Thermoplastic composite material for reinforced

Abstract

The invention relates to a thermoplastic composite material (1) comprising:-at least one straight portion (10) having a circular cross-section having an outer diameter (d) and a longitudinal axis (L),-at least one curved portion (11),-at least one bending radius (r), the factor f of the bending radius (r) of the at least one curved portion (11) relative to the outer diameter of the at least one straight portion (10) being at most equal to 5, and-a thermoplastic matrix and a fibrous reinforcement. The invention also relates to a structure to be reinforced comprising at least one thermoplastic material (1), to the use of a thermoplastic composite material (1) and to a method (100) for producing a thermoplastic composite material (1).

Description

[0001] [Field of the Invention] The present invention relates to the field of construction, and in particular to the field of thermoplastic composite materials for structural reinforcement.

[0002] The present invention provides novel thermoplastic composites and methods of producing thermoplastic composites preferably for use in reinforcing structures.

[0003] [Description of related fields] In various buildings, construction sites, and civil engineering sites related to buildings or structures, building materials are often used, and reinforcing bars (rebars) are generally used as building materials.

[0004] Typically, rebar is a steel bar used in reinforced structures and preferably in reinforced concrete and / or reinforced masonry as a tensioning device to strengthen and help the concrete / mortar withstand tension. Currently, rebar is used in many fields from construction to aerospace.

[0005] For example, concrete is a very strong material in compression but weak in tension (flexural strength) and shear. It exhibits brittle behavior when breaking / rupturing. To compensate for this imbalance, reinforcing bars are incorporated into the concrete mass to withstand these forces and provide ductility. Masonry and its mortar joints share the same weaknesses as concrete. To increase tensile strength, steel bars are also incorporated into masonry structures. This is also true for most structures that are reinforced in various applications of rebar.

[0006] Furthermore, the structure to be reinforced has a complex arrangement and configuration that evolves over time and with demand.The distribution of the resistance properties then becomes a priori non-uniform in a complex configuration (ie comprising at least one angle or at least one corner).

[0007] Furthermore, the distribution of the reinforcement within the structure to be reinforced has become extremely limited by the shape of the structure, or even the shape of the formwork to be filled and certain locations within the structure and / or formwork remain empty. However, as the fields of application develop, new geometries are also necessary and so are their reinforcements.

[0008] Furthermore, within the steel bar itself, stresses vary along its length in the tensile zone. In fact, extending the length of the bar sufficiently beyond the point where it reaches its elastic limit is essential to prevent it from cracking. This length must also be at least equal to the developed length. However, if the actual length available is insufficient for full development, the structure risks cracking or even collapse.

[0009] The most common type of reinforcement is steel rebar, typically made from hot-rolled round bars with a raised deformation pattern on their surface. These bars are typically longitudinal. They offer some advantages, such as their resistance to bending (flexural strength). However, they are susceptible to corrosion, which can lead to degradation. Several solutions have been developed to improve their adhesion to the reinforced structure and their chemical resistance.

[0010] For example, stainless steels derived from iron alloys are known to be corrosion resistant, but they are very expensive.

[0011] Another example involves steel rebars coated with a coating, typically epoxy resin. The surface of the rebar is typically roughened (e.g., with ribs) to promote better adhesion to the concrete / mortar and reduce the risk of slippage. However, these coatings tend to make the coated rebar more expensive than the base steel rebar and may have lower mechanical properties. The coating is applied to the rebar after it has been produced. During forming processes such as bending, or even when connecting to other rebar, cracking or breaking of the coating can lead to a reduction in the mechanical and chemical properties of the reinforcement and, therefore, the structure being reinforced.

[0012] Other types of rebar are made from fiber-reinforced polymers (FRP), such as glass fibers, carbon fibers or basalt fibers, and are typically embedded in thermosetting resins. With thermosetting resins, it is no longer possible to change the shape of the rebar after it has been produced and formed. In addition, it is impossible to produce thermosetting rebars without precise indications of the requirements of the structure to be reinforced, resulting in long production and supply times. Moreover, once formed, these thermosetting rebars cannot withstand any modifications, even minor ones. Furthermore, thermosetting rebars have other disadvantages, such as long cycle times, high energy consumption, low recyclability of the materials used, toxicity of certain components and emissions of volatile organic compounds, especially during the manufacture of bent / formed rebars. Furthermore, it is well known that thermosetting polymers, and in particular bent rebars, cannot be widely used due to high transport volumes and storage.

[0013] Furthermore, with current curved thermoset rebar, the point of curvature involves compression of the fibers, which becomes unable to withstand tension and significantly reduces the structure's reinforcement. Furthermore, today's thermoset resins need to be manually formed during the pultrusion process, which incurs additional costs and time. Consequently, it's impossible to adapt the thermoset rebar to the structure being reinforced or modify it after cooling. The same problem applies to steel, and therefore epoxy-coated rebar, due to its epoxy coating.

[0014] The design and application of non-metallic reinforcements present many challenges. These reinforcements behave differently from metals, for example in terms of shear strength, creep, and elasticity. However, good mechanical properties are essential.

[0015] In addition, current rebar (such as stainless steel, epoxy resin and thermosetting resin) is placed with reinforcement supports and / or spacers that separate the rebar from the concrete / mortar formwork to establish the concrete / mortar cover and ensure proper embedment and avoid corrosion. The rebar in the formwork is connected by spot welding, by tying steel wire or with mechanical connectors. In order to connect epoxy-coated or plated rebar, epoxy-coated or plated wire is usually used. All of these mechanical elements (supports, spacers, welding, mechanical connectors) are effective means to reduce the congestion of rebar in the heavily reinforced areas on site. However, these elements require the organization of the rebar, which is almost impossible to strengthen the entire structure, especially to adapt to the various shapes of the structure to be strengthened. For example, the reinforcing bars are glued together to form a circle of a predetermined diameter, which is not suitable for strengthening the corners of various structures. This also reduces the space available to ensure continuous reinforcement of the structure (distribution of resistance properties and continuity of force).

[0016] The reinforcement is usually longitudinal and has a curvature at its ends. New forms of reinforcement have also been developed for assembly, such as stirrups or pins. The curvature allows the reinforcement to be assembled together within the formwork or structure to be reinforced.

[0017] A problem with FRP is its efficiency in shear. Compared to steel or straight fiber structures, FRP reinforcement bars formed by bending before hardening generally have relatively poor performance. When tensioned, the area between the straight and curved areas is subject to high bending, shear, and longitudinal stresses.

[0018] Thus, for rebar made of polymer (FRP), and in particular thermosetting polymers, the radius of curvature is 6 to 7 times the rebar diameter, according to the formula r = f * d, where r is the bending radius, f is a factor between 6 and 7 (limits inclusive), and d is the diameter of the rebar, preferably the outer diameter (typically between 6 mm and 30 mm, limits inclusive). Such a factor of 6 or 7 prevents the risk of cracks in the bend, thereby preventing cracks in the rebar and, consequently, in the structure. This bending radius is particularly significant and increases the size of the formwork or structure. It also increases the amount of material (concrete, mortar, or other material) required to fill the formwork, for example. Finally, due to such a bending radius and the resulting bulk, it is impossible to ensure force continuity for structures with complex shapes (e.g., at least one angle) and / or different shapes. Finally, due to such a bending radius, assembling the rebar together becomes particularly difficult.

[0019] Furthermore, the steel bars are produced away from the construction site and subsequently assembled at the construction site by tying, welding or mechanical couplings to form a reinforced formwork which will be filled with a substance (concrete or mortar or other). They are usually passively embedded in the concrete / mortar before the concrete / mortar cures.

[0020] Therefore, the reinforcements, whether made of steel or thermosetting polymers, have a significant dimension in the structure and must be provided in large quantities to provide reinforcement in tension / bending / compression / shear. Moreover, they do not allow the reinforcement of the entire structure when it has a specific shape (i.e. at least one angle) (coatings, optical fibers, connecting elements, bending radii, congestion issues).

[0021] Furthermore, the reinforcements have difficult assembly between themselves or with the structure to be reinforced, thus reducing the reinforcement of the structure, especially with high factors.

[0022] Finally, it becomes important to be able to facilitate the transport and storage of reinforcement while being able to provide freedom in the possible forms of the structure to be reinforced.

[0023] Therefore, there is a need for solutions that allow the creation of new devices for reinforcing the structure to be reinforced that are small, adaptable to various shapes, have good mechanical and / or chemical properties and at the same time allow easy anchoring to the structure to be reinforced or between reinforcements.

[0024] Lower curvature radii allow for smaller structures and more design freedom. Additionally, less material, especially concrete, can be used, and smaller structures can be achieved due to the lower bending radius.

[0025] There is also a need to come up with steel bars that can be bent like steel bars but are lighter.

[0026] Document CA 2839915 discloses a bendable FRP steel bar. The steel bar is made of a flexible polyester designated by the French title.

[0027] Document FR 3 087 203 discloses (meth)acrylic compositions suitable for use in steel bars. The steel bars may be curved, but the bending radius is not mentioned.

[0028] Document FR 3060577 discloses a liquid composition comprising monomers, a (meth)acrylic polymer and at least two initiators with different half-lives. Composite steel bars are mentioned as a possible application of the polymeric liquid composition, but not curved and not even with a bending radius.

[0029] Furthermore, it would be advantageous if the device were cheap and easy to manufacture, yet easy to transport and store. Finally, it would be interesting if the device were more easily recyclable. [Summary of the Invention] For the purpose of providing a basic understanding of the present invention, a simplified summary of selected aspects, embodiments and examples of the present invention is set forth below. However, this summary does not constitute a comprehensive overview of all aspects, embodiments and examples of the present invention. The sole purpose of the summary is to present selected aspects, embodiments and examples of the present invention in a concise form as an introduction to a more detailed description of the aspects, embodiments and examples of the present invention that follow the summary.

