System and process for the continuous manufacturing of an elongate composite part

Abstract

A system (100) for the continuous manufacturing of an elongate composite part (EF) comprising a bundle of multifilament fibers impregnated with a polymerizable material, the system comprising N stages, with N being greater than or equal to 2, and a translational drive device (D) for advancing the bundle of multifilament fibers to make same successively travel through the N stages, each stage comprising, in the direction of travel of the bundle of multifilament fibers: at least one module (110, 120, 130) for preparing multifilament fibers impregnated with polymerizable material; at least one calibration nozzle (116, 126); and at least one radiation device (117, 118, 127) which is located downstream of the calibration nozzle and through which the multi-filament fibers impregnated with polymerizable material travel and which is configured to carry out a partial or total polymerization.

Description

[0001] DESCRIPTION

[0002] TITLE: Installation and process for the continuous manufacturing of an elongated composite element

[0003] The present invention relates to the field of continuous manufacturing of elongated composite materials produced by impregnation of a polymerizable composition of multifilament fibers.

[0004] More particularly, the present invention relates to an installation and a method for manufacturing composites in the form of single strands comprising continuous, unidirectional multifilament fibers embedded in a polymerizable resin.

[0005] The present invention relates more particularly, but not exclusively, to the manufacture of single strands of glass resin composite, with the acronym “CVR”, having high mechanical properties.

[0006] Such elongated composite materials can be used in the form of composite reinforcements which can be used, in particular, for the reinforcement of semi-finished products or finished rubber articles such as vehicle tires, for example of the pneumatic or non-pneumatic type, or in applications for reinforcement in concrete, snowmobile tracks, tubular structures, etc.

[0007] We know the document EP 1 174 250 - A l which describes a process for the continuous manufacture of CVR monostrands comprising the following steps:

[0008] - making a rectilinear arrangement of glass fibers and driving this arrangement in a direction of advancement;

[0009] - degas the fiber arrangement by the action of vacuum in a vacuum chamber;

[0010] - at the outlet of the vacuum chamber, after degassing, passing through an impregnation chamber filled with resin so as to impregnate said arrangement of fibers with a resin in the liquid state to obtain an impregnated material containing the fibers and the resin; - passing said impregnated material through a calibration die having a predefined surface section and shape, to impose a single-strand shape on it; and

[0011] - downstream of the calibration line, in an irradiation chamber, stabilize, solidify the single strand by photopolymerization of the resin in a UV and / or IR radiation device

[0012] Experience shows, however, that the described CVR monofilaments can still be improved.

[0013] Generally, with reference to figure 1, a device 1 for manufacturing a single strand of glass-resin composite comprises a reel 10 containing glass fibers 11 in the form of multifilaments and continuously unwound by driving along the arrow F by a driving means (not shown), so as to produce a rectilinear arrangement 12 of these fibers 11.

[0014] The arrangement 12 then passes through a vacuum chamber 13 arranged between an inlet pipe 13a and an outlet pipe 13b and an impregnation chamber 14 downstream of the outlet pipe 13b and filled with impregnation composition 15 based on a curable resin. The device 1 further comprises a calibration die 16 at the outlet of the impregnation chamber 14 so as to form a single strand 17 and a radiation device 18 comprising, for example, a protection tube 18a through which the composite single strand 17 circulates and a plurality of UV irradiators 18b in line in order to obtain a polymerized single strand 19. The radiation device 18 further comprises a nitrogen injection system (not shown).

[0015] In this regard, reference may be made to document FR 3 009 226 - B 1 which describes a method for manufacturing a single strand of glass-resin composite using this type of manufacturing device.

[0016] However, the core polymerization of the impregnated single strand by UV lamps is not satisfactory.

