ⁇ , 50 to 300 ⁇ , 50 to 200 ⁇ , 50 to 100 ⁇ , 100 to 500 ⁇ , 100 to 300 ⁇ , 100 to 200 ⁇ , 200 to 500 ⁇ , or 200 to 300 ⁇ , the limits of the intervals being systematically included.
- the method enables the production of a continuous filament of length equal to or greater than 1 m, preferably equal to or greater than 2 m, preferably equal to or greater than 5 m, preferably equal to or greater than 10 m, preferably equal to or greater than 50 m, preferably equal to or greater than 100 m.
- the produced filament is homogeneous over its entire length or over a length greater than 1 m, preferably greater than 10 m, preferably greater than 100 m.
- homogeneous over a length is meant that the properties of the filament and in particular its physical and / or mechanical properties do not vary locally by more than 10%, preferably 5% and preferably 2.5%, over a fraction of the filament. of said length.
- the diameter of the filament is homogeneous over a length of at least 1 m, preferably at least 10 m and even more preferably at least 100 m.
- the filament like the fiber, defines unitary formations. Most often, however, these filaments or fibers are handled in the form of a multitude of fibers or filaments.
- the method of the invention allows the simultaneous production of several filaments, for example by using several dies, which can be combined into a bundle, said multifilament and, if necessary, manipulated (in particular stretched, wound, etc.) under this form.
- the filaments of the bundle can be cut into fibers, thus producing a pile of fibers, called bundle.
- the fibrous structure is, in general, a linear filament, that is to say that its aspect ratio is greater than 1000 and that it has a shape (architecture or structure) unbranched (or unplugged).
- This characteristic is understood, as will be apparent to those skilled in the art, the macroscopically described filament and not the molecular structure of the polymer constituting the filament.
- the fibrous structure here refers in particular to a linear filament.
- each fiber is linear and, in particular, there is no physical connection between the fibers, which distinguishes such a cluster of fibers, for example, fibrous structures consisting of a solid network of branched fibers.
- the method of the invention uses a liquid composition comprising essentially or consisting of monomers, prepolymers and oligomers.
- monomer refers in this application to a substance consisting of monomeric molecules, that is to say molecules, in particular organic molecules, which do not comprise a repeating structural unit, in particular when these molecules have one or more groups ) functional (s) allowing an association with other molecules, identical or different, to form a pre-polymer, an oligomer and / or a polymer.
- a prepolymer in the present application, denotes a substance consisting of pre-polymer molecules, that is to say molecules capable of associating, in particular with other identical pre-polymer molecules or different, to form the (or one of) pattern (s) repeated in a polymer.
- a monomer or prepolymer as defined herein is not a polymer.
- An oligomer in the present application, denotes a substance consisting of oligomeric molecules, that is to say molecules, in particular organic, having a repeating structural unit, but whose molar mass (and / or the number of repetitions of the pattern) is sufficiently weak that the addition of an additional repeating unit modifies certain chemical or physical properties of the molecule.
- an oligomer has a molar mass of less than 2 kg / mol.
- an oligomer is not a polymer.
- a polymer in the present application, denotes a substance composed of polymeric molecules, that is to say molecules, in particular organic molecules, comprising at least one repeating unit, and in particular a molecule comprising a sufficient number of these units for that the addition of an additional repeating unit does not modify certain chemical or physical properties of the molecule.
- a polymer has a molar mass greater than 2 kg / mol.
- the invention provides a process for producing a fibrous structure, in particular fibers or filaments, by polymerizing a radiation-initiated liquid composition during or immediately after extrusion, characterized in that the liquid composition essentially comprises monomers, oligomers and / or reactive prepolymers.
- the invention particularly relates to a method comprising the following steps:
- a liquid composition essentially comprising reactive monomers, oligomers and / or prepolymers, in particular by mixing the reagents;
- heating and / or maintaining the liquid composition at a given temperature, in particular below 100 ° C, and in particular between the glass transition temperature and the polymer melting temperature when a polymer is incorporated in the composition photopolymerizable;
- Treatment (s) or implementation of optional (s) or complementary (s) on extrudate cutting, texturing, complementary radiation, especially from a complementary radiation source, in particular of different nature and / or at different wavelengths, thermal post-treatment, air blowing, pulsed air, conditioned air, cooled or heated air, vaporization, ventilation, atmospheric inerting, cooling bath or any other downstream process.
- treatments or processes include in particular any post-treatment possible on fiber or filament: texturing, stretching, coagulation bath, winding, assembly, twisting, wrapping ...
- the path of the extrudate at the outlet of the die can be disturbed (by scrambling, air flow, air blowing, etc.) for the formation of a nonwoven web
- the liquid composition essentially comprises reactive monomers, oligomers and / or prepolymers means here that said reactive monomers, oligomers and / or prepolymers constitute the majority components of the liquid composition and that the polymer obtained will consist mainly of an assembly of said monomers, oligomers and / or prepolymers; majority, meaning here more than 50% by weight, in particular more than 80% by weight and more particularly more than 90% by mass and preferably greater than 95% by mass, these thresholds being those of the ratio of the total mass of the monomers, oligomers and pre-polymers to the mass of the liquid composition or the ratio of the mass of the atoms of the polymer originating from said reactants to the mass total of the polymer.
- the liquid composition consists of, or essentially comprises, reactive substances, that is substances which constitute the reactants of the polymerization reaction and in particular are incorporated by covalent bond into the reaction medium. polymer. All substances of the liquid composition which are incorporated by a polymerization reaction in the polymer obtained from "reactive substances" as opposed to non-reactive substances which, although they may play a role in reactions in composition, and in particular in the polymerization reaction (s), are not incorporated by polymerization into the polymer.
- the initiators described below which facilitate or make possible the polymerization, are qualified here as non-reactive substances since, even if they participate directly in the polymerization reaction, they do not themselves form part of the polymer obtained.
- additives which could for example be incorporated in the polymer by mechanisms other than polymerization (eg because they are trapped in the polymer network, or react with a reaction distinct from the polymerization system).
- polymerization with the polymer and / or the reactive monomers, oligomers or prepolymers are not reactive substances.
- composition is sufficiently fluid (i.e., sufficiently low in viscosity) to be extruded, the filament solidification being achieved by creating a covalent macromolecular network.
- a chemical composition according to the invention may comprise a certain proportion of polymers, but this proportion is such that the viscosity of the liquid composition remains sufficiently low.
- the liquid composition is not essentially composed of polymers.
- the liquid composition does not comprise an elastomer and / or does not comprise a polymer.
- the polymers (and elastomers) of the liquid composition represent less than 10%, more particularly less than 5% of the total mass of the liquid composition.
- the desired viscosity is obtained without the use of non-reactive substances and in particular nonreactive solvent or diluent.
- these non-reactive substances do not significantly modify the viscosity of the liquid composition, and in particular do not reduce the viscosity of the liquid composition.
- the viscosity of the liquid composition comprising the non-reactive substances is not different (and in particular is not lower) by more than 50%, preferably more than 20%, preferably more than 10%. and even more preferably more than 5% relative to the viscosity of the liquid composition comprising the same reactive substances (in the same relative proportions) and devoid of non-reactive substances.
- the monomers of the liquid composition, or a part thereof have a functionality greater than 2 and in particular can form at least 3 bonds in the polymer, and thus allow the formation of a branched or crosslinked macromolecular structure.
- a polymer and / or an oligomer according to the invention consists of molecules which all have the same composition.
- the polymeric or oligomeric molecules of the invention are homopolymeric, that is to say they comprise only one repeated structural unit.
- the polymeric or oligomeric molecules of the invention are copolymeric, that is to say comprise several distinct repetitive structural units.
- the oligomers and / or the polymers according to the invention are linear polymers, that is to say that each repeated structural unit "n” is linked to two other units ("n-1"). and "n + 1"), the bonds between motifs involving the same functional groups (that is, the bond between the n-1 motif and the n-motif implements the same functional groups of the n-1 motifs and n, respectively, that the functional groups of the units of n and n + 1, respectively, implemented in the bond between the unit n and the unit n + 1.