[0031] The present invention aims to overcome the shortcomings of the prior art. In particular, the present invention provides a thermoplastic composite material comprising: - at least one straight portion having a circular cross-section, having an outer diameter and a longitudinal axis, - at least one curved portion, at least one bending radius, the at least one bending radius of said at least one curved portion having a factor of at most 5 relative to said outer diameter of said at least one straight portion, and -Thermoplastic matrix and fiber reinforcement.

[0032] The advantage of such a thermoplastic composite material is that it exhibits good mechanical and / or chemical properties.The thermoplastic composite material according to the invention allows easy and simplified assembly between thermoplastic composite materials or with the structure to be reinforced and improves the reinforcement of the structure to be reinforced.

[0033] The composite thermoplastic according to the invention is also relatively small in size, adaptable to various shapes, has good mechanical and / or chemical properties, and at the same time allows easy anchoring to the structure to be reinforced or between reinforcing elements.

[0034] The thermoplastic composite material according to the invention makes it possible to facilitate the transport and storage of reinforcements while offering freedom in the possible shapes of the structure to be reinforced.

[0035] Furthermore, the thermoplastic composite material according to the present invention is cheaper and easier to manufacture, while being easier to transport and store.

[0036] Finally, it’s easier to recycle.

[0037] Other optional features of the thermoplastic composite material according to the present invention may optionally include one or more of the following features, alone or in combination: - the thermoplastic matrix comprises a thermoplastic polymer selected from the group consisting of polyamides, polyureas, polyacrylic acids, poly(aryletherketones), polyimides, aromatic polyetherimides, polysulfides, polysulfones, polyolefins, polylactic acid, polyethylene, polyvinyl alcohol, fluoropolymers, styrenes, cellulosics, polyesters and / or polycarbonates, - the thermoplastic matrix comprises a (meth)acrylic polymer, - the thermoplastic composite material comprises at most 35% by volume of a thermoplastic matrix comprising a (meth)acrylic polymer and at least 65% by volume of fibers, - the thermoplastic composite material comprises 20% to 50% by volume of a polymer matrix comprising a (meth)acrylic polymer and 50% to 80% by volume of fibers, - said at least one bending radius relative to said outer diameter of said at least one straight portion has a factor at least equal to 2, - the outer diameter of said at least one straight portion of said thermoplastic composite material is between 4 mm and 40 mm, - said at least one bending radius is between 8 mm and 200 mm according to the formula r=d*f, where r is the bending radius in mm, d is the outer diameter in mm, and f is a factor, where f is between 2 and 5 relative to the outer diameter of said at least one straight portion, - said thermoplastic composite material comprises at least one bending angle, defined relative to said longitudinal axis of said thermoplastic composite material, said bending angle being between 0° and 360°, excluding 0°, - said at least one straight portion and said at least one curved portion are from the same thermoplastic matrix.

[0038] According to another aspect, the present invention may also relate to a structure to be reinforced comprising at least one thermoplastic composite material according to the invention. Such a structure has better reinforcement and may have a longer lifespan.

[0039] The invention may also relate to the use of the thermoplastic composite material according to the invention in automotive, transport, marine, railway, aviation, aerospace, photovoltaic, building and construction, concrete reinforcement, masonry, civil engineering and / or wind energy applications. The composite thermoplastic according to the invention is advantageously suitable for use in any type of sector and makes it possible to reinforce structures in several fields.

[0040] The present invention may also relate to the use of the thermoplastic composite material according to the present invention as a reinforcing element, building material, hook, multi-link, stirrup, anchor, stake, fixing, chaining, header, coupler, connector, plug, splice, fitting, support, frame, strut, spacer, cage, T-bar, I-bar, spliced ​​bar, sliced ​​bar, longitudinal bar, transverse bar, continuous bar, panel, rod, rebar and / or sheet. The thermoplastic composite material according to the present invention can take several forms and can therefore be used in various and different ways without the need to modify the thermoplastic composite material.

[0041] According to another aspect, the present invention may also relate to a method for producing a thermoplastic composite material comprising at least one straight portion with a circular cross-section and at least one curved portion, the straight portion having an outer diameter and a longitudinal axis, the method comprising: - a step of providing a thermoplastic composite material having at least one straight portion with a circular cross section, said straight portion having an outer diameter, said thermoplastic composite material comprising a thermoplastic matrix and a fiber reinforcement, - a step of heating a portion of the thermoplastic composite material, preferably by conduction, convection, radial and / or volumetric heating, - a step of forming at least one curved portion in said heated portion by bending said heated portion according to a bending radius having a factor at most equal to 5 relative to the outer diameter of said at least one straight portion of said thermoplastic composite material, - a step of cooling said at least one curved portion to form a thermoplastic composite material comprising at least one straight portion and at least one curved portion.

[0042] The method according to the invention allows thermoplastic composite materials to be produced easily and in a relatively cheap manner: the method allows the production of thermoplastic composite materials having lower bending radii while having improved mechanical and / or chemical properties.

[0043] The foregoing and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which: Figure 1 is a schematic diagram of a thermoplastic composite material according to an embodiment of the present invention.

[0044] Figure 2 A is a schematic diagram of the shape of a thermoplastic composite material according to an embodiment of the present invention.

[0045] Figure 2 B is a schematic diagram of the shape of a thermoplastic composite material according to an embodiment of the present invention.

[0046] Figure 2 C is a schematic diagram of the shape of a thermoplastic composite material according to an embodiment of the present invention.

[0047] Figure 2 D is a schematic diagram of the shape of a thermoplastic composite material according to an embodiment of the present invention.

[0048] Figure 3 is a flow chart of a method according to an embodiment of the present invention.

[0049] Several aspects of the present invention are disclosed with reference to flowchart illustrations and / or block diagrams of methods and apparatus according to embodiments of the invention.

[0050] In the accompanying drawings, the flowcharts and / or block diagrams illustrate the architecture, functions, and feasible implementations of devices, systems, or methods according to several embodiments of the present invention.

[0051] To this end, each block in the flowchart or block diagrams may represent a system, an apparatus, or a module including a number of executable instructions for performing the specified logical function(s).

[0052] In some implementations, the functionality associated with the blocks may occur in a different order than indicated in the figures.

[0053] For example, two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

[0054] Each block of the flowchart or block diagrams, and combinations of blocks in the flowchart or block diagrams, can be implemented by specific systems that perform the specified functions or actions or execute combinations of specific devices and computer instructions.

[0055] [Details] A description of exemplary embodiments of the invention follows.

[0056] "Polymer" refers to a copolymer, homopolymer, or block copolymer. The term "copolymer" refers to a polymer composed of several different monomer units, and the term "homopolymer" refers to a polymer composed of the same monomer units. A "block copolymer" refers to a polymer comprising one or more uninterrupted blocks of each different polymer species, the polymer blocks being chemically distinct from one another and linked together by covalent bonds. These polymer blocks are also referred to as polymer segments.

[0057] Within the meaning of the present invention, the expression "polymer composite material" denotes a multicomponent material comprising at least two immiscible components, wherein at least one component is a polymer and the other component may, for example, be a fiber reinforcement.

[0058] Within the meaning of the present invention, "fibrous reinforcement" or "fibrous substrate" or "fiber" refers to several fibers, unidirectional fibers or fiber braids, or continuous filament mats, fabrics, felts or nonwovens, which can be in the form of tapes, webs, braids, cores or sheets.

[0059] The term "matrix" may refer to a material that acts as a binder and is capable of transmitting forces to the fiber reinforcement.

[0060] A "polymer matrix" may include polymers, but may also include other compounds or materials.

[0061] "(Meth)acrylic polymer matrix" may refer to all types of compounds, polymers, oligomers, copolymers or block copolymers, acrylic acid and methacrylic acid. However, it does not depart from the scope of the present invention if the (meth)acrylic polymer matrix contains up to 10% by weight, preferably less than 5% by weight, of other non-acrylic monomers, for example selected from butadiene, isoprene, styrene, substituted styrenes such as α-methylstyrene or tert-butylstyrene, cyclosiloxanes, vinylnaphthalene and vinylpyridine.

[0062] Within the meaning of the present invention, the term "initiator" or "precursor" may refer to a compound that can start / initiate the polymerization of a monomer or monomers.

[0063] Within the meaning of the present invention, the term "polymerization" may refer to a process of converting monomers or monomer mixtures into polymers.

[0064] Within the meaning of the present invention, the term "monomer" may refer to a molecule that can undergo polymerization.

[0065] For the purposes of the present invention, the term "thermoplastic polymer" may refer to a polymer that is generally solid at room temperature, may be crystalline, semi-crystalline, or amorphous, and softens during temperature increases, particularly after passing its glass transition temperature (Tg) and flowing at higher temperatures, and / or can undergo significant melting when passing its so-called melting temperature (Tf) (when semi-crystalline), and becomes solid again when the temperature drops below its melting point and below its glass transition temperature. This also applies to thermoplastic polymers that are slightly crosslinked by the presence of multifunctional monomers or oligomers in the "syrup" (meth)acrylate formulation, preferably in a weight percentage of less than 10%, preferably less than 5%, and thus preferably less than 2%, and may be at least 0.5%, and can be thermoformed when heated above the softening temperature. Tg and Tm can be determined by differential scanning calorimetry (DSC) according to standards 11357-2:2013 and 11357-3:2013, respectively.

[0066] The term "thermoplastic composition" may refer to a thermoplastic syrup or a thermoplastic resin or a thermoplastic resin precursor.

[0067] The term "thermoset polymer" may refer to a plastic material that is irreversibly transformed by polymerization.

[0068] The term "(meth)acrylic monomer" may refer to any type of acrylic and methacrylic monomers.

[0069] The term “(meth)acrylic polymer” may refer to a polymer substantially including a (meth)acrylic monomer accounting for at least 50 wt % or more of the (meth)acrylic polymer.