[0017] Document FR 3 1 17 061 - B 1 is also known, which describes a method and a device for manufacturing composites based on multifilament fibers comprising means for producing an arrangement of multifilament fibers in the form of several individual strands, a vacuum chamber and an impregnation chamber through which all the individual strands are passed, a plurality of partial polymerization dies through which the impregnated strands are passed, a calibration die capable of forming a single strand from the impregnated individual strands and a UV and / or IR radiation device in which the final polymerization of the single strand is carried out. Each polymerization die comprises an annular lamp with LEDs directed axially relative to the impregnated strand and a reflector intended to direct the radiation emitted by the LEDs radially towards the impregnated strand.

[0018] In this document, the fibers distributed in several strands are introduced into the impregnation chamber by passing them through different orifices of a separation plate and exit through orifices passing through an outlet plate, so that the strands travel linear and parallel paths between them from one plate to the other while being parallel to the longitudinal axis of the device. The number of orifices corresponds to the number of strands which make up the bundle.

[0019] Such a solution is particularly radially bulky since the section of the impregnation chamber is directly proportional to the number of individual strands making up the multifilament bundle and therefore to the diameter of the final single strand. The radius of the individual strands increases with the root of the number of individual strands. It is therefore not possible to increase the diameter of the final single strand without increasing the radial size of the manufacturing device.

[0020] Furthermore, such a solution presents a risk of fouling the reflectors and LEDs in the polymerization lines, which significantly degrades the performance of the manufacturing device.

[0021] Thus, there is a need to overcome the aforementioned drawbacks. The invention aims to optimize the polymerization of composite monostrands in order to facilitate access and maintenance of the installation, to reduce the radial dimension of the installation, to increase the reliability of production, to allow the increase of the cross-section of the final monostrand while maintaining a high production speed.

[0022] The present invention relates to an installation for the continuous manufacture of an elongated composite element comprising a bundle of multifilament fibers impregnated with a composition based on a polymerizable material.

[0023] The installation comprises N stages for manufacturing a composite element, with N greater than or equal to 2 and a translational drive device configured to drive the bundle of multifilament fibers in translation to successively pass through the N stages.

[0024] Each stage comprises, in the direction of advancement of the bundle of multifilament fibers:

[0025] - at least one module for preparing multifilament fibers impregnated with polymerizable material; at least one calibration nozzle; and

[0026] - at least one radiation device arranged downstream of the calibration nozzle and through which the multifilament fibers impregnated with polymerizable material circulate and configured to carry out partial or total polymerization to form a composite single strand.

[0027] Thus, each manufacturing stage of a composite monostrand includes a degassing chamber, an impregnation chamber, in order to impregnate only the multifilament fibers necessary to carry out the partial or final polymerization stage.

[0028] Such an installation makes it easy to add additional preparation modules, and more generally stages for manufacturing a composite single strand in order to increase the diameter of the final composite strand.

[0029] Instead of taking all the yarns and impregnating them at the same time, only those necessary for the layer to be polymerized will be impregnated. This allows the size of the vacuum and impregnation chamber to be reduced, directly proportional to the number of fibers and therefore to the final diameter of the monostrand. Such an installation also allows the replacement and / or addition of polymerization devices in order to increase the cross-section of the final composite monostrand.

[0030] Such staged polymerization makes it possible to obtain a composite monostrand with a diameter between 10mm and 30mm with a rate between 10m / min and 50m / min, for example 30m / min.

[0031] Furthermore, such an installation allows access to the calibration nozzles and the radiation devices, which are not surrounded by impregnated fibers unlike the known prior art, which facilitates their replacement or maintenance if necessary.

[0032] Impregnated multifilament fibers can be in the form of single strands or fiber bundles.

[0033] Vacuum chambers and impregnation chambers can, for example, be fitted with covers to facilitate cleaning and the installation of multifilament fibres.

[0034] By "elongated composite element" is meant a very long composite element comprising a bundle of multifilament fibers embedded in a composition based on a polymerizable material, which is manufactured continuously from several supply reels of multifilament fibers to form a bundle which is driven in translation to successively impregnate its fibers with polymerizable material and polymerize the material as the bundle moves.

[0035] By “multifilament fiber” is meant a fiber which comprises several elementary filaments Fi arranged side by side to form a bundle whose elementary fibers are unidirectional while being substantially parallel to each other.