- the oligomers and / or the polymers according to the invention are branched, that is to say that at least some of the repeating structural units are associated with more than two other units, the molecule thus comprising branches.
- the liquid composition comprises a mixture of two monomers of functionality equal to or greater than 2; preferably, and in particular when their number is greater than 2, distinct functions (or functions) are present on these monomers and participate in the formation of active polymerization centers, making it possible to obtain a linear polymer mixture by polymerization hybrid.
- the functional group (or function) of a monomer (or oligomer, or prepolymer) which participates in the bond created between this monomer and another monomer by the polymerization reaction is denoted indifferently as functionality (or function) monomer or polymerizable functionality (or function).
- Two distinct functional groups can be considered to represent the same monomeric function when they participate chemically equivalent to the polymerization (in particular, eg if they are two groups belonging to the same chemical family).
- the liquid composition comprises at least one reactive substance, in particular at least one monomer, carrying at least two identical monomer functions to form a first covalent network, and at least one other reactive substance, in particular at least one monomer, carrying one or more monomer functions of another type, polymerizing by a different chemical mechanism.
- the liquid composition comprises two reactive substances, in particular two monomers, thus defined.
- the liquid composition comprises more reactive substances, comprising at least one substance of each type so defined.
- the polymerization of the monomers, prepolymers or oligomers of the liquid composition is initiated just after the extrusion, in particular is initiated in the extrudate.
- initiation of the polymerization means the first step in the polymerization reaction, during which at least a fraction of the monomers, prepolymers or oligomers is activated, most often in the presence of an initiator, so that that the activated reactive group or groups can form a bond with other monomers, prepolymers or oligomers and thus constitute the first repeating units of a polymer.
- initiation results in the formation of a free radical in the case of a radical polymerization reaction and by the formation of an ion (in particular a cation) in the case of ionic polymerization (in particular cationic) .
- Propagation refers to post-initiation reactions that result in the addition of additional repeating structural units on a polymeric molecule.
- Termination refers to the reaction by which a polymeric molecule is made inactive, i.e. unable to react with monomers, prepolymers or oligomers to add additional repeating structural units.
- polymerization refers to the addition of repeating units to an oligomer or a polymer
- crosslinking refers to the creation of bonds between two polymers.
- the two types of reactions are simultaneous and that there is a cross-linking polymerization; we do not distinguish the polymerization and the crosslinking and the term polymerization is used here to refer to both types of reaction.
- transfer agents such as thiols for a radical polymerization mechanism, or alcohols for a cationic polymerization mechanism, is compatible with the process. This possibility can be exploited to adjust the reactivity of the polymerizable compositions as well as the properties of the yarns and fibrous structures obtained.
- the polymerization of the reactive substances of the liquid composition results from several distinct mechanisms and in particular which involve separate monomer functions and / or active centers of a distinct nature.
- Hybrid polymerization is here called a complex chemical process in which two different polymerization mechanisms operate concomitantly with two different types of monomer functions carried by separate monomers or in particular cases on the same monomer. Growth mechanisms are considered independent.
- the hybrid polymerizations lead to polymers that may have a wide range of architectures:
- one of the reagents carrying at least two polymerizable monomer functional groups, that is to say trifunctional or tetrafunctional or higher order monomers according to IUPAC, to form a first covalent network with d other monomers and another or other monomers bearing one or more monomer functions of another type, polymerising by a different chemical mechanism.
- polymerising chain monomers such as acrylates or epoxies
- the required functionalities would be a multiple of 2.
- this type of monomer would have 3 or more polymerizable functions;
- an interpenetrating polymer network designates a polymer comprising two or more networks, at least partially intertwined at the molecular scale without any relevant relationship between them and which can not be separated without breaking the chemical bond.
- the result of a mixture of two preformed polymer networks is not an interpenetrating polymer network.
- a semi-interpenetrating polymer network refers to a polymer comprising one or more polymeric networks and one or more branched or linear polymers, wherein at least some of said branched or linear polymers penetrate at least some of said networks at the molecular scale.
- the linear polymers of such a semi-interpenetrating network can be separated from the polymer network (s) without breaking the chemical bond. This is also the case for mixed networks, consisting of polymerized segments of different types that are interconnected by covalent bonds.
- the polymerization is a hybrid polymerization involving a radical mechanism and a non-radical mechanism.
- the polymerization is a hybrid polymerization involving a radical mechanism and an ionic mechanism, in particular cationic.
- the polymerization is a hybrid polymerization involving a radical mechanism and a mechanism catalyzed by a base, in particular through the use of a basic photogenerator.
- the concomitant radical and cationic hybridization polymerization makes it possible in particular: to overcome the phenomena of inhibition specific to each of the mechanisms (oxygen of the air for the radical process, humidity and nucleophiles for the cationic mechanism); to benefit from the pseudo-living character of the cationic mechanism which can continue for periods much longer than the residence time of the polymerizable composition flowing in the activation zone; to create semi-interpenetrating, interpenetrating or mixed polymer networks (ie consisting of distinct interconnected segments), endowed with unique physical and mechanical properties, compared to networks resulting from single-mechanism polymerization.
- Another advantage lies in the possibility of achieving during the residence time of the extrudate in the radiation exposure zone a sufficient level of polymerization to ensure the gelation of the composition in the form of a solid visco yarn. -elastic.
- the latter may undergo deformations (elongation, diameter reduction, orientation) by means of conventional devices used in spinning processes, and be ultimately consolidated by pseudo-living cationic polymerization, delayed in time by design.
- the substance intended to be polymerized is initially provided in the form of a liquid composition, in particular a viscous liquid, in particular a liquid whose viscosity at ambient temperature is less than or equal to 10 Pa.s, and more particularly is between 1 and 4 Pa.s, inclusive (in the present application, unless otherwise stated, the viscosity of a liquid refers to its dynamic viscosity, measurable by means known to man of career).
- the liquid composition does not comprise a solvent, that is to say a liquid substance present in a significant amount (in particular greater than 1% or 10% of the total mass) which is not intended to be incorporated in the polymer, but is intended to reduce the viscosity of the liquid composition to allow extrusion.
- the liquid composition comprises, in addition to the reactive substances, at least one initiator and / or additives.
- additive is meant m compound present in a limited proportion (in particular less than 10% of the total mass, and more particularly less than 1%), the presence of which is not essential for the polymerization reaction, but which makes it possible to modify the properties of the liquid composition (stability, viscosity, etc.) and / or the polymer obtained.
- the additives may or may not be incorporated into the polymer obtained.
- the additives may either simply be physically trapped in the polymer or form chemical bonds, particularly covalent, with the polymer.
- Those skilled in the art will be able to adapt the nature and the quantity of additives, in particular according to the methods illustrated in the examples, to obtain the desired properties for the liquid composition (in particular to facilitate the production) and / or for the polymer obtained. .
- the additives comprise or consist of at least one of the following compounds: mineral fillers, metal fillers, dyes, polymers, surfactants, antistatic agents, lubricants, fluidifiers, debullers, defoamers, sacrificial component, functionalizing filler (antimicrobial, flame retardant, microcapsules, antifungals, anti-odor, chromophore, conductive fillers ).
- the liquid composition comprises one (or more) sacrificial component (s).
- a component is intended to be removed from the fibrous structure during its manufacture, preferably after the polymerization of the filament.
- such components can be incorporated in the filament, in particular be trapped in the gel constituted by the polymer without forming a covalent bond with the elements of the polymer, then removed, particularly to confer a porous character to the filament.
- the liquid composition comprises an initiator.
- a primer means a substance or a mixture of substances (activating substances) intended to activate the functional groups of the monomers, prepolymers and / or oligomers of the liquid composition in order to induce their polymerization by a chain reaction mechanism.
- activating substances a substance or a mixture of substances (activating substances) intended to activate the functional groups of the monomers, prepolymers and / or oligomers of the liquid composition in order to induce their polymerization by a chain reaction mechanism.