[0070] Within the meaning of the present invention, the term "PMMA" may refer to homopolymers and copolymers of methyl methacrylate (MMA), with the weight proportion of MMA in PMMA being preferably at least 70% by weight for MMA copolymers.

[0071] The expression "reinforcement element" as used may refer to an element used in / with a structure to reinforce it, support it, solidify it, consolidate it, improve its mechanical properties (reinforcement, stretching, elongation, etc.), its thermal, electrical and / or chemical characteristics.

[0072] The term "rebar" may refer to reinforcing bars used as tensile devices in reinforced concrete and masonry structures to strengthen and assist the concrete under tensile forces. Rebar significantly increases the tensile strength of a structure's concrete.

[0073] The expression "structure" or "structure to be reinforced" or "concrete structure" or "masonry structure" or "mortar structure" or "formwork" may refer to any structure that is generally reinforced or that requires reinforcement. For example, the construction or composition, arrangement and assembly of the elements of a building (or more specifically, the elements forming its frame) of something (such as a building). In addition, concrete or mortar can also be used. The structure to be reinforced can be any type of structure that needs to be reinforced, preferably by a reinforcing element. Such a structure to be reinforced can include concrete and / or mortar and / or a polymer matrix with fibers. Preferably, the structure can correspond to any structure comprising cast concrete.

[0074] The abbreviation "phr" can refer to parts by weight per hundred parts of the composition. For example, 1 phr of initiator in the composition means that 1 kg of initiator is added to 100 kg of the composition.

[0075] The abbreviation "ppm" can refer to parts per million by weight of a composition. For example, 1000 ppm of a compound in a composition means that 0.1 kg of the compound is present in 100 kg of the composition.

[0076] In the following description, "bend radius" may refer to the level of curvature of a reinforcing element. The bend radius may be the radius of a circle known as an osculating circle. The osculating circle may be the circle that "fits the curve as best as possible." In other words, the bend radius is the absolute value of the radius of a circle tangent to the curve (the osculating circle), with its diameter perpendicular to the tangent line. Bending radius is well known in the art of rebar, for example, as disclosed in Branz, "Site-bending of inforcing steel," Build, October / September 2004, pp. 22-24.

[0077] As used herein, the term "about" can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of the stated value or limit of the stated range.

[0078] As mentioned above, existing steel bars do not ensure consistent force within the structure being reinforced. In fact, their bulk within the structure or during its assembly is significant. They are also difficult to assemble with each other or with the structure being reinforced, thus reducing the structural reinforcement. Consequently, the resistance is uneven.

[0079] Furthermore, certain types of steel reinforcement have reduced mechanical properties due to the presence of coatings, flexural cracks or even ruptures of the reinforcing fibers.

[0080] Rebar is also difficult to transport and store, and requires significant cost and time during its production.

[0081] Finally, currently the reinforcements are not designed to improve their recyclability, or even the recyclability of the structure, or even to allow for a reduction in CO2 consumption.

[0082] There is a need for a new device for reinforcing structures that is compact, small in size, adaptable to various shapes, exhibits good mechanical and / or chemical properties, and uniform resistance, while allowing for easy assembly into the structure to be reinforced or between steel bars. There is also a need for a new reinforcement device that allows for easy transport to construction sites and easy storage. Ultimately, it is always advantageous to be able to improve costs and production times in the industrial sector. Furthermore, it is also relevant that this new method be more environmentally friendly.

[0083] Current rebars do not allow these objectives to be achieved because they are made of stainless steel, which increases the cost, or of steel with a coating such as an epoxy coating that breaks when bent, or are difficult to assemble, transport and store because they are made of thermosetting polymers and are therefore brittle when bent, difficult to achieve and not very adaptable.

[0084] New thermoplastic composite materials have been developed.

[0085] According to a first aspect, the present invention relates to a thermoplastic composite material 1 .

[0086] Preferably, the new thermoplastic composite material is suitable for reinforcing a structure, more preferably is intended to reinforce a structure, and even more preferably, the new thermoplastic composite material is used to reinforce a structure.

[0087] The structure is preferably a structure in a building that needs to be reinforced. It can be any structural concrete, mortar or other building material. The structure to be reinforced can have any shape or size.

[0088] The thermoplastic composite material can be a reinforcing element, a building material, a hook, a multi-link, a stirrup, an anchor, a stake, a fixing, a chain lock, a header, a coupler, a connector, a plug, a splice, a fitting, a support, a frame, a strut, a spacer, a retainer, a T-bar, an I-bar, a spliced ​​bar, a sliced ​​bar, a longitudinal bar, a transverse bar, a continuous bar, a panel, a rod, a rebar and / or a sheet, and is preferably rebar. According to one embodiment, the thermoplastic composite material can include several sheets.

[0089] In particular, Figure 1 As shown, the thermoplastic composite material 1 includes at least one straight portion 10 and at least one curved portion 11 .

[0090] Thermoplastic composites may comprise a matrix (usually a polymer matrix comprising a thermoplastic polymer) and fibers (as a fiber matrix). Such thermoplastic composites are usually produced by a pultrusion process, and the matrix is ​​derived from a thermoplastic composition.

[0091] According to the present invention, the thermoplastic composite material 1 comprises a thermoplastic matrix and a fiber reinforcement.

[0092] As explained, thermoplastic composite materials are generally solid at room temperature, they can be crystalline, semi-crystalline or amorphous, and soften during temperature increases, in particular after passing through their glass transition temperature (Tg) and flowing at higher temperatures, and / or can be observed to undergo significant melting when passing through their so-called melting temperature (Tf) (when they are semi-crystalline), and become solid again when the temperature drops below their melting point and below their glass transition temperature. Advantageously, this makes it easier to transport the composite thermoplastic material and facilitates its storage.

[0093] According to a first embodiment A, the thermoplastic matrix may comprise a thermoplastic polymer from the following family: polyamides, polyureas, polyacrylics, poly(aryletherketones), polyimides, aromatic polyetherimides, polysulfides, polysulfones, polyolefins, polylactic acid, polyethylene, polyvinyl alcohol, fluoropolymers, styrenes, cellulosics, polyesters and / or polycarbonates.

[0094] Preferably, the thermoplastic polymer incorporated into the thermoplastic composition for the thermoplastic matrix can be selected from the following families: polyamides, polyureas, polyacrylics, poly(aryletherketones), polyimides, aromatic polyetherimides, polysulfides, polysulfones, polyolefins, polylactic acid, polyethylene, polyvinyl alcohol, fluoropolymers, styrenes, cellulosics, polyesters and / or polycarbonates.

[0095] More preferably, the thermoplastic polymer incorporated into the thermoplastic composition for the thermoplastic matrix may be chosen from the following families: polymers and copolymers of aliphatic or cycloaliphatic polyamides (PA) or semiaromatic PAs (also known as polyphthalamides (PPA)), amorphous polyamides, polyamides (nylons), poly(ether-block-amides) (PEBA), polyureas, aromatic polyureas, polyacrylates, and more particularly polymethyl methacrylate (PMMA) or derivatives thereof, poly(aryletherketones) (PAEKs) such as poly(etheretherketones) (PEEK), or poly(aryletherketoneketones) (PAEKKs) such as poly(etherketoneketones) (PEKK) or derivatives thereof, aromatic polyetherimides (PEI), polyarylethersulfides, in particular polyphenylenesulfide (PPS), polyarylsulfones, in particular polyphenylene sulfone (PPSU), polyolefins, in particular polypropylene (PP), polylactic acid (PLA), polyvinyl alcohol (PVA), fluoropolymers, in particular poly(vinylidene fluoride) (PVDF) or polytetrafluoroethylene (PTFE) or polychlorotrifluoroethylene (PCTFE), polystyrene, acrylonitrile butadiene styrene (ABS), polyethylene, polyethylene terephthalate (PET), polyethylene, glycolated polyethylene terephthalate (PET-G), polycarbonate, polyethylene, polyvinyl acetate, polyvinyl chloride (PVC), polyvinylidene chloride, polyurethane, polyacetal, polybutylene terephthalate (PBT), polyphenylene sulfide and / or blends thereof.

[0096] Advantageously, the thermoplastic polymer constituting the thermoplastic matrix may be a prepolymer and / or a polymer chosen from the following families: polyamides (PA), in particular chosen from aliphatic polyamides, cycloaliphatic polyamides and semiaromatic polyamides (polyphthalamide) optionally modified with urea groups, and copolymers thereof, polymethyl methacrylate (PPMA) and copolymers thereof, polyetherimide (PEI), polyphenylene sulfide (PPS), polyphenylene sulfone (PPSU), poly(vinylidene fluoride) (PVDF), poly(etherketoneketone) (PEKK), poly(etheretherketone) (PEEK), fluoropolymers such as poly(vinylidene fluoride) (PVDF).

[0097] The thermoplastic composite material can include 60% by volume or less polymer matrix, and the polymer matrix includes a thermoplastic polymer, preferably a thermoplastic polymer selected from polyamide, polypropylene, polyether, poly(meth) acrylic acid and / or polyester. The thermoplastic composite material can include preferably 55% by volume or less polymer matrix, and more preferably 50% by volume or less polymer matrix. The thermoplastic composite material can include 30% by volume or more polymer matrix, preferably 35% by volume or more polymer matrix, and more preferably 40% by volume or more polymer matrix. According to one embodiment, the thermoplastic composite material can include 30% by volume to 60% by volume polymer matrix, preferably 35% by volume to 55% by volume polymer matrix, and more preferably 40% by volume to 50% by volume polymer matrix.

[0098] The thermoplastic composite material may comprise at least 40% by volume of fibers, preferably at least 45% by volume of fibers, and more preferably at least 50% by volume of fibers. According to one embodiment, the thermoplastic composite material may comprise up to 70% by volume of fibers, preferably up to 65% by volume of fibers, and more preferably up to 60% by volume of fibers. According to one embodiment, the thermoplastic composite material may comprise from 40% to 70% by volume of fibers, preferably from 45% to 65% by volume of fibers, and more preferably from 50% to 60% by volume of fibers.