[0036] The multifilament fibers can be chosen from the group consisting of glass, carbon, silica, ceramic, flax, hemp, basalt, cellulose, etc. fibers. These multifilament fibers are used to produce elongated composites produced by impregnation of a polymerizable composition of the multifilament fibers. The polymerizable material can be of the thermosetting type, preferably thermocrosslinkable, preferably of the vinylester type. By polymerizable material is meant a material comprising, by weight, more than 50%, preferably more than 75%, of organic matter and even more preferably more than 90% of organic matter.

[0037] Thus, this material may be a thermopolymerizable polymeric material, for example based on unsaturated polyester, polyepoxide, phenolic derivative, or aminoplast. Preferably, the polymerizable material is crosslinked.

[0038] For example, the polymerizable material is a resin that can be crosslinked by ionizing radiation, and the final polymerization can be easily triggered and controlled by means of an ionizing treatment, for example of the UV type.

[0039] The glass transition temperature Tg of the polymerizable material is preferably greater than or equal to 130°C, for example greater than 170°C, preferably greater than or equal to 180°C.

[0040] For example, the final composite element is a single strand comprising multifilament fibers embedded in a polymerizable material, such as a thermosetting resin.

[0041] The final composite monofilament can take any known form, it can be, for example, a cylindrical monofilament of large diameter, for example between 10mm and 30mm or a cylindrical monofilament of small diameter, for example between 0.5mm and 2.5mm

[0042] The elementary filaments, for example, each have an average diameter of between 5pm and 30pm.

[0043] The installation of the invention allows, of course, the manufacture of single strands of circular, rectangular, oval, elliptical, tubular, etc. cross-section, and whose circumferential dimensions can be greater than 30 mm.

[0044] The drive device is, for example, of the type comprising a motorized traction drum allowing the composite element to be wound around its axis or comprising two motorized drums facing each other, being spaced apart by a corresponding distance at least equal to the thickness of the composite element and which rotate in opposite directions to drive the final composite element, by friction, in a translational movement, making it pass into the space located between the two drums.

[0045] Advantageously, the installation comprises at least a first stage for manufacturing a main composite monostrand and a second stage for manufacturing a composite monostrand.

[0046] The second floor, for example, forms a final floor.

[0047] Advantageously, the first stage of manufacturing the main composite monostrand comprises, in the direction of advancement of the bundle of multifilament fibers:

[0048] - a feeding device comprising, for example, several elementary filament feeding reels to form a bundle of multifilament fibers;

[0049] - a vacuum chamber or degassing chamber arranged for example between an inlet nozzle and a separation nozzle;

[0050] - an impregnation chamber downstream of the vacuum chamber and in particular of the separation nozzle and filled with an impregnation composition based on a polymerizable material;

[0051] - a first calibration die at the outlet of the impregnation chamber so as to form a first single strand impregnated with polymerizable material; and

[0052] - a first radiation device configured to partially or completely polymerize the first monostrand impregnated with polymerizable material and to form a main composite monostrand.

[0053] By "partial polymerization or pre-polymerization" is meant that the degree of polymerization of the impregnated multifilament fibers has reached between 0.5% and 5% of complete polymerization.

[0054] As a non-limiting example, the degree of radiation can be assessed using a “DSC” type measuring instrument, an acronym for “Differential Scanning Calorimetry” in English terms.

[0055] The so-called “complete” or “final” polymerization of the composite is obtained when the degree of polymerization of the polymerizable material is close to 100%, preferably greater than or equal to 95% of the complete polymerization.

[0056] For example, the second stage of manufacturing the composite monostrand comprises, in the direction of advancement of the bundle of multifilament fibers:

[0057] - at least one module for preparing additional or secondary impregnated multifilament fibers,

[0058] - a second calibration die configured to receive the additional multifilament fibers from the additional impregnated multifilament fiber preparation module, for example in the form of a single strand or a bundle, and the main composite single strand so as to form a first intermediate single strand; and at least

[0059] - a final radiation device located downstream of the calibration die, through which the first intermediate monostrand circulates and configured to carry out complete or final polymerization of said first intermediate monostrand and form a final composite monostrand.