- the term "initiator system” is used here with a meaning identical to "initiator” (and in particular an initiator system comprises one or more activating substances) and the expression “the substances constituting the initiator system” designates the single substance, in the case where the initiator system consists of a single substance.
- the proportion of initiator in the liquid composition is less than 10%, 5% or 1% by weight, and more particularly less than 0.1% by weight.
- the initiator is not incorporated, in particular not by covalent bond, in the polymer obtained.
- the initiator is activatable by radiation.
- the initiator is a photoinitiator, that is to say it is activatable by light radiation.
- the photoinitiator is activatable in particular by UV radiation.
- the photoinitiator is capable of absorbing the energy of a photon to restore this energy in the form of chemical activation, by energy transfer, electron transfer and / or reduction of free radicals. This energy transfer which results in the activation of the monomers, pre-polymers and / or oligomers can comprise several reaction steps, and in particular use several substances.
- the initiators can generate free radicals, cationic entities (Bronsted or Lewis acids, carbenium ions), basic (amine) entities.
- the simultaneous production by one or more initiators of radical or ionic entities (cationic or anionic) is also possible.
- the initiator systems and the resulting polymerizations are then referred to as hybrid systems and polymerizations.
- the initiator system is a hybrid initiator system, allowing the simultaneous production of radical and ionic entities and in particular radical entities (s). and cationic (s).
- the initiator system comprises two or more activating substances, in particular two substances.
- the initiator system comprises three or more activating substances, in particular three substances.
- the different types of photoinitiators may include a photosensitizer, ie a chromophore-carrying component whose primary role is to absorb the incident light energy, then induce, by various mechanisms of energy transfer, of electron transfer or following photolysis, reactions involving other constituents of the composition acting as co-initiators and ultimately leading to the formation of active centers of polymerization.
- a photosensitizer is naturally particularly useful in the case of activation by means of light radiation.
- the initiator system comprises or consists of a photoinitiator and a photosensitizer, optionally supplemented with another co-initiator substance, for example a hydrogen donor.
- initiators in particular free-radical type I photoinitiators (for example benzoin ethers, benzil ketals, ⁇ -hydroxy alkyl aryl ketones, acyl phosphine oxides, titanocenes),
- free-radical type I photoinitiators for example benzoin ethers, benzil ketals, ⁇ -hydroxy alkyl aryl ketones, acyl phosphine oxides, titanocenes
- type II radical initiators eg benzophenones, thioxanthones, associated with a hydrogen donor
- cationic photoinitiators for example triaryl sulphonium salts, diaryl iodonium salts, cyclopentadienyl arene Fe (II) salts
- triaryl sulphonium salts for example triaryl sulphonium salts, diaryl iodonium salts, cyclopentadienyl arene Fe (II) salts
- photo-sensitizers eg xanthones, fluorenones
- the initiator allows the initiation of a radical polymerization and / or ionic, in particular cationic.
- the initiator (or the initiator system) allows the simultaneous priming of several different polymerization mechanisms.
- the initiator or initiator system allows the creation of distinct active centers and particularly of distinct natures (eg free radicals and ions). The same atom or the same function, in a molecule of monomer, oligomer or prepolymer, can be activated by distinct mechanisms and thus generate distinct active centers. It is also possible that the distinct active centers are carried by distinct functional groups (and thus atoms) in the reactive substances of the liquid composition, whether by functional groups of distinct molecules or by distinct functional groups carried by a same molecule.
- the energy required for polymerization and in particular for activation via the initiator system is produced by the same source and in particular by the same radiation source for the various polymerization mechanisms. .
- only one type of radiation is used, in particular light radiation or electron bombardment, to obtain the hybrid polymerization.
- the polymerization is obtained by exposure to light radiation of single wavelength (or monomodal spectrum).
- the initiator comprises a photosensitizer, such as ⁇ , a diaryl iodonium salt comprising a non-nucleophilic and non-toxic counteranion, such as cumyltolyliodonium tetrakis-pentafluorophenyl borate (Ar2I +) , and a hydrogen donor such as isopropanol (HD or iPrOH).
- a photosensitizer such as ⁇
- a diaryl iodonium salt comprising a non-nucleophilic and non-toxic counteranion, such as cumyltolyliodonium tetrakis-pentafluorophenyl borate (Ar2I +)
- a hydrogen donor such as isopropanol (HD or iPrOH).
- the respective proportions of the various substances constituting the initiator may be adjusted by those skilled in the art, in particular according to the methods illustrated in the examples, to modify the polymerization conditions
- the variation of the composition of the hybrid initiator system into activating substances and / or in proportion to these substances makes it possible to obtain fibers with various properties (in particular mechanical properties), including in the case of a liquid composition whose composition does not vary in terms of reactive substances.
- the hybrid polymerization can be modulated to modify the kinetics (in particular relative) of the various mechanisms involved.
- the composition of the initiator system can be selected, according to the invention, to obtain a faster radical polymerization (higher initial velocity and / or kinetic profile showing a higher reactivity in the initial phase of the process) than cationic polymerization, faster cationic polymerization than radical polymerization, or similar polymerization kinetics (near initial velocities and / or or kinetic profile showing similar reactivities in the initial phase of the process) for both mechanisms.
- the proportions of the activating substances of the initiator system are selected as described in the examples, and more particularly:
- the following substances are used in the following proportions, determined as a percentage by weight with respect to 100 parts of the monomer mixture (equivalent “pcr”: parts per hundred parts of resin).
- Adaptations of the composition of the initiator system can be made to obtain the above kinetic ratios, preferably according to the proportions indications provided in the examples and / or by determining, according to these indications, the proportions adapted for others. modes (different liquid composition, etc.).
- modes different liquid composition, etc.
- a liquid composition comprising epoxy monomers, in majority proportion, and acrylate monomers:
- a minimum quantity (within the indicated range) of ITX in particular 0.2% to 0.5% and preferably 0.2% to 0.3%) a high amount of Ar2I + (in particular 2.5 to 5% and preferably 4 to 5%) and an intermediate amount of isopropanol (in particular 2 to 4% and more particularly 2.5 to 3.5%) ;
- a maximum amount (within the indicated range) of ITX in particular 0.6% to 1% and preferably 0.8% to 1%
- an intermediate quantity Ar2I + in particular 2 to 4% and preferably 2.5 to 4%)
- a minimum amount of isopropanol in particular 1 to 3% and more particularly 1 to 2%
- a high amount (in the indicated range) of ITX in particular 0.5% to 1% and preferably 0.7% to 1%
- a small amount of Ar2I + in particular 1 to 3% and preferably 1 to 2.5%) and an intermediate to high amount of isopropanol (in particular 2 to 5% and more particularly 2.5 to 4.5% ).
- the subject of the invention is the use of an initiator system for carrying out a hybrid polymerization of monomers in a mixture, in particular a hybrid radical and ionic polymerization, in particular cationic, system in which the activating substances comprise or consist of a photosensitizer (in a proportion of 0.2 to 2% by weight), a photoinitiator (in a proportion of 1 to 6% by weight) and, where appropriate, a donor of hydrogen (in a proportion of 1 to 25% by weight), the weight percentages being determined per 100 parts of monomer mixture.
- the activating substances comprise or consist of a photosensitizer (in a proportion of 0.2 to 2% by weight), a photoinitiator (in a proportion of 1 to 6% by weight) and, where appropriate, a donor of hydrogen (in a proportion of 1 to 25% by weight), the weight percentages being determined per 100 parts of monomer mixture.
- the liquid composition is chemically and physically stable, particularly at room temperature.
- chemically and physically stable herein denote a composition or substance that can be stored in a closed system or in a thermostatically controlled system, without spontaneous modification of its physical state or its chemical structure, for a relatively long period of time, in particular compatible with with manufacturing constraints (especially more than one hour, more than 6 hours, more than 12 hours or more than 24 hours).
- a stable liquid composition may require permanent or periodic agitation to maintain its physical properties and in particular its homogeneity.