[0099] The thermoplastic composite material may comprise 30% to 60% by volume of the polymer matrix and 40% to 70% by volume of the fibers.

[0100] According to a second embodiment B, the thermoplastic matrix may comprise a thermoplastic polymer from the family of acrylic polymers, and preferably from the family of (meth)acrylic polymers, and even more preferably from the family of polymethyl methacrylates.

[0101] The thermoplastic composite material may comprise at least 50% by volume of fibers, preferably at least 55% by volume of fibers, and more preferably at least 60% by volume of fibers, and even more preferably at least 65% by volume of fibers. According to one embodiment, the thermoplastic composite material may comprise up to 80% by volume of fibers, preferably up to 75% by volume of fibers, and more preferably up to 70% by volume of fibers. According to one embodiment, the thermoplastic composite material may comprise from 50% to 80% by volume of fibers, preferably from 55% to 75% by volume of fibers, and more preferably from 60% to 70% by volume of fibers, and even more preferably from 65% to 70% by volume of fibers.

[0102] The thermoplastic composite material may comprise 50% by volume or less of a polymer matrix comprising a (meth)acrylic polymer, preferably 45% by volume or less of a polymer matrix comprising a (meth)acrylic polymer, and more preferably 40% by volume or less of a polymer matrix comprising a (meth)acrylic polymer, and even more preferably 35% by volume or less of a polymer matrix comprising a (meth)acrylic polymer. The thermoplastic composite material may comprise 20% by volume or more of a polymer matrix comprising a (meth)acrylic polymer, preferably 25% by volume or more of a polymer matrix comprising a (meth)acrylic polymer, and more preferably 30% by volume or more of a polymer matrix comprising a (meth)acrylic polymer. According to one embodiment, the thermoplastic composite material may comprise 20% to 50% by volume of a polymer matrix comprising a (meth)acrylic polymer, preferably 25% to 45% by volume of a polymer matrix comprising a (meth)acrylic polymer, and more preferably 30% to 40% by volume of a polymer matrix comprising a (meth)acrylic polymer, and even more preferably 35% to 40% by volume of a polymer matrix comprising a (meth)acrylic polymer.

[0103] The thermoplastic composite material may comprise 20% to 50% by volume of a polymer matrix comprising a (meth)acrylic polymer and 50% to 80% by volume of fibers.

[0104] The thermoplastic composite may comprise 35 volume percent or less of a polymer matrix comprising a (meth)acrylic polymer and at least 65 volume percent of fibers.

[0105] According to the first and / or second embodiment, the fibers can be made of several fibers, unidirectional rovings or continuous filament mats, fabrics, felts or nonwovens, which can be in the form of strips, loops, braids, locks or sheets. The fiber material of the composite material can have various forms and sizes, one-dimensional, two-dimensional or three-dimensional.

[0106] One-dimensional form corresponds to a linear long fiber. The fiber can be discontinuous or continuous. The fibers can be randomly arranged in the form of continuous filaments or arranged parallel to each other. The fiber is defined by its aspect ratio, which is the ratio between the length and diameter of the fiber. Preferably, the fiber used in the present invention is a long fiber or a continuous fiber. The fiber can have an aspect ratio of at least 1000, preferably at least 1500, more preferably at least 2000, advantageously at least 3000, and more advantageously at least 5000, even more advantageously at least 6000, still more advantageously at least 7500, and most advantageously at least 10000.

[0107] A two-dimensional form corresponds to a nonwoven or woven fiber mat or reinforcement or fiber bundle, which may also be woven. Even if a two-dimensional form has a certain thickness and thus in principle has a third dimension, it is considered to be two-dimensional according to the invention.

[0108] Three-dimensional forms correspond to, for example, nonwoven fiber mats or reinforcements or stacked or folded fiber bundles or mixtures thereof, ie, assemblies of two-dimensional forms in the third dimension.

[0109] The origin of the fiber material can be natural or synthetic. As natural materials, there may be mentioned plant fibers, wood fibers, animal fibers or mineral fibers.

[0110] Natural fibers are, for example, sisal, jute, hemp, flax, cotton, coconut fibers and banana fibers. Animal fibers are, for example, wool or hair.

[0111] As synthetic materials, mention may be made of polymer fibers chosen from fibers of thermosetting polymers, thermoplastic polymers, polyamides (aliphatic or aromatic), polyesters, polyvinyl alcohol, polyolefins, polyurethanes, polyvinyl chloride, polyethylene, acrylics, unsaturated polyesters, epoxy resins and vinyl esters, and / or carbon fibers or mixtures thereof.

[0112] The mineral fibers may also be chosen from glass fibers, in particular glass fibers of the E, R or S2 type, boron fibers, basalt fibers or silica fibers.

[0113] The fibrous substrate of the present invention may be selected from plant fibers, wood fibers, animal fibers, mineral fibers, synthetic polymer fibers, glass fibers and carbon fibers, and mixtures thereof.

[0114] Preferably, the fiber substrate is selected from mineral fibers. More preferably, the fiber substrate is selected from glass fibers or carbon fibers.

[0115] The diameter of the fibers of the fibrous substrate may be 0.005 μm to 100 μm, preferably 1 μm to 50 μm, more preferably 5 μm to 30 μm, and advantageously 10 μm to 25 μm.

[0116] Preferably, the fibers of the fibrous substrate of the present invention are selected from continuous fibers for one-dimensional form (meaning the aspect ratio does not necessarily apply to long fibers), or long fibers or continuous fibers for two-dimensional or three-dimensional form of fibrous substrates.

[0117] According to a second embodiment, the thermoplastic composite material may comprise a thermoplastic matrix. Preferably, the thermoplastic matrix may comprise a thermoplastic composition. More preferably, the thermoplastic matrix is ​​derived from a thermoplastic composition.

[0118] The thermoplastic composition may be a thermoplastic resin or a thermoplastic resin precursor. The thermoplastic composition may comprise at least 50 wt% of a thermoplastic polymer monomer. The thermoplastic composition may comprise a polymer and a monomer.

[0119] Preferably, the monomers of the thermoplastic composite are selected from alkyl acrylic monomers, alkyl methacrylic monomers, hydroxyalkyl acrylic monomers and hydroxyalkyl methacrylic monomers, and mixtures thereof.

[0120] Preferably, the polymer of the thermoplastic composite is chosen from all types of compounds, polymers, oligomers, copolymers or block copolymers, acrylic and methacrylic. However, it does not depart from the scope of the invention if the (meth)acrylic polymer matrix contains up to 10% by weight, preferably less than 5% by weight, of other non-acrylic monomers, for example chosen from butadiene, isoprene, styrene, substituted styrenes such as α-methylstyrene or tert-butylstyrene, cyclosiloxanes, vinylnaphthalene and vinylpyridine.

[0121] The thermoplastic composition according to the present invention may contain 10% to 50% by weight of the (meth)acrylic polymer (PI) and 50% to 90% by weight of the (meth)acrylic monomer (M1). Preferably, the thermoplastic composition contains 10% to 40% by weight of the (meth)acrylic polymer (PI) and 60% to 90% by weight of the (meth)acrylic monomer (M1); more preferably, 10% to 30% by weight of the (meth)acrylic polymer (PI) and 70% to 90% by weight of the (meth)acrylic monomer (M1).

[0122] The dynamic viscosity of the thermoplastic composition is from 10 mPa*s to 10 000 mPa*s, preferably from 20 mPa*s to 7000 mPa*s, and advantageously from 20 mPa*s to 5000 mPa*s, and more advantageously from 20 mPa*s to 2000 mPa*s, and even more advantageously from 20 mPa*s to 1000 mPa*s. The viscosity of the thermoplastic composition can be easily measured with a rheometer or a viscometer. The dynamic viscosity is measured at 25°C. If the thermoplastic composition has Newtonian behavior, meaning no shear thinning, the dynamic viscosity is independent of the shear in the rheometer or the movement speed in the viscometer. If the thermoplastic composition has non-Newtonian behavior, meaning shear thinning, the dynamic viscosity is independent of the shear in the rheometer or the movement speed in the viscometer. If the thermoplastic composition has non-Newtonian behavior, meaning shear thinning, the dynamic viscosity is independent of the shear in the rheometer or the movement speed in the viscometer. -1 The dynamic viscosity is measured at 25°C at a shear rate of 1000 Å. Regarding the thermoplastic composition of the present invention, it comprises a (meth)acrylic monomer (M1) and a (meth)acrylic polymer (PI). Upon polymerization, the (meth)acrylic monomer (M1) is converted into a (meth)acrylic polymer (P2) comprising monomer units of the (meth)acrylic monomer (M1) and possibly other monomers.

[0123] Preferably, the (meth)acrylic composition MCI also has a dynamic viscosity of 10 to 10,000 mPa*s, preferably 20 to 7,000 mPa*s, and advantageously 20 to 5,000 mPa*s, and more advantageously 20 to 2,000 mPa*s, and even more advantageously 20 to 1,000 mPa*s.

[0124] As regards the (meth)acrylic polymer (PI), mention may be made of polyalkyl methacrylates or polyalkyl acrylates. According to a preferred embodiment, the (meth)acrylic polymer (PI) is polymethyl methacrylate (PMMA).

[0125] According to one embodiment, the methyl methacrylate (MMA) homopolymer or copolymer comprises at least 70%, preferably at least 80%, advantageously at least 90% and more advantageously at least 95% by weight of methyl methacrylate.

[0126] According to another embodiment, PMMA is a mixture of at least one homopolymer and at least one copolymer of MMA, or a mixture of at least two homopolymers or two copolymers of MMA having different average molecular weights, or a mixture of at least two copolymers of MMA having different monomer compositions.