[0060] Alternatively, provision could be made to add an additional radiation device downstream of the second calibration die and upstream of the final radiation device. The additional radiation device is configured to carry out partial or intermediate polymerization of the first intermediate monostrand and to form a second pre-polymerized monostrand or second intermediate monostrand.

[0061] According to yet another variant, provision could be made to add a second additional radiation device arranged between the first additional radiation device and the final radiation device. The second additional radiation device comprises an additional light source, for example ultraviolet radiation.

[0062] According to another embodiment, the installation comprises a third stage for manufacturing the final composite monostrand and the second stage is configured to manufacture a second intermediate composite monostrand, the second stage comprising, in the direction of advancement of the multifilament fibers:

[0063] - at least one module for preparing additional or secondary impregnated multifilament fibers,

[0064] - a second calibration die configured to receive the additional multifilament fibers from the additional impregnated multifilament fiber preparation module and the main composite monostrand so as to form a first intermediate monostrand; and at least

[0065] - a first intermediate radiation device located downstream of the second calibration die and configured to carry out partial or intermediate polymerization of the first intermediate single strand and to form a second intermediate single strand.

[0066] The second floor here forms an intermediate floor and the third floor here forms a final floor.

[0067] For example, the third stage includes, in the direction of advancement of the multifilament fibers:

[0068] - at least one module for preparing additional or secondary impregnated multifilament fibers,

[0069] - a third calibration die configured to receive the additional multifilament fibers from the additional impregnated multifilament fiber preparation module and the second intermediate monostrand so as to form a third intermediate monostrand; and at least

[0070] - a final radiation device located downstream of the third calibration die, through which the third intermediate monostrand circulates and configured to carry out complete or final polymerization of said third intermediate monostrand and form a final composite monostrand.

[0071] Alternatively, the third stage could comprise, between the third calibration die and the final radiation device, a first additional radiation device located downstream of the third calibration die and configured to carry out a partial or intermediate polymerization of the third intermediate monostrand and to form a pre-polymerized monostrand. In this case, the final radiation device is configured to carry out a complete or final polymerization of said pre-polymerized monostrand and to form a final composite monostrand.

[0072] According to yet another variant, provision could be made to add, in the third stage, a second additional radiation device arranged between the first additional radiation device and the final radiation device. The second additional radiation device comprises an additional light source, for example ultraviolet radiation.

[0073] For example, the first radiation device comprises a first ultraviolet radiation light source.

[0074] According to one embodiment, in which the last stage comprises a final radiation device and at least one first additional radiation device arranged upstream of said final radiation device, the final radiation device comprises a final light source at least with infrared radiation advantageously for completing the polymerization of the pre-polymerized impregnated multifilament fiber bundle.

[0075] Preferably, the final light source is configured to emit only infrared radiation, with a wavelength between 1 pm and 3 pm.

[0076] According to one embodiment, in which the last stage comprises only a final radiation device, the final radiation device comprises a final light source configured to emit both infrared radiation and ultraviolet radiation.

[0077] For example, the first ultraviolet light source and / or the additional light source / or the final light source may comprise a plurality of light-emitting diodes, acronym LED, preferably directed radially towards the impregnated multifilament fibers, preferably via reflectors.

[0078] Alternatively, the first light source and / or the additional light source and / or the final light source could comprise a plurality of mercury vapor lamps configured to emit at least broad spectrum ultraviolet radiation (UV), and infrared radiation.

[0079] The use of protective tubes helps protect radiation sources from vapors and possible splashes.

[0080] Furthermore, the use of LEDs can reduce the release of styrene vapors, reduce fouling of the protection tube, and reduce variations in light intensity over time, which allows for more consistent polymerization of the multifilament fiber bundle.