- the liquid composition is stable at room temperature, in particular from 10 ° C to 30 ° C, from 15 ° C to 25 ° C and more particularly at 20 ° C.
- the liquid composition is stable at a temperature below the melting temperature of the polymer obtained and in particular the temperature of the substance is maintained below this melting temperature during the duration of the process of the invention, or at least in the liquid composition and during the extrusion phase.
- the liquid composition is stable in a temperature range, in particular between 20 ° C and 100 ° C, in particular greater than or equal to 50 ° C, in particular between 50 ° C and 70 ° C. C and more particularly between 50 ° C and 65 ° C (inclusive).
- the liquid composition is maintained in this temperature range, in particular for 2 to 4 hours, in particular during the process of manufacturing the fibrous structure of the invention, or at least in the liquid composition and during the extrusion phase.
- the liquid composition is kept stirred and / or is periodically stirred.
- the liquid composition, the extrudate and / or the filament are brought or maintained at a given temperature, in particular less than 100 ° C. and more particularly between 20 ° C. and 100 ° C.
- extrusion refers to the action of imposing on a liquid substance, particularly a viscous substance, an elongated shape of given section, forcing its passage through a hollow device and / or provided with a orifice (die) whose shape determines in particular the shape of said section.
- the die may for example be included in an extrusion nozzle and / or a spin pack or be constituted by a syringe needle or any other orifice of varied geometry, for the production of filament of circular section or not, for the realization monofilament or multicomponent filament for the elaboration of "island at sea", “orange quarter” or “pie wedge” conjugated fibers, trilobées, "side by side” ).
- the substance which after passing through the die adopts said elongated shape is designated extrudate. More particularly, the substance is thus designated as long as it is still essentially in the liquid or gel state.
- spinning (sometimes in extrusion / spinning form) is used here to refer to the whole process that starts with (and includes) extrusion and results in the production of a filament, a multi-filament or fibers and preceding assembly of filaments, multi-filament or fibers.
- the radiation polymerization step, the eventual drawing at the die outlet, the joining of the filaments to form multi-filaments, the cutting of the filaments or multi-filament fibers, the filament winding or multi - Filament are all steps included in the term spinning (when implemented in the embodiment considered).
- the substance constituting the extrudate is solidified by polymerization so that, without any other mechanical constraint than its own weight, it retains its shape, it is designated here by the term filament (sometimes in the form of a polymerized filament, for the sake of clarity) as long as it is not joined with other filaments to form multi-filaments and / or cut to form fibers.
- liquid composition before extrusion, the extrudate and the filament forming in the general case a continuous volume of material the terms of liquid composition, extrudate and filament therefore designate local fractions of this volume of material, whose physical and / or chemical properties are relatively homogeneous.
- certain operations may, depending on the particular production constraints, be carried out on unit filaments or on multi-filaments, fiber, flock, etc.
- certain features or process steps described with respect to the filaments can be understood as also applying to multi-filaments and / or fibers.
- no component is added to the liquid composition just before or during extrusion.
- no solvent evaporation occurs between the process step where the composition is liquid and that where the filament is polymerized.
- less than 10%, less than 5% or less than 1% by weight of the liquid composition is evaporated between the process step where the composition is liquid and that where the filament is polymerized.
- the elemental composition of the liquid composition does not vary during extrusion so that, in particular, the elemental composition of the polymer network is identical to that of the liquid composition.
- Elemental composition refers to the proportion of elements that enter a compound body or a mixture of such bodies. Without adding or removing material (and excluding fission reactions or nuclear fusion), the elemental composition of a mixture does not vary, it being understood that the molecular composition of the mixture may vary, in particular by reaction of the molecules constituting the mixture between them. When the elemental composition does not vary, the respective proportions of carbon, hydrogen, oxygen, nitrogen, in particular, do not vary.
- the elemental composition does not vary significantly during extrusion, which means that the elemental composition does not vary more than 10%, and in particular not more than 5% or 1% per element, i.e., the fraction of each element of the composition in the extrudate is not different by more than 10%, 5% or 1% of its fraction in the liquid composition prior to extrusion.
- the elemental composition does not vary by more than 10%, 5% or 1% per element between the process step where the composition is liquid and the stage where the filament is polymerized.
- the polymerization is obtained by radiation.
- the extrudate is subjected to radiation which allows the initiation and optional propagation of the polymerization.
- Radiation allows priming means here that, all other conditions being identical, the polymerization would not be initiated in the absence of radiation. Radiation here means any transfer of energy which does not require mechanical contact with the object subjected to radiation, and in particular by transfer of elementary particles, including electromagnetic radiation (that is to say, the transfer photons), in particular light or ionizing radiation such as electron beams and microwaves.
- the radiation is visible light (wavelength 400 to 800 nm) or ultraviolet (UV, wavelength 10 nm to 400 nm), or have lengths in the UV and visible domains, in particular from 100 nm to 500 nm, and more particularly between 300 nm and 450 nm or between 320 and 410 nm).
- UV ultraviolet
- the composition is photopolymerizable, it is necessary that it be kept before extrusion in the dark, at least at wavelengths that can allow polymerization.
- the liquid composition is preserved before extrusion in an opaque container, in particular opaque to visible radiation and / or UV.
- the source of the radiation should be arranged such that the extrudate receives sufficient radiation and that it may be necessary, or preferable, to provide a device. allowing the concentration of radiation in the volume occupied by the extrudate.
- the radiation is only necessary for the initiation of the polymerization.
- the radiation is necessary for, or favorable to, the propagation of the polymerization.
- the radiation is produced by light-emitting diodes (LEDs, LEDs).
- the radiation is produced by LEDs emitting in one or more wavelengths between 300 and 450 nm, preferably between 350 and 400 nm and even more preferably between 365 and 395 nm, with a length of 365 nm or 395 nm waveform.
- the use of the process described herein in particular described liquid compositions, and more particularly when an initiator system comprising a photoinitiator is used, provides a satisfactory polymerization using a reduced amount of energy.
- the energy consumption required by the process is less than 3000 kW / h per kg of filament produced.
- the light radiation has a power of less than or equal to 50 W / cm 2 , preferably less than or equal to 25 W / cm 2 .
- the power of radiation is measured, preferably, at a distance corresponding to the distance separating the radiation source from the extrudate during the implementation of the method.
- the invention also relates to any mode of radiation polymerization during the spinning process, in particular electron bombardment, the polymerization reactions being similar to the photopolymerization reactions.
- the polymerization is initiated by exposing the liquid extrudate to ionizing radiation, particularly to electron beams.
- This treatment effectively induces the radical polymerization of liquid compositions of monomers and pre-polymers sensitive to a radical mechanism, the cationic polymerization of liquid compositions of monomers and pre-polymers sensitive to a cationic mechanism including an appropriate onium salt, as well as the hybrid polymerization of liquid compositions combining the two types of monomers and pre-polymers by the two concomitant mechanisms.
- a photoinitiator or a photosensitizer into these compositions is not necessary, insofar as the ionizing radiation-material interaction which thus occurs within the extrudate generates reactive intermediates. (Free radicals, thermalised electrons) in sufficient number to induce priming processes equivalent to those observed by the photochemical pathway.
- Energy electron beams of between 50 keV and 10 MeV also have the advantage of inducing the polymerization of opaque or highly absorbent liquid compositions with respect to radiation lengths. waves between 300 and 600 nm, which respond less effectively when exposed to UV-visible radiation.
- the exposure doses leading to the solidification of the liquid compositions are compatible with the implementation of a variant of the process that is the subject of the present application, with one or more accelerated electron emitters placed out of the die instead of UV-visible radiation sources.
- the area of radiation exposure of the filament after extrusion should be of sufficient length to allow initiation of polymerization.
- the total implementation length corresponding to the length traveled by the filament between the die to the first contact with a solid object (for example the collection coil, or the first coil of a drawing mechanism , etc.), should be sufficient to allow polymerization and in particular the slow reactions of the cationic polymerization, in the case of a polymerization comprising such a cationic mechanism.