[0127] The copolymer of methyl methacrylate (MMA) comprises 70% to 99.9% by weight of methyl methacrylate and 0.1% to 30% by weight of at least one monomer containing at least one ethylenic unsaturation copolymerizable with methyl methacrylate.

[0128] These monomers are well known and mention may be made in particular of acrylic acid and methacrylic acid and alkyl (meth)acrylates, wherein the alkyl group contains 1 to 12 carbon atoms. For example, mention may be made of methyl acrylate and ethyl (meth)acrylate, butyl (meth)acrylate or 2-ethylhexyl (meth)acrylate. Preferably, the comonomer is an alkyl acrylate, wherein the alkyl group contains 1 to 4 carbon atoms.

[0129] According to a first preferred embodiment, the copolymer of methyl methacrylate (MMA) comprises from 80% to 99.9% by weight, advantageously from 90% to 99.9% by weight and more advantageously from 90% to 99.9% by weight of methyl methacrylate and from 0.1% to 20% by weight, advantageously from 0.1% to 10% by weight and more advantageously from 0.1% to 10% by weight of at least one monomer containing at least one ethylenic unsaturation copolymerizable with methyl methacrylate. Preferably, the comonomer is chosen from methyl acrylate and ethyl acrylate and mixtures thereof.

[0130] The weight average molecular weight of the (meth)acrylic polymer (PI) should be high, which means greater than 50,000 g / mol, and preferably greater than 100,000 g / mol. The weight average molecular weight can be measured by size exclusion chromatography (SEC).

[0131] The (meth)acrylic polymer (PI) is completely soluble in the (meth)acrylic monomer (M1) or the mixture of (meth)acrylic monomers. It allows the viscosity of the (meth)acrylic monomer (M1) or the mixture of (meth)acrylic monomers to increase. The resulting solution is a liquid composition commonly referred to as a "syrup" or "prepolymer". The dynamic viscosity of the liquid (meth)acrylic syrup is between 10 mPa.s and 10,000 mPa.s. The viscosity of the syrup can be easily measured using a rheometer or a viscometer. The dynamic viscosity is measured at 25°C.

[0132] Advantageously, the liquid (meth)acrylic composition or syrup contains no additional self-added solvent.

[0133] As for the (meth)acrylic monomer (M1), the monomer is selected from alkyl acrylic monomers, alkyl methacrylic monomers, hydroxyalkyl acrylic monomers, hydroxyalkyl methacrylic monomers, and mixtures thereof.

[0134] Preferably, the (meth)acrylic monomer (M1) is selected from hydroxyalkyl acrylic monomers, hydroxyalkyl methacrylic monomers, alkyl acrylic monomers, alkyl methacrylic monomers and mixtures thereof, wherein the alkyl group contains 1 to 22 linear, branched or cyclic carbon atoms; the alkyl group preferably contains 1 to 12 linear, branched or cyclic carbon atoms.

[0135] More preferably, the (meth)acrylic monomer (M1) is selected from alkyl acrylic monomers or alkyl methacrylic monomers and mixtures thereof, wherein the alkyl group contains 1 to 22 linear, branched or cyclic carbons; the alkyl group preferably contains 1 to 12 linear, branched or cyclic carbons.

[0136] Advantageously, the (meth)acrylic monomer (M1) is chosen from methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, methacrylic acid, acrylic acid, n-butyl acrylate, isobutyl acrylate, n-butyl methacrylate, isobutyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, isobornyl acrylate, isobornyl methacrylate, hydroxyethyl acrylate and hydroxyethyl methacrylate, and mixtures thereof.

[0137] More advantageously, the (meth)acrylic monomer (M1) is selected from methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, methacrylic acid, acrylic acid, n-butyl acrylate, isobutyl acrylate, n-butyl methacrylate, isobutyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, isobornyl acrylate, isobornyl methacrylate, and mixtures thereof.

[0138] According to a preferred embodiment, at least 50% by weight, and preferably at least 60% by weight, of the (meth)acrylic monomers (M1) are methyl methacrylate.

[0139] According to a first more preferred embodiment, at least 50% by weight, preferably at least 60% by weight, more preferably at least 70% by weight, advantageously at least 80% by weight and even more advantageously 90% by weight of the monomers (M1) are a mixture of methyl methacrylate and optionally at least one further monomer (M2).

[0140] The at least one other monomer is a (meth)acrylic monomer (M2). Monomer (M2) is multifunctional. Preferably, the (meth)acrylic monomer (M2) is selected from compounds containing at least two (meth)acrylic acid functional groups. The (meth)acrylic monomer (M2) can also be selected from a mixture of at least two compounds (M2a) and (M2b), each containing at least two (meth)acrylic acid functional groups.

[0141] The (meth)acrylic monomer (M2) may be selected from 1,3-butanediol dimethacrylate; 1,4-butanediol dimethacrylate; 1,6-hexanediol diacrylate; 1,6-hexanediol dimethacrylate; diethylene glycol dimethacrylate; dipropylene glycol diacrylate; ethoxylated (10) bisphenol A diacrylate; ethoxylated (2) bisphenol A dimethacrylate; ethoxylated (3) bisphenol A diacrylate; ethoxylated (3) bisphenol A dimethacrylate; ethoxylated (4) bisphenol A diacrylate; ethoxylated (4) bisphenol A dimethacrylate; ethoxylated bisphenol A dimethacrylate; ethoxylated (10) bisphenol dimethacrylate; ethylene glycol dimethacrylate; polyethylene glycol (200) diacrylate; polyethylene glycol (400) diacrylate; polyethylene glycol (400) dimethacrylate; polyethylene glycol (40 0) dimethacrylate; polyethylene glycol (600) diacrylate; polyethylene glycol (600) dimethacrylate; polyethylene glycol 400 diacrylate; propoxylated (2) neopentyl glycol diacrylate; tetraethylene glycol diacrylate; tetraethylene glycol dimethacrylate; tricyclodecane dimethanol diacrylate; tricyclodecane dimethanol dimethacrylate; triethylene glycol diacrylate; triethylene glycol dimethacrylate; tripropylene glycol diacrylate; ethoxylated (15) trimethylolpropane triacrylate; ethoxylated (3) trimethylolpropane triacrylate; ethoxylated (6) trimethylolpropane triacrylate; ethoxylated (9) trimethylolpropane triacrylate; ethoxylated 5 pentaerythritol triacrylate; ethoxylated (20) trimethylolpropane triacrylate; propoxylated (3) glycerol triacrylate; trimethylolpropane triacrylate; propoxylated (5.5) Glycerol triacrylate; Pentaerythritol triacrylate; Propoxylated (3) glycerol triacrylate; Propoxylated (3) trimethylolpropane triacrylate; Trimethylolpropane triacrylate; Trimethylolpropane trimethacrylate; Tris(2-hydroxyethyl)isocyanurate triacrylate; Di-trimethylolpropane tetraacrylate; Dipentaerythritol pentaacrylate; Ethoxylated (4) pentaerythritol tetraacrylate; Pentaerythritol tetraacrylate; Dipentaerythritol hexaacrylate; 1,10-decanediol diacrylate; 1,3-butanediol diacrylate; 1,4-butanediol diacrylate; 1,9-nonanediol diacrylate; 2-(2-vinyloxyethoxy)ethyl acrylate; 2-butyl-2-ethyl-1 ,3-Propanediol diacrylate; 2-methyl-1,3-propanediol diacrylate; 2-methyl-1,3-propanediol ethoxyacrylate; 3-methyl-1,5-pentanediol diacrylate; alkoxylated cyclohexanedimethanol diacrylate; alkoxylated hexanediol diacrylate; cyclohexanedimethanol diacrylate; ethoxylated cyclohexanedimethanol diacrylate; diethylene glycol diacrylate; dioxanediol diacrylate; ethoxylated dipentaerythritol hexaacrylate; ethoxylated glycerol triacrylate; ethoxylated neopentyl glycol diacrylate; hydroxyneopentyl hydroxyneopentyl diacrylate; neopentyl glycol diacrylate; poly(tetramethylene glycol) diacrylate; polypropylene glycol 400 diacrylate; polypropylene glycol 700 diacrylate; propoxylated (6) ethoxylated bisphenol A diacrylate; propoxylated ethylene glycol diacrylate; propoxylated (5) pentaerythritol tetraacrylate; and propoxylated trimethylolpropane triacrylate.

[0142] Preferably, the (meth)acrylic monomer (M2) is selected from ethylene glycol dimethacrylate, neopentyl glycol diacrylate, neopentyl glycol dimethacrylate, 1,4-butanediol dimethacrylate, 1,4-butanediol diacrylate, 1,3-butanediol diacrylate, 1,3-butanediol dimethacrylate, triethylene glycol dimethacrylate and triethylene glycol diacrylate or a mixture thereof.

[0143] The (meth)acrylic monomer (M2) may be present in the (meth)acrylic composition MCI in an amount of 0.01 to 10 phr by weight, preferably in an amount of 0.1 to 9.5 phr, more preferably in an amount of 0.1 to 9 phr, even more preferably in an amount of 0.1 to 8.5 phr and advantageously in an amount of 0.1 to 8 phr, per 100 parts of liquid (meth)acrylic syrup.

[0144] In a first more preferred embodiment, the (meth)acrylic monomer (M2) is present in the (meth)acrylic composition MCI in an amount ranging from 0.01 to 9 phr and is chosen from compounds comprising two (meth)acrylic functional groups.

[0145] In a second more preferred embodiment, the (meth)acrylic monomer (M2) is present in the (meth)acrylic composition MCI in an amount ranging from 0.01 to 9 phr and is chosen from a mixture of compounds comprising two (meth)acrylic functional groups.

[0146] In a third more preferred embodiment, the (meth)acrylic monomer (M2) is present in the (meth)acrylic composition MCI at 0.01 to 9 phr and is chosen from a mixture of compounds comprising at least two (meth)acrylic functional groups.