- the length of setting work is typically of the order of magnitude of 2 m.
- the implementation length is between 25 cm and 5 m, more particularly between 50 cm and 3 m and more particularly between 1.5 m and 2.5 m.
- the fibrous structure, and in particular the filament is produced in a controlled orientation, in particular the filament at the die outlet is produced unidirectionally and preferably vertically downwardly.
- a fibrous structure, in particular a fiber or a filament, the orientation of which is controlled during production can be collected and / or treated after polymerization according to the methods known in the field of textile fiber production in a particularly easy manner.
- the fibrous structure produced, in particular the filament is collected on a spool, a mandrel, a cone, or any other winding device.
- the winding device is located vertically below and under the die. Production in a controlled orientation at first (out of die) is not exclusive, p. ex.
- the extrusion is followed by an intermediate step of stabilizing the fiber or filament.
- This stabilization is effected, for example, in air or any other fluid that may make it possible in particular to coagulate, precipitate or cool the extruded materials (non-exhaustive processes).
- This stabilization may result from the simple path in the air extruded filament between the die and the first solid object contacted by the filament, in particular between the exit of the radiation exposure zone said first solid object (which may in particular consist in a rotating cylinder (coil, etc.) for collection or further manipulation.
- the polymerized yarn is subjected to at least one post-treatment.
- a post-treatment here refers to any treatment carried out on the polymer (possibly during polymerization), which is not required for the actual polymerization, but allows for example to modify the properties of the polymer obtained.
- the production of the fibrous structure can be followed by the reception of the fibrous structure, in particular the filament, unidirectionally oriented around a coil, a mandrel or any known device for winding on coils, cone to other support dedicated to textile processes downstream of the implementation of conventional or innovative flat structures (weaving, braiding, knitting, nonwovens ).
- Speed differential and / or temperature winding systems can be used prior to spool collection to draw the unidirectional fibrous structure produced.
- the buckets used in such systems can in particular be heated and / or placed in a liquid.
- the filament is stretched after its exit from the die and in particular at the outlet of the radiation exposure zone.
- Such stretching can be achieved, for example, by differential speed bucket systems according to techniques known in the art.
- Such stretching makes it possible in particular to improve the mechanical properties, in particular the toughness, of the fiber produced.
- Such a stretching can be particularly advantageous in the case where the polymerization is "alive” and therefore continues after exposure of the fiber to radiation. More particularly, such stretching is advantageous for a filament obtained by cationic and preferably cationic and radical hybridization polymerization, or for any other form of hybrid polymerization involving a faster polymerization mechanism and a slower and living mechanism.
- stretching can thus also occur during the formation of the macromolecular network by the action of a thermomechanical or mechanical stress. In this case, the invention allows the drawing during the propagation of the living polymerization.
- the filament is subjected at the die exit and / or at the outlet of the radiation exposure zone, to a heat treatment, in particular by heating at a temperature between 40 ° C. and 100 ° C, in particular between 60 ° C and 100 ° C and more particularly between 70 ° C and 90 ° C.
- a heat treatment in particular by heating at a temperature between 40 ° C. and 100 ° C, in particular between 60 ° C and 100 ° C and more particularly between 70 ° C and 90 ° C.
- Such treatment is in particular practiced for a period of a few seconds to a few minutes, or more if necessary, for example for at least 10 minutes.
- the inventors have shown that such a treatment makes it possible to accelerate the completion of the cationic polymerization in the case where the polymerization comprises such a cationic mechanism, which makes it possible in particular to improve the productivity of the method and / or the tenacity. of the filament.
- the monomers, prepolymers and / or oligomers of the liquid composition are at least partly epoxide compounds.
- the liquid composition consists essentially of epoxy compounds.
- Epoxides refer to chemical substances, in particular organic substances, comprising oxygen bridged on a carbon-carbon bond, that is to say an oxygen engaged by covalent bonds with two carbon atoms bonded to each other by a covalent bond ( in systematic nomenclature, these compounds are designated oxacycloalkanes).
- the polymer obtained is an epoxy polymer.
- An epoxy polymer designates a polymer obtained, or that can be obtained, by polymerization of monomers d epoxide.
- the reactive substances of the liquid composition consist of or comprise an epoxide compound and an acrylate compound, in particular a compound having both types of polymerizable functions.
- an epoxide compound and an acrylate compound, in particular a compound having both types of polymerizable functions.
- the use of a tel mixture makes it possible to obtain, by hybrid polymerization (and in particular by radical polymerization of the acrylate functional groups and by cationic polymerization of the epoxy functional groups), interpenetrated polymer networks.
- the reactive substances of the liquid composition consist of an epoxide monomer representing 70 to 80% by weight and an epoxy acrylate monomer representing 20 to 30% by weight.
- the fibrous structure and in particular the filament obtained has a density of less than 1.
- a density is made possible, in particular, by the hybrid polymerization which endows, via the production of interpenetrated polymer networks. , the fiber of a microporous macromolecular structure.
- the reactive monomers, oligomers or prepolymers that can enter the photopolymerizable compositions may also belong to the different families described below, or to their combinations: non-bio-sourced "epoxides", such as diglycidylether of bis-phenol A, bio-sourced or non-bio-based vinyl ethers, such as butanediol monovinyl ether or isosorbide divinyl ether, bio-sourced or non-bioetoxic oxetanes, such as bis (1-ethyl (3-oxetanyl)) methylether or (3-ethyl-3-oxetanyl) methyl methacrylate, (meth) acrylates that are bio-sourced or not, such as tripropylene glycol diacrylate and tetrahydrofurfuryl methacrylate, or bio-sourced or non-styrenic, such as vinyl naphthalene and 4-vinyl pyridine, vinyl esters of bio-sourced or otherwise,
- the liquid composition does not comprise silicone elastomer, or essentially does not comprise silicone elastomer. In a particular embodiment, the liquid composition comprises 20% or less silicone elastomer, in particular 10% or less and preferably 5% or less. In a particular embodiment, the polymer obtained does not belong to the family of silicones.
- the monomers, prepolymers and / or oligomers of the liquid composition are at least partly bio-sourced.
- the non-reactive additives and / or the initiators of the liquid composition are at least partially bio-sourced.
- the liquid composition consists essentially of bio-sourced compounds.
- a compound is said to be bio-sourced when it is obtained essentially from a biological source, that is to say in the absence of artificial chemical synthesis and more particularly when it is derived from plant or animal biomass. The synthesis of such a compound is in particular carried out by a (or within a) biological organism (in particular animal, plant, unicellular or multicellular organism).
- a biobased compound usually has to be isolated from its biological source, but the compound obtained essentially corresponds to the compound as synthesized by the biological organism.
- the product can be obtained, for example, from plant crops, and in particular cereals.
- the source of the compound may be a product of agriculture (agro-sourced compound).
- the compound may be subject to chemical or biotechnological modifications giving it new properties and / or new chemical functionalities.
- the method of the invention is provided in particular for its applications in the field of conventional textiles (clothing sector, furniture, textile articles for outdoor applications - outdoor or indoor, sportswear sector, textile articles made of ...) and technical textiles: medical, building, transport, electronics, functional materials, composite materials, personal protective equipment, etc.
- the invention also relates to the polymers obtainable by the process and in particular fibrous structures or fibers having at least one of the following properties, or a combination of the following properties:
- epoxide compositions in particular compositions consisting mainly of epoxidized linseed oil (ELO) and cardanol (NC547 and / or NC514), in particular with, in the resulting composition, proportions by weight of 'ELO on the total mass of ELO, NC547 and NC514 included in the following ranges (including their limits): 10 to 90%, in particular 20% to 90%.
- the composition may also include other multifunctional epoxidized reactive species in a proportion within the following ranges (including their boundaries): 10 to 90%, especially 10% to 20%.
- the photoinitiator system contains a photosensitizer, such as ⁇ , a diaryl iodonium salt comprising a low nucleophilic and non-toxic counter anion, such as cumyltolyliodonium tetrakis-pentafluorophenyl borate (Ar2I +), and a hydrogen donor such as as isopropanol (HD or iPrOH) for UV radiation between 365 and 410 nm wavelength generated by a monochromatic light-emitting diode system.
- a photosensitizer such as ⁇
- a diaryl iodonium salt comprising a low nucleophilic and non-toxic counter anion, such as cumyltolyliodonium tetrakis-pentafluorophenyl borate (Ar2I +)
- a hydrogen donor such as as isopropanol (HD or iPrOH) for UV radiation between 365 and 410 nm wavelength
- the fiber has a density less than or equal to 0.8, more particularly less than or equal to 0.7, more particularly less than or equal to 0.6, and more particularly from 0.5 to 0.6;
- the aqueous extract has a pH greater than or equal to 3.5, more particularly greater than or equal to 4, more particularly from 4 to 6 and more particularly from 4.1 to 4.5;
- the fiber has a formaldehyde content of less than or equal to an average of 75 mg / kg, more particularly less than or equal to an average of 50 mg / kg, more particularly less than or equal to an average of 20 mg / kg and more particularly less than or equal to on average 18 mg / kg;
- the fiber has a diameter of 210 to 300 ⁇ , more particularly from 230 to 280 ⁇ , and more particularly from 250 to 260 ⁇ ;
- the fiber retains its morphology (physical properties) after 24 hours immersion in any one of the following solvents: acetone, aqua regia, acetonitrile, 100% chloroform, dichloromethane, dimethylformamide, ethyl acetate, concentrated hydrochloric acid, peroxide hydrogen, methanol, n-butanol, concentrated nitric acid, 70% nitric acid, concentrated perchloric acid, phosphoric acid, 50% sodium hydroxide, sodium hypochlorite, xylene.
- the fiber retains, after such immersion, physical properties which remain acceptable for use in the manufacture of textiles, and in particular the mechanical properties defined herein, in particular the values of toughness, tensile strength and elongation at break. are included in the intervals defined herein, and / or are not decreased by more than 20% (preferably 10%) and / or are not increased by more than 20% (preferably 10%) relative to their value before immersion;
- the fiber has an average titre of 450 to 520 dTex, in particular 470 to 500 dTex and more particularly 480 to 490 dTex;
- the fiber has an average tensile strength, calculated according to standard NF EN ISO 5079 (February 1993 version) greater than or equal to 80 cN, more particularly greater than 100 cN, more particularly greater than or equal to 120 cN and more particularly between 120 cN and 130 cN and an elongation at break of 20% to 45%, more particularly from 25% to 40%, more particularly from 30% to 35%.
- Fibers having, as an alternative to the above values, an average titre of 40 to 70 dTex, in particular 45 to 65 dTex and more particularly 50 to 60 dTex and an average resistance, are also concerned by the invention.
- to traction calculated according to standard NF EN ISO 5079 (February 1993 version) greater than or equal to 1 N, more particularly greater than 1.2 N, more particularly greater than or equal to 1.5 N and more particularly between 1 , 5 N and 1.7 N and an elongation at break of 15% to 40%, more preferably 20% to 35%, more preferably 25% to 30%.
- Filaments, multifilament, fibrous structures consisting essentially of a polymer as described above are also contemplated in the invention.
- the properties described with respect to the fibers then apply respectively to the filaments, to the filaments constituting the multi-filament, or to the fibers constituting the fibrous material. If necessary, the properties of the filaments must be evaluated on fragments of limited size of the filaments, in particular fibers originating from the filament.
- FIG. 1 Main steps of the process.
- the method comprises three main steps and an optional processing step at the end of the sequence.
- Stretching may be replaced and / or supplemented by any other form of manipulation of the filaments according to the constraints of the production, in particular texturing, cutting, reactivation by radiation or heat, etc.
- Figure 2 Simplified mechanism for initiating and propagating a cationic reaction of epoxide monomers.
- A Priming;
- B Propagation by a "terminal active center”;
- C Propagation by "activated monomer”;
- D Transfer reaction.
- ELO epoxidized linseed oil
- LDO epoxidized limonene
- ENR epoxidized natural rubber
- EC glycidyl ethers and epoxides derived from cardanol
- DGES diglycidyl ether of isosorbide
- EMD glycidyl ethers of maltodextrin
- ELG modified lignin epoxidized
- ETN epoxidized modified tannins
- FO furyl oxirane
- THFA tetrahydrofurfuryl acrylate.
- FIG. 1 Filaments obtained in the form of mono-strands.
- A Filament received on reel.
- B Cliché of a fiber and its diameter.
- Figure 8. Graphical responses by the kinetics of polymerization of formulations G.
- Figure 9 Variation in the physical and mechanical properties of IPN-type materials Gl as a function of the components of the priming system-SyPh (DMA - bars (17,5X10X1; mm): UV-curing with two faces 10 and 10 seconds with 2 , 7 W.cm "2 followed by post-firing at 70 ° C to a complete conversion; Deben brand traction micromachine, tests on films of dimensions (20 x 5 x 0.12 mm 3 ): exposure to UV radiation for a duration of 20 seconds on each side with 2.7 W.cm -2 , followed by a post-cure at 70 ° C to obtain a complete conversion (> 95%) of the epoxide functions).
- DMA - bars (17,5X10X1; mm
- mm UV-curing with two faces 10 and 10 seconds with 2 , 7 W.cm "2 followed by post-firing at 70 ° C to a complete conversion
- Deben brand traction micromachine tests on films of dimensions (20 x
- FIG. 1 shows the whole process schematically.
- An inlet reservoir containing the formulation (1) in which is inserted the raw material in liquid form in the monomer / oligomer / pre-polymer reactive state.
- This tank can be closed, the material can be under pressure (piston, depressurization, evacuation %), heated (heating ribbons, water bath, electric resistances ...), mixed (mechanical stirrers, grinding, reflux system %), degassed to be extruded thereafter through the spin pack and / or extrusion head with or without filter beds to ensure the purity of the extruded material.
- the material prepared in the tank is then transferred to the die by means of an extrusion system (screw without screw, mono or twin screw system, gear pump, volumetric pump ).
- the die may be in the form of a spinning pack (monofilament or multi-strand of round section or specific trilobed geometry, cruciform ..) or in the form of a syringe or any element allowing to obtain an extrudate of the raw material of constant dimension and controlled by the diameter / geometry of the die and the extrusion speed.
- UV-Visible radiation of specific wavelengths is used to initiate the consolidation reaction of the wire extrudate.
- the UV radiation is provided by a mono- or poly-chromatic lamp, coupled to a reflector if necessary so as to concentrate and maximize the luminous flux in the geographical area of passage of the filament / extrudate.
- the reflector (4) is for optimizing and concentrating the radiant flux from a UV radiation source (5) for initiating the polymerization / crosslinking reaction.
- the extrusion of the material takes place in liquid form (6) with a wide range of viscosity, having an extrusion rate in accordance with the UV dose necessary to ensure the initiation of the photo-polymerization.
- the yarn (7) is consolidated and / or being consolidated by exposure to UV radiation.
- Reception of the formed wire the reception of the filament (8) is provided by winding (9) and / or other method of conditioning the filament.
- the use of a draw cup (10) and / or conditioning at ambient temperature or slightly heated near the glass transition temperature of the filament allows the wire (11) to be stretched to enhance the mechanical properties of the filament.
- Post-treatment (optional step): as a result of these operations, a thermal post-treatment (texturing, post-polymerization, etc.) may be performed depending on the state of polymerization of the wire. Indeed, depending on the formulation and the technological parameters used during the spinning, a post-polymerization step on coil, filament or cut fibers may be necessary according to the specifications and applications.
- the main objective in the experimental approach of the invention is to develop chemical fibers, within the meaning of the vocabulary of textile specialists, based on biosourced monomers, by a cationic polymerization process initiated under visible radiation. or very close UV (black light).
- Example 2 Chemical reaction of photopolymerization in the UV radiation zone.