[0147] In a fourth more preferred embodiment, the (meth)acrylic monomer (M2) is present in the (meth)acrylic composition MCI in an amount of 0.01 to 9 phr and is selected from a mixture of compounds comprising at least two (meth)acrylic acid functional groups. At least one compound of the mixture comprises only two (meth)acrylic acid functional groups and represents at least 50% by weight, preferably at least 60% by weight, of the mixture of (meth)acrylic acid monomers (M2). Another compound of the mixture comprises more than two (meth)acrylic acid functional groups.

[0148] According to another embodiment, the thermoplastic composition may be a thermoplastic resin precursor.

[0149] The precursor or initiator (Ini) will be able to start the polymerization of the (meth)acrylic monomers (M1) and (M2) and it is chosen from free radical initiators.

[0150] Preferably, the initiator (Ini) is activated by heating.

[0151] The free radical initiator (Ini) may be selected from compounds comprising a peroxide group or compounds comprising an azo group, and is preferably selected from compounds comprising a peroxide group.

[0152] Preferably, the compound comprising a peroxide group comprises from 2 to 30 carbon atoms.

[0153] Preferably, the compound comprising a peroxy group is selected from diacyl peroxides, peroxyesters, peroxydicarbonates, dialkyl peroxides, peroxyacetals, hydroperoxides or peroxyketones.

[0154] The initiator (Ini) is selected from diisobutyryl peroxide, isopropyl peroxyneodecanoate, di(3-methoxybutyl) peroxydicarbonate, 1,1,3,3-tetramethylbutyl peroxyneodecanoate, isopropyl peroxyneoheptanoate, di-n-propyl peroxydicarbonate, tert-amyl peroxyneodecanoate, di-sec-butyl peroxydicarbonate, diisopropyl peroxydicarbonate, di(4-tert-butylcyclohexyl) peroxydicarbonate, di(2-ethylhexyl) peroxydicarbonate, tert-amyl peroxyneodecanoate, tert-butyl peroxyneodecanoate, di-n-butyl peroxydicarbonate, dicetyl peroxydicarbonate, di-methane peroxydicarbonate Myristyl peroxide, 1,1,3,3-tetramethylbutyl peroxypivalate, tert-butyl peroxyneoheptanoate, tert-amyl peroxypivalate, tert-butyl peroxypivalate, di(3,5,5-trimethylhexanoyl)peroxide, dilauroyl peroxide, didecanoyl peroxide, 2,5-dimethyl-2,5-di(2-ethylhexanoylperoxy)-hexane, 1,1,3,3-tetramethylbutyl peroxy-2-ethylhexanoate, tert-amyl peroxy-2-ethylhexanoate, dibenzoyl peroxide, tert-butyl peroxy-2-ethylhexanoate, tert-butyl peroxydiethyl acetate, tert-butyl peroxyisobutyrate, 1,1-di-(tert-butylperoxy) tert-Butylperoxy)-3,3,5-trimethylcyclohexane, 1,1-di(tert-amylperoxy)cyclohexane, 1,1-di-(tert-butylperoxy)-cyclohexane, tert-amylperoxy-2-ethylhexyl carbonate, tert-amylperoxyacetate, tert-butylperoxy-3,5,5-trimethylhexanoate, 2,2-di-(tert-butylperoxy)-butane, tert-butylperoxyisopropylcarbonate, tert-butylperoxy-2-ethylhexylcarbonate, tert-amylperoxybenzoate, tert-butylperoxyacetate, butyl 4,4-di(tert-butylperoxy)valerate, tert-butylperoxybenzoate, di-tert-amylperoxide, diisopropylbenzene peroxide, di-(2-tert-butylperoxy)butane butylperoxyisopropyl)-benzene, 2,5-dimethyl-2,5-di-(tert-butylperoxy)-hexane, tert-butyl peroxide, 2,5-dimethyl-2,5-di-(tert-butylperoxy)hexyne-3, di-tert-butyl peroxide, 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane, 2,2'-azobisisobutyronitrile (AIBN), 2,2'-azobis-(2-methylbutyronitrile), azobisisobutyramide, 2,2'-azobis(2,4-dimethylvaleronitrile), 1,1'-azobis(hexahydrobenzonitrile), or 4,4'-azobis(4-cyanovaleric acid).

[0155] Preferably, the initiator (Ini) is selected from the group consisting of cumyl peroxyneodecanoate, di(3-methoxybutyl) peroxydicarbonate, 1,1,3,3-tetramethylbutyl peroxyneodecanoate, cumyl peroxyneoheptanoate, di-n-propyl peroxydicarbonate, tert-amyl peroxyneodecanoate, di-sec-butyl peroxydicarbonate, diisopropyl peroxydicarbonate, di(4-tert-butylcyclohexyl) peroxydicarbonate, di(2-ethylhexyl) peroxydicarbonate, tert-amyl peroxyneodecanoate, tert-butyl peroxyneodecanoate, Di-n-butyl peroxydicarbonate, dicetyl peroxydicarbonate, dimyristyl peroxydicarbonate, 1,1,3,3-tetramethylbutyl peroxypivalate, tert-butyl peroxyneoheptanoate, tert-amyl peroxypivalate, tert-butyl peroxypivalate, di-(3,5,5-trimethylhexanoyl) peroxide, dilauroyl peroxide, didecanoyl peroxide, 2,5-dimethyl-2,5-di(2-ethylhexanoylperoxy)-hexane, or 1,1,3,3-tetramethylbutyl peroxy-2-ethylhexanoate.

[0156] The thermoplastic composition may comprise 0.1 to 5 phr of an initiator (Ini) to start the polymerization of the (meth)acrylic monomer (M1) and the (meth)acrylic comonomer (M2).

[0157] Such composite thermoplastic materials can be bent or molded when heated to a certain temperature, returning to a more rigid state upon cooling and repeated several times. Furthermore, their thermoplastic properties make them easy to transport or even store. Once on site, they can be reshaped to accommodate the structure being reinforced or the assembly of thermoplastic composite materials between them, without any shape restrictions. Thus, thermoplastic composites make it possible to adapt to the various and complex shapes that the structure being reinforced may have, or even to accommodate the assembly of thermoplastic composite materials in different forms.

[0158] Back to Figure 1 The thermoplastic composite material 1 may include at least one straight portion 10. The straight portion 10 may have a longitudinal axis L. The straight portion 10 may have a lower wall 111 and an upper wall, preferably aligned with the longitudinal axis L. The straight portion 10 may have a circular cross-section with an outer diameter d. Preferably, the outer diameter may be 4 mm to 40 mm, preferably 6 mm to 35 mm, and more preferably 8 mm to 30 mm.

[0159] Preferably, the smaller the outer diameter d, the better the covering material (e.g. concrete) can be reduced and the bulk of the structure or thermoplastic composite material between them can be avoided. Therefore, the structure can include more steel bars and less concrete, and thus have a lower concrete volume.

[0160] Advantageously, at least one straight portion 10 is not limited in its length.

[0161] The thermoplastic composite material 1 may include at least one curved portion 11 .

[0162] Preferably, the at least one curved portion 11 can have a circular cross-section. Circular refers to any shape reminiscent of a circle. The at least one curved portion 11 can have an outer diameter. The outer diameter of the at least one curved portion 11 is substantially equal to the outer diameter d of the at least one straight portion 10 and can be between 4 mm and 40 mm. Substantially equal can mean a difference of 10%, preferably 5%, from the outer diameter. It should be noted that a change in the outer diameter of the at least one curved portion can be a sign of quality. In fact, when the at least one curved portion of the thermoplastic composite material is bent, the outer diameter of the at least one curved portion increases, which reflects the presence of fiber continuity. If the diameter change is less than 5%, this can indicate fiber breakage.

[0163] The at least one curved portion 11 may be curved according to the longitudinal axis L and may have upper and lower walls 112 .

[0164] Advantageously, at least one curved portion 11 is not limited in its length.

[0165] The thermoplastic composite material 1 may have at least one bending radius r.

[0166] The bending radius r may be defined as the radius of the osculating circle C of the at least one curved portion 11. Preferably, the bending radius r corresponds to the curvature of the curved portion 11.

[0167] The bending radius r can be calculated according to the formula r=d*f, where r is the bending radius (mm), d is the outer diameter (mm), and f is a factor.

[0168] The preferred factor f of the bending radius r relative to the outer diameter d of the at least one straight portion 10 is at most equal to 5. Preferably, the factor f of the bending radius r relative to the outer diameter d of the at least one straight portion 10 is at most equal to 4, and more preferably the factor f relative to the outer diameter d of the at least one straight portion 10 is at most equal to 3.

[0169] The bending radius r preferably has a factor f at least equal to 2 relative to the outer diameter d of the at least one straight portion 10 .

[0170] The factor f of the bending radius r relative to the outer diameter d of the at least one straight portion 10 may be 2 to 5. Preferably, the factor f of the bending radius r relative to the outer diameter d of the at least one straight portion 10 may be 2 to 4, and more preferably, the factor f of the bending radius r relative to the outer diameter d of the at least one straight portion 10 may be 2 to 3.

[0171] The bending radius r can be measured by methods known to those skilled in the art (geometric or production).

[0172] The bending radius r may be between 8 mm and 200 mm, preferably between 12 mm and 175 mm, and more preferably between 16 mm and 150 mm.

[0173] According to an embodiment with several bending radii (several meaning at least two), the bending radii may be equal to or different from each other.

[0174] This factor f of the bending radius r allows for a reduction in the volume of the structure to be reinforced. Advantageously, this factor f also makes it easier to assemble the thermoplastic composite material 1. The thermoplastic composite material 1 occupies less space within the structure. Furthermore, the smaller bending radius r allows for better force continuity and, therefore, distribution. Thus, the thermoplastic composite material 1 can accommodate various and complex shapes that the structure to be reinforced may have, or even different configurations of the thermoplastic composite materials 1 assembled together.