- UV-Visible sources may have mono- or poly-chromatic radiation emission (Table 2 and Table 3). Table 2. Overview of UV sources: type of sources, wavelengths and power
- the cationic initiators in the presence of a hydrogen donor form by photolysis a stronger acid of the type: (i) Bronsted acid (by diaryliodonium salt: Ar2I + X- or triarylsulfonium: Ar3S + X -) or (ii) Lewis acid (by aryldiazonium salt: Ar2N2 + X- or cyclopentadienyl Fe (II) arene).
- the photolysis reaction is faster if the nucleophilic character of the counter-ion (X-) is lower.
- the acid thus formed is capable of initiating the cationic polymerization of monomers which do not polymerize radically, such as vinyl ethers or monomers heterocyclics (epoxides, lactones, cyclic ethers, epoxysilicones), as shown in the reaction scheme of Figure 2.
- monomers which do not polymerize radically such as vinyl ethers or monomers heterocyclics (epoxides, lactones, cyclic ethers, epoxysilicones), as shown in the reaction scheme of Figure 2.
- onium salts as cationic initiators is limited because of their low absorption in the range of the emission wavelengths of the usual lamps (these compounds are characterized by an absorption band for ⁇ ⁇ 320 nm).
- the initiator can be sensitized using a radical photoinitiator.
- the three-component photoinitiator system was designed accordingly: 2-isopropylthioxanthone as photosensitizer (ITX), a diaryl iodonium salt comprising a low nucleophilic and non-toxic counter anion, cumyltolyliodonium tetrakis-pentafluorophenyl borate (Ar2I +), and an isopropanol donor (HD or iPrOH).
- ITX 2-isopropylthioxanthone as photosensitizer
- Ar2I + cumyltolyliodonium tetrakis-pentafluorophenyl borate
- HD or iPrOH isopropanol donor
- ITX as a "key component" selectively absorbs incident photons and may result in various elemental reactions based on generally accepted mechanisms, such as (i) energy transfer, (ii) electron transfer, and (iii) the reduction of free radicals produced by photolysis, or the presence of H donors.
- the cationic mechanism polymerization is a reaction with a living character (can continue after stopping irradiation or following a thermal activation ).
- the termini occur mainly by interaction with nucleophiles (water, amines or alcohols), by transfer reactions (intramolecular cyclization, reaction with a counter-ion of the photoinitiator, for example) or simply by occlusion of the cation.
- Bio-sourced monomers can be easily obtained from annual plants or trees, or even the recovery of waste from the treatment of natural materials (agrochemicals, textile industries, paper / paperboard industries).
- fatty oils from vegetable plants epoxidized soybean oil - ESO, epoxidized linseed oil - ELO, epoxidized castor oil - ECO); terpenes (epoxidized limonene LDO and LMO), natural rubber (ENR);
- epoxy reagents epichlorohydrin
- hydroxyl phenoxyl
- carboxyl groups vegetable oil, such as cardanol (CE), saccharides and polysaccharides (diglycidyl-isosorbide ether - DGES, maltodextrin epoxide - EMD), lignins (ELG) and tannins (ETN);
- CCR dimethyloxosulfonium methylide ((CH 3) 2 SOCH 2 ) such as furyl oxirane (FO).
- Polyols are commonly used to provide flexibility in networks obtained by polymerization of epoxy prepolymers. They can also contribute to the adjustment of other properties, such as viscosity, cure rate and toughness. These oligomers act as a chain transfer agent, and can thus be incorporated into the crosslinked network during the UV radiation curing process.
- Bio-sourced or biodegradable polyols ethers or esters
- PLC polycaprolactone
- PTHF poly (tetrahydrofuran)
- PEG polyethylene glycol
- PEG poly (L (D) -lactic acid)
- the flow of the liquid extrudate is optionally facilitated by wearing the fluid at a temperature above the melting or homogenizing temperature of the photopolymerizable compositions.
- the proposed model formulations for the development of the pilot spinning assembly include as an essential component an epoxy vegetable oil - ELO (epoxy linseed oil, Ackros) as a bio-sourced ingredient commercially available.
- ELO epoxy linseed oil
- Some characteristics of the ELO are easily adjusted by combination with other ingredients, bio-sourced or not, having properties of viscosifier or reactive diluent:
- Viscosifiable reactive prepolymers Novolac type epoxy cardanol and BPA type (CEv: NC547 and NC514, from Cardolite): aromatic glycidyl ether monomer, bio-sourced, rigidifying for fibers; epoxy acrylate based on vegetable oil (AESO, CN111 from Sartomer): aliphatic epoxy acrylate monomer, bio-sourced; Epoxidized polybutadiene (PolyBDE605E, Sartomer-FR) - natural rubber model -ENR): aliphatic epoxy monomer, synthetic, hydrogen donors with terminal -OH
- Epoxy resins and other reagents have been characterized by several physico - chemical analysis techniques: NMR, IR and UV - Visible spectroscopies; steric exclusion chromato graphy; chemical dosage.
- the main parameters targeted for the evaluation were as follows: the content according to the interest, the molar mass, the solubility, the viscosity.
- the formulation methodology is underpinned by selection criteria: the viscosity of the formulation, the reactivity of the system and the physico-thermal properties of the materials developed.
- the priming system (SyPh - by the photoinitiator (PI), photosensitizer (PS) and hydrogen donor (DH) levels) and the effect of different monomers, prepolymers and polymers polyols on the relation viscosity - reactivity is optimized for each type of formulation based on Experimental Design (Experimental Design) - Matrices de Scheffé - special cubic model.
- the main stages of the Scheffé Plan are based on: (i) choice of variables; (ii) definition of the experimental domain; (iii) implementation of the Scheffé plan (iv) analysis of experimental responses and graphical exploitation of the response function (fields of the isoréponses with a view to optimizing the formulation).
- the optimization of the SyPh composition is expressed by a term called Desirability.
- Desirability function allows multiple responses to be taken into account or the desired responses can be: PI-min; PS-min; DH-max; Rp-Max. Values close to 1 are ideal for desirability.
- the optimization of the prepolymer composition can be guided by the search for coupled characteristics such as maximum viscosity and reactivity, or minimum viscosity and maximum reactivity. Materials developed by optimized formulations were characterized in terms of physical and mechanical properties and evaluated as a function of conversion and variable parameters: SyPh composition or prepolymer composition.
- the spinning method of the optimized formulation involves two steps: (i) Development of the extrusion and UV polymerization assembly (reservoir, type of die, extrusion mode, etc.) and (ii) Control of the concentration of irradiated UV dose on the extrudate (assembly of lamps in series, choice of reflector ...)
- the main parameters targeted for the characterization of the son obtained were as follows: (i) the conversion of reactive groups of the starting formulation - IR spectroscopic method; (ii) wire size - optical microscopy method; (iii) the physical properties of the wire, such as: diameter, strength, toughness, elasticity, tensile strength ...
- the average diameter of the filament obtained depends in particular on the geometry of the extrusion head (diameter, geometry and die length, shape) and the speed imposed on the extrudate at the die outlet.
- the filaments obtained in the form of mono-strands have a diameter of between 50 and 500 ⁇ and a titre of up to 600 dTex (FIG. 5).
- Formulations G are intended for the preparation of a polymer network of the IPN (interpenetrating network) type by competitive mechanisms of cationic polymerizations which may be concomitant with a faster radical reaction in monomers derived from vegetable oils.
- the criteria for evaluating efficacy are: Simultaneous Hybrid Polymerization; Faster polymerization of acrylate and faster polymerization of epoxy.
- the concomitant cationic and radical radical hybrid photopolymerization process aims to: (i) limit the sensitivity to oxygen of radical polymerization and moisture of cationic polymerization, (ii) increase the consolidation wire for greater reactivity and (ii) to prepare hybrid networks with a microstructure potentially different (thanks to the temporal control of the progress of each type of polymerisation) ( Figure 6).
- the monomer mixture consists of ELO and AESO.