[0175] Advantageously, the smaller the bending radius r, the greater the flexibility of the material (thermoplastic composite material), in other words, the smaller the curvature radius, the greater the curvature.

[0176] The thermoplastic composite material 1 may have at least one bending angle α.

[0177] The thermoplastic composite material 1 is bent by any desired defined bending angle α (depending on the factor f of the bending radius r) about the longitudinal axis L of the thermoplastic composite material 1. Preferably, the bending angle α is defined according to the longitudinal axis L of the thermoplastic composite material 1, more preferably according to the longitudinal axis L of the at least one straight portion 10 of the thermoplastic composite material 1.

[0178] The bending angle α may be between 0° and 360°, excluding 0°. Preferably, the bending angle α may be between 20° and 300°, more preferably between 45° and 270°.

[0179] According to an embodiment, the bending angle α may be between 0° and n*360°, excluding 0° and n being greater than 1. In practice, the bending angle α may be a multiple of 360°. For example, the bending angle α may be determined based on the length of the steel bar.

[0180] The multiple is limited by the length of the thermoplastic composite material 1 , and without wishing to be bound by theory, the thermoplastic composite material 1 is not limited by its length.

[0181] According to an embodiment with several bending angles α (several meaning at least two), the bending angles α may be equal to or different from each other.

[0182] Such at least one curved portion 11 allows varying the different possible configurations of the thermoplastic composite material 1. Furthermore, it ensures a uniform resistance within a structure or between thermoplastic composite materials 1.

[0183] Thus, the thermoplastic composite material 1 can have various shapes and sizes. For example, the thermoplastic composite material 1 can have a V, U, J, O, and / or L shape. These shapes are illustrative and do not limit the present invention. In fact, in one embodiment, the thermoplastic composite material 1 can include at least two straight portions 10 and one curved portion 11, or at least two straight portions 10 and at least two curved portions 11. Thus, the thermoplastic composite material 1 can have various shapes, such as S, Z, M, and / or N. Furthermore, each curved portion 11 can have its own bending radius r and / or factor f, its own bending angle α, and / or its own dimensions, or the curved portions can be identical.

[0184] For example, Figure 2 As shown, the composite thermoplastic material 1 can have different shapes in order to be an anchor Figure 2 A. Framework Figure 2 B. Stirrup Figure 2 C or even pin Figure 2 The form of D.

[0185] Furthermore, the arrangement of the parts within the thermoplastic composite material 1 is not limited.

[0186] For example, a curved portion 11 may be between two straight portions 10. A straight portion 10 may be between two curved locations 11. The two curved portions 11 may be continuous.

[0187] In addition, the at least one straight portion 10 and the at least one curved portion 11 may be continuous with each other.

[0188] Preferably, the at least one straight portion 10 and the at least one curved portion 11 are from the same thermoplastic matrix.

[0189] This thermoplastic composite material 1 exhibits improved mechanical resistance even at curvature. Flexibility is improved, and in particular, the fibers of the thermoplastic composite material 1 used in the at least one curved portion 11 exhibit no buckling or cracking and uniform strength. Furthermore, this thermoplastic composite material 1 exhibits no surface degradation. Furthermore, this thermoplastic composite material 1 can be easily bent and positioned close to the site as needed. This facilitates transportation and storage. Advantageously, the thermoplastic composite material 1 meets construction requirements and exhibits mechanical properties similar to commercial steel rebar. Thermoplastic composite material 1 is less expensive than stainless steel rebar and more flexible than epoxy and thermoset rebar. Thermoplastic composite material 1 is also corrosion-resistant. Finally, a key advantage of the thermoplastic composite material 1 lies in its mechanical properties. This thermoplastic composite material 1 enables the creation of consistent mechanical properties in different concrete, mortar, and / or building materials. Therefore, this thermoplastic composite material 1 is suitable for any structure to be reinforced. Due to its thermoplastic composite material 1, a smaller bending radius r can be achieved, which improves force continuity within the structure, facilitates the layout of thermoplastic composite materials within the structure and between them, and reduces bulk within the structure. Therefore, the entire structure can be reinforced even when it has a complex shape.

[0190] Table 1: Properties according to ASTM D7957:2020 (thermoplastic material according to the invention, preferably according to the second embodiment B of the invention for thermosetting vinyl ester VE) .

[0191] Furthermore, with regard to steel rebars (SR), the bent portions may exhibit a factor f between 3 and 6, except for epoxy-coated rebars comprising bent portions less than or equal to 5, which exhibit cracks and / or fractures. VE cannot be bent by a factor f less than 5, unlike the thermoplastic composite material according to the present invention, which allows for partial support of factors of 3 to 6, and preferably 2 to 6, without damage.

[0192] Table 2: Properties according to ASTM D7957:2020 (thermoplastic according to the invention, preferably according to the second embodiment B of the invention for thermosetting vinyl esters VE) .

[0193] Furthermore, SR exhibits similar characteristics, such as cross-section, tensile modulus, tensile strain, transverse shear strength, and bonding to concrete, with the exception of DSC. Therefore, the thermoplastic composite material according to the present invention exhibits the same qualities as VE or SR. The thermoplastic composite material according to the present invention allows compliance with the requirements of ASTM D7957. However, SR does not include fibers, which allow for improved mechanical and chemical properties, particularly in curved sections.

[0194] Table 3: Mechanical and / or chemical properties of thermoplastic composite materials according to the invention comprising fibers.

[0195] Thermoplastic composites exhibit mechanical properties comparable to thermoset steel bars. They can be adapted to various international standards. They are also bendable and eliminate the bottlenecks associated with widespread FRP applications. Furthermore, the thermoplastic composites according to the present invention can be bent to a radius equal to the diameter, preferably three times the outer diameter. Thermoplastic composites contain fibers with improved bulk, resulting in increased stiffness.

[0196] According to another embodiment, the present invention relates to a structure to be reinforced comprising at least one thermoplastic composite material.Preferred is a thermoplastic composite material according to the present invention.

[0197] The structure can include as much thermoplastic composite material as desired. For example, depending on the size, shape and / or location of the structure to be reinforced. Furthermore, the structure to be reinforced is not limited by its shape, size or location.

[0198] The structure may be a structure in automotive, transportation, marine, railroad, aviation, aerospace, photovoltaic, building and construction, concrete reinforcement, masonry, civil engineering and / or wind energy applications.

[0199] According to another aspect, the present invention relates to a thermoplastic composite material, preferably to the use of a thermoplastic composite material according to the present invention.

[0200] Thermoplastic composite materials, preferably the thermoplastic composite materials according to the present invention, can be used in different fields. Preferably, the thermoplastic composite materials can be used in automotive, transportation, marine, railway, aviation, aerospace, photovoltaic, building and construction, concrete reinforcement, masonry, civil engineering and / or wind energy applications.

[0201] More precisely, the thermoplastic composite material, preferably the thermoplastic composite material according to the present invention, can be used as a reinforcing element, a building material, a hook, a multi-link, a stirrup, an anchor, a stake, a fixing, a chain lock, a header, a coupler, a connector, a plug, a splice, a fitting, a support, a frame, a pillar, a spacer, a cage, a T-bar, an I-bar, a spliced ​​bar, a sliced ​​bar, a longitudinal bar, a transverse bar, a continuous bar, a panel, a rod, a rebar and / or a sheet.

[0202] In another aspect, the present invention relates to a method for producing a thermoplastic composite material, preferably a thermoplastic composite material according to the present invention.

[0203] like Figure 3As shown, the method 100 may include the steps of providing 110 a thermoplastic composite material, heating 120 , generating 130 at least one curved portion, and cooling 140 .

[0204] like Figure 3 As shown, the method according to the present invention comprises the step of providing 110 a thermoplastic composite material, preferably a thermoplastic composite material according to the present invention.

[0205] Preferably, the thermoplastic composite material is obtained by a pultrusion process. The pultrusion process may involve drawing fiber bundles through a pultrusion die that allows the fibers to be wetted, impregnating them by passing them through a resin bath or in an injection molding box, polymerizing the resin and cooling the impregnated bundles to form a composite profile at the outlet of the die.

[0206] The pultrusion process allows to obtain profiles of constant cross-section with high mechanical properties. The thermoplastic composite material is formed as it leaves the pultrusion die. During the pultrusion die, the diameter and preferably the outer diameter is determined.

[0207] Thus, the step of providing 110 the thermoplastic composite material may comprise the step of feeding the pultrusion die, preferably via a fiber feeder device. The step of feeding the fibers allows the fibers to be provided in the direction of the pultrusion path. Preferably, the fibers are as described above.

[0208] The step of providing 110 the thermoplastic composite material may include wetting the fibers. This step is preferably performed using an impregnation device. The wetting step allows the fibers to be impregnated with the thermoplastic composition; in other words, the thermoplastic composition penetrates the fibers. Wetting the fibers may include passing the fibers through the thermoplastic composition, preferably as described above. For example, the fibers may be passed through a bath or injection molding chamber containing the thermoplastic composition.

[0209] Method 100 according to the present invention may include a heating step 120. Preferably, the heating step is performed by a heating device. The heating step triggers and initiates polymerization of the thermoplastic composition with the impregnated fibers to form a heated thermoplastic composite. The heating step may be performed at a given temperature and / or for a given duration.

[0210] Heating also increases the spacing between molecules, which increases the flexibility of the thermoplastic composite, facilitating the next step of creating at least one curved portion. As explained, thermoplastic composites are generally solid at room temperature, softening during temperature increases, particularly after passing their glass transition temperature (Tg) or melting temperature (Tf), and becoming solid again when the temperature drops below their melting point and below their glass transition temperature. The heating step causes polymerization, which increases the partial pressure and ensures greater fluidity and flexibility; thus, the heated thermoplastic composite becomes more deformable. The fibers facilitate this deformation.