- the three-component photoinitiator system was designed accordingly: ⁇ , PAr2I + and iPrOH.
- Three formulations were prepared with different viscosities, different epoxy / acrylate ratios, and different compositions of the initiator system (Table 5).
- FIG. 8-a shows that the high rates of acrylate polymerization are obtained for the mixture of the three components (ITX / Ar2I + 0.2 and ITX / iPrOH of 0.16 in real values) and with the ITX aid for the viscous formulation (G3) (ITX / Ar2I + 0.36 in actual values).
- the rate of acrylate polymerization tends to decrease with the addition of Ar2I + or iPrOH and their association.
- Hybrid polymerization (Crt I) with radical and cationic simultaneous polymerizations is not possible for G3 formulations because the areas of variability for the polymerization rates of acrylate and epoxy are different.
- the faster polymerization of epoxy (Crt III) is not possible for formulations G2 and G3 since, the polymerization rate of acrylate for formulations G2 has the lower limit value very close to the upper limit of the speed epoxy and the epoxy polymerization rate of the G3 formulations at the upper limit much lower than the lower limit of the acrylate polymerization rate.
- the activation of the polymerizable liquid compositions can also be carried out by exposure to ionizing radiation, in particular to a medium energy electron beam (100 - 300 keV).
- ionizing radiation in particular to a medium energy electron beam (100 - 300 keV).
- the initiation of radical processes results from the interaction of the radiation with the composition.
- the initiation of cationic processes is assisted by the presence of onium salts.
- Liquid films with a thickness of between 5 and 150 micrometers were polymerized and cured by exposure to a 150 keV electron beam with lower doses of between 5 and 100 kGy (Advanced Electron Beam Lab Unit).
- a polymerizable liquid composition comprising epoxidized linseed oil (100 parts by weight) and cumyltolyliodonium tetrakis-pentafluorophenylborate (1 part by weight) was spread on a flat substrate (aluminum plate) to obtain films in the state. liquid of thickness 80 micrometers. Electron beam processing (125 kV, 50 kGy) results in a dry, flexible film.
- the IPN polymer networks obtained according to the G1 formulations are: (i) network obtained by faster polymerization acrylate (AGI); (ii) network obtained by hybrid polymerization (HG11 and HG12) and (iii) network obtained by faster polymerization epoxy (EGI).
- AGI faster polymerization acrylate
- HG11 and HG12 hybrid polymerization
- EGI faster polymerization epoxy
- a deconvolution method was applied to the FTIR spectra to separately quantify the progress of the polymerization of the acrylate and epoxy functions, respectively.
- the formulation of a three-component photoinitiator system ( ⁇ as photo-sensitizer, Ar2I + as acid generator and iPrOH as hydrogen donor) was examined in detail in order to exert a control of the kinetics of polymerization of one type of monomer with respect to the other.
- the results obtained based on the Scheffé plan were used to prepare IPN type networks with different microstructures using the set of optimal conditions favorable to the sequential or simultaneous development of hybrid networks.
- the materials obtained have been characterized by DSC, DMA and micromechanical tests on a Deben brand apparatus showing that the networks having the same pre-polymer composition exhibit different physical and mechanical properties.
- the glass transitions were recorded as a function of the degree of progress of the polymerization: the faster polymerization of the epoxy leads to a lower glass transition temperature (Tg) while the faster polymerization of the acrylate leads to a higher High Tg.
- Tg glass transition temperature
- the mechanical properties are also influenced by the kinetics of the polymerization of acrylate and epoxy monomers.
- the 395nm LED irradiation of AESO and ELO photo-polymerizable formulations provides a simple procedure for developing IPNs with adjustable properties.
- Control of the extrusion-spinning process followed by photopolymerization requires control and control of the parameters impacting the photopolymerization reactions.
- the kinetics and conversion rate of a functional group via a photopolymerization reaction depend primarily on the intensity of the radiation and the amount of photons absorbed.
- the effective dose depends on the overlap between the absorption spectrum of the initiator and the emission spectrum of the source, the light intensity in the effective wavelength range and the exposure time.
- the choice of a radiation source was on a wavelength of 385 - 395 nm. This process parameter is kept constant in our examples.
- the first orientation feasibility studies were carried out with a petrochemical system by radical photopolymerization from the irradiated TPO photoinitiator with an LED source centered on 365 nm.
- the UV radiation source can vary or even couple using LEDs of different wavelengths.
- the luminous intensity emitted by the LED is a fixed datum. In this example, the LEDs used have a radiation intensity of 4 W / cm 2 .
- the UV dose is modified by: i. Extrusion flow rate (pump speed, diameter of dies)
- the extrudate is refined under its own weight, associated with residual internal stress relaxation mechanisms. Imposed extrusion speed and die geometry control the constant formulated resin extrudate diameter.
- the intensity of the UV radiation weakens as the light source moves away.
- the distance between the lamp and the extrudate is fixed at 1 cm.
- the extrudate When the lamps are in series, that is to say one above the other, the extrudate is irradiated over a length of 2 x 10 cm or 20 cm. On the other hand, by placing the lamps facing each other or at a 90 ° angle, the light curing is not triggered quickly enough to maintain the continuity of the wire.
- the series configuration is therefore the most interesting and also increases the speed (or flow) of the extrudate.
- the average exposure time of the extrudate to the lamps is typically less than 100 ms.
- the temperature of the formulation By preheating the resins around 60 ° C., it is easy to restore the fluidity and transparency necessary for the process by photopolymerization, if these characteristics have evolved after storage for several months.
- the characteristics of the filaments produced are: i.
- Linear mass The average linear density was calculated from the mass measurement of test pieces of a given length.
- the average fiber grade is 485 dTex ii.
- the epoxy fiber floats in the water for a few days, gets loaded with water and sinks.
- the tenacity of the fiber is 2.4 cN / Tex, perfectible via process optimizations, in particular intensity of radiation, UV dose, hermeticity and degassing of the liquid composition ...
- Moisture recovery rate the average moisture recovery rate is 4%.
- the objective of the invention is the photopolymerization of bio-sourced monomers for the development of a novel photon radiation radiation technology for bio-sourced fibers.
- Photocurable formulations contain the following components: (i) mono- or oligomers, (ii) initiator system and (iii) additives (surfactants, viscosifiers, fillers, pigments, etc.)
- Epoxidized vegetable oil - ELO (epoxidized linseed oil, Ackros) is "the key bio-sourced resin” for all formulations.
- the limiting characteristics of the ELO (low Tg and other mechanical properties) are adjusted / corrected by combination with other bio-sourced materials having reactive viscosifier properties (ENR or PolyBDE605E, AESO, CEv: NC547 and NC514) or not reagent (PCL) and reactive diluents (LDO or UVR6105, CEd: NC513 and LITE 2513 HP).
- the priming system contains a photoinitiator (PI), a photosensitizer (PS) and a hydrogen donor (DH).
- the formulation methodology is based on an experimental design according to Scheffé by correlation of rheological properties, reactivity and properties of materials as a function of composition.
- C photo-crosslinked formulation by cationic mechanism based on a bio-sourced epoxide monomer (ELO) and a biodegradable, biodegradable additive (PCL);
- ELO bio-sourced epoxide monomer
- PCL biodegradable, biodegradable additive
- G photo-crosslinked formulation by two competitive mechanisms: cationic and radical (hybrid mechanism) based on a bio-sourced epoxy monomer (ELO) and a biosourced epoxy acrylate monomer (AESO).
- ELO bio-sourced epoxy monomer
- AESO biosourced epoxy acrylate monomer
- Electron-beam curing of epoxy resins effect of alcohols on cationic polymerization
Abstract
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PCT/FR2016/050944 WO2016170278A1 (en) | 2015-04-23 | 2016-04-21 | Method for manufacturing fiber materials by photopolymerization |
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EP1709219A4 (en) * | 2003-09-05 | 2008-03-05 | Univ Louisiana State | Nanofibers, and apparatus and methods for fabricating nanofibers by reactive electrospinning |
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