[0211] For example, the Tg may be below 130° C., preferably below 120° C., and more preferably below 110° C. The glass transition (Tg) of a polymer can be determined by differential scanning calorimetry (DSC) according to standard 11357-2:2013.

[0212] The heating step may include heating by convection, by conduction, by IR (infrared) including NIR and MIR (near and mid infrared), by microwaves, by UV (ultraviolet) and / or by induction.

[0213] According to one embodiment of the heating 120 step, the polymerization may be carried out at a temperature generally below 150°C, preferably below 140°C, and even more preferably below 130°C, preferably according to the B embodiment.

[0214] According to one embodiment of the heating step, the polymerization may be carried out at a temperature of at least 30°C, preferably at least 40°C, and more preferably at least 50°C, and even more preferably from 80°C to 140°C, preferably according to the B embodiment.

[0215] Preferably, the polymerization may be carried out at a temperature of 30°C to 150°C, preferably 40°C to 140°C, even more preferably 50°C to 130°C.

[0216] Advantageously, the heating step can be performed continuously or discontinuously.

[0217] The heating step and the polymerization allow the transformation from the thermoplastic composition that has impregnated the fibers and is liquid into a thermoplastic composite material that preferably has at least one straight portion with a circular cross-section with an external diameter.

[0218] Preferably, the heating step allows heating of at least a portion of the thermoplastic composite material. A portion may correspond to a portion of the entire thermoplastic composite material that is heated. Depending on the embodiment, several portions may be heated simultaneously, or may be heated at different times, for example as the composite thermoplastic material advances.

[0219] The method according to the present invention includes the step of generating 130 at least one curved portion. Preferably, the step of generating at least one curved portion is generated in the heated portion by bending the heated portion according to a bending radius and / or a bending angle. The values ​​of the bending radius and the bending angle are preferably the same as those disclosed above. The step of generating at least one curved portion can be achieved by a bending device.

[0220] The thermoplastic composite material is preferably linear about a longitudinal axis, and the step of creating a bend allows for bending of the heated portion. The resulting bent portion can be a bend, curve, complex shape, or any combination thereof. Preferably, the bending device parameters are set to achieve a predetermined bend radius and / or bend angle.

[0221] The step of creating a bend may be by simple bending, compression bending, folding and / or twisting. Preferably, the step of creating a bend comprises twisting.

[0222] The method according to the present invention may include a cooling 140 step. The cooling step may be achieved by a cooling device. In addition, the cooling step may be implemented at a given cooling temperature and / or within a given cooling duration.

[0223] According to one embodiment, the cooling temperature and / or cooling duration may be selected according to the glass transition temperature (Tg) and / or melting temperature of the heated thermoplastic composite material. Preferably, the cooling step is performed at a cooling temperature below the glass transition temperature of the heated thermoplastic composite material.

[0224] For example, the cooling temperature may be less than or equal to 150° C., preferably less than or equal to 130° C., more preferably less than or equal to 110° C., and even more preferably less than or equal to 100° C. The cooling temperature may be greater than or equal to 50° C., preferably greater than or equal to 60° C., more preferably greater than or equal to 70° C., even more preferably greater than or equal to 80° C. The cooling temperature may be between 50° C. and 150° C., preferably between 60° C. and 130° C., more preferably between 70° C. and 130° C., even more preferably between 80° C. and 110° C.

[0225] The cooling step allows producing a thermoplastic composite material comprising at least one straight portion and at least one curved portion.

[0226] According to a preferred embodiment, the cooling step may be performed simultaneously with the generating step. According to another embodiment, the cooling step may be performed after the generating step.

[0227] The method according to the present invention may include other optional steps, such as coating, bending, heating, cooling, cutting, welding, gluing and / or laminating. The optional steps may be implemented according to the thermoplastic composite material to be produced. The optional steps may also improve the quality and / or performance of the thermoplastic composite material.

[0228] Advantageously, the thermoplastic composite material according to the invention meets all the requirements of the standard specification for solid circular glass-fiber reinforced polymer bars for concrete reinforcement.

[0229] The present invention may be subject to many variations and applications beyond those described above. In particular, unless otherwise indicated, the various structural and functional features of each of the embodiments described above should not be considered combined and / or tightly and / or inextricably linked to one another, but rather as simple juxtapositions. Furthermore, the structural and / or functional features of the various embodiments described above may be the subject of any different juxtaposition or any different combination, in whole or in part.

Claims

1. A thermoplastic composite material (1), comprising: - at least one straight portion (10) of circular cross-section having an outer diameter (d) and a longitudinal axis (L), - at least one curved portion (11), at least one bending radius (r), the bending radius (r) of said at least one curved portion (11) being relative to the outer diameter (d) of said at least one straight portion (10) by a factor f at most equal to 5, and -Thermoplastic matrix and fiber reinforcement.

2. Thermoplastic composite material (1) according to claim 1, wherein the thermoplastic matrix comprises a thermoplastic polymer selected from the following families: polyamides, polyureas, polyacrylics, poly(aryletherketones), polyimides, aromatic polyetherimides, polysulfides, polysulfones, polyolefins, polylactic acid, polyethylene, polyvinyl alcohol, fluoropolymers, styrenes, cellulosics, polyesters and / or polycarbonates.

3. The thermoplastic composite material (1) according to claim 2, wherein the thermoplastic composite material (1) is 30% to 60% by volume of polymer matrix and 40% to 70% by volume of fibers.

4. Thermoplastic composite material (1) according to claim 1, wherein the thermoplastic matrix comprises a (meth)acrylic polymer.

5. Thermoplastic composite material (1) according to claim 4, wherein the thermoplastic composite material (1) comprises at most 35% by volume of a thermoplastic matrix comprising a (meth)acrylic polymer and at least 65% by volume of fibers.

6. The thermoplastic composite material (1) according to claim 4, wherein the thermoplastic composite material (1) comprises 20% to 50% by volume of a polymer matrix comprising a (meth)acrylic polymer and 50% to 80% by volume of fibers.

7. Thermoplastic composite material (1) according to any one of the preceding claims, wherein the fiber reinforcement is selected from glass fibers or carbon fibers.

8. Thermoplastic composite material (1) according to any one of the preceding claims, wherein the factor f of said at least one bending radius (r) relative to the outer diameter (d) of said at least one straight portion (10) is at least equal to 2.

9. Thermoplastic composite material (1) according to any one of the preceding claims, wherein the factor f of said at least one bending radius (r) relative to the outer diameter (d) of said at least one straight portion (10) is between 2 and 5.

10. Thermoplastic composite material (1) according to any one of the preceding claims, wherein the factor f of said at least one bending radius (r) relative to the outer diameter (d) of said at least one straight portion (10) is between 2 and 3.

11. Thermoplastic composite material (1) according to any one of the preceding claims, wherein the outer diameter (d) of at least one straight portion (10) of the thermoplastic composite material (1) is between 4 mm and 40 mm.

12. Thermoplastic composite material (1) according to any one of the preceding claims, wherein the at least one bending radius (r) is between 8 mm and 200 mm according to the formula r=d*f, where r is the bending radius (mm), d is the outer diameter (mm), and f is a factor, where f is 2 to 5 relative to the outer diameter (d) of the at least one straight portion (10).

13. Thermoplastic composite material (1) according to any one of the preceding claims, wherein the thermoplastic composite material (1) comprises at least one bending angle (α), the bending angle (α) being defined according to the longitudinal axis (L) of the thermoplastic composite material (1), the bending angle (α) being between 0° and 360°, excluding 0°.

14. Thermoplastic composite material (1) according to any one of the preceding claims, wherein the at least one straight portion (10) and the at least one curved portion (11) are from the same thermoplastic matrix.

15. The structure to be reinforced comprises at least one thermoplastic composite material (1) according to claims 1 to 14.

16. Use of the thermoplastic composite material (1) according to claims 1 to 14 in automotive, transport, marine, railway, aviation, aerospace, photovoltaic, building and construction, concrete reinforcement, masonry, civil engineering and / or wind energy applications.

17. Use of the thermoplastic composite material (1) according to claims 1 to 14 as a reinforcing element, building material, hook, multi-link, stirrup, anchor, pile, fixing, chain lock, header, coupler, connector, plug, splice, fitting, support, frame, pillar, spacer, cage, T-bar, I-bar, spliced ​​bar, sliced ​​bar, longitudinal bar, transverse bar, continuous bar, panel, rod, rebar and / or sheet.

18. A method (100) for producing a thermoplastic composite material (1) comprising at least one straight portion (10) having a circular cross section and at least one curved portion (11), the straight portion (10) having an outer diameter (d) and a longitudinal axis (L), the method comprising: - a step of providing (110) a thermoplastic composite material (1) having at least one straight portion (10), said straight portion (10) having a circular cross-section and an outer diameter (d), said thermoplastic composite material (1) comprising a thermoplastic matrix and a fiber reinforcement, - a step of heating (120) a portion of the thermoplastic composite material (1), preferably by conduction, convection, radial and / or volumetric heating, - a step of producing (130) at least one curved portion (11) in the heated portion by bending the heated portion according to a bending radius (r) having a factor f at most equal to 5 relative to the outer diameter (d) of the at least one straight portion (10) of the thermoplastic composite material (1), - a step of cooling (140) the at least one curved portion (11) to form a thermoplastic composite material (1) comprising at least one straight portion (10) and at least one curved portion (11).

19. The method (100) according to claim 18, wherein the provided thermoplastic composite material (1) has a thermoplastic matrix comprising a thermoplastic polymer from the family of acrylic polymers, and preferably (meth)acrylic polymers, and even more preferably polymethyl methacrylate.

20. The method (100) according to claim 18, wherein the provided thermoplastic composite material (1) is obtained by a pultrusion process.

21. The method (100) of claim 18, wherein the step of creating (130) the bend is performed by bending, compression bending, folding, and / or twisting.

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