[0081] Furthermore, LEDs have a longer lifespan and lower or similar energy consumption than mercury vapor lamps and can reduce the release of styrene vapors into the atmosphere.

[0082] The final radiation device is distinct from the first radiation device and the additional radiation device.

[0083] The exposure time of the impregnated multifilament fiber bundle to the first UV light source is between 0.2 s and 2 s.

[0084] The power of the first UV light source is between 1000Watts and 3000Watts.

[0085] According to another variant, the final light source may comprise the combination of a plurality of mercury vapor lamps configured to emit at least broad spectrum ultraviolet radiation (UV), and infrared radiation and an infrared radiation device configured to emit only infrared radiation with an infrared radiation wavelength between 1 pm and 3 pm.

[0086] According to another variant, the final light source may comprise a combination of a plurality of light-emitting diodes, acronym LED, and a plurality of mercury vapor lamps configured to emit at least broad spectrum ultraviolet radiation (UV), and infrared radiation. According to yet another variant, the final light source may comprise the combination of mercury vapor UV lamps, LEDs and infrared radiation.

[0087] According to one embodiment, in which the last stage comprises a final radiation device and at least one first additional radiation device arranged upstream of said final radiation device, the duration of exposure of the intermediate single strand to the additional UV light source is between 0.5s and 9s.

[0088] In this case, the power of the additional UV light source is between 1.1kW and 98kW.

[0089] In this case, the exposure time of the pre-polymerized monostrand to the final IR light source is between 2.6s and 23s and the power of the final IR light source is between 2.2kW and 98kW.

[0090] In the case where the last stage comprises only a final radiation device, the exposure time of the pre-polymerized monostrand to the final light source is between 4s and 12s and the power of the final light source is between 8.7kW and 130kW.

[0091] Such an installation is particularly advantageous for manufacturing a composite monofilament from a bundle of large diameter multifilament fibers, between 10mm and 30mm. Indeed, because the bundle of large diameter multifilament fibers retains heat for longer, it is not necessary to immediately complete the polymerization after the partial polymerization by the UV light source. It is then possible to add bundles of multifilament fibers to the main bundle of multifilament fibers before carrying out the final polymerization by UV and IR rays.

[0092] Furthermore, at the end of the process, at the outlet of the final radiation device, thanks to the large diameter of the final composite monostrand, the polymerization could be completed thanks to the exothermicity of the monostrand. Advantageously, the module for preparing the additional or secondary impregnated multifilament fibers comprises a feed device for forming multifilament fibers, in the form of a bundle or monostrand, a vacuum chamber or degassing chamber and an impregnation chamber downstream of the vacuum chamber and filled with an impregnation composition based on a polymerizable material.

[0093] For example, the second stage of manufacturing the final composite monofilament comprises two additional modules arranged in parallel. Alternatively, it could be provided that the second stage of manufacturing comprises only one module or more than two additional modules.

[0094] Advantageously, each manufacturing stage of the composite monostrand comprises a heating device associated with the corresponding impregnation chamber and configured to heat the polymerizable material present in said impregnation chamber to a temperature between 50°C and 95°C, preferably 60°C to 80°C.

[0095] According to a second aspect, the invention relates to a method for the continuous manufacture of an elongated composite element comprising a bundle of multifilament fibers impregnated with a composition based on a polymerizable material, comprising the following successive steps:

[0096] - manufacturing of a main single strand in a first manufacturing stage; and at least

[0097] - manufacturing of a second single strand in a second manufacturing stage.

[0098] Advantageously, each stage of manufacturing a composite monostrand comprises a step of preparing impregnated multifilament fibers comprising the following successive steps:

[0099] - feeding of elementary filaments to form multifilament fibers,

[0100] - degassing, in a vacuum chamber, of multifilament fibers,

[0101] - impregnation of the multifilament fibers with a composition based on a polymerizable material contained in an impregnation chamber filled with said composition, and

[0102] - calibration of the impregnated multifilament fibers, via a calibration die so as to form a single strand impregnated with polymerizable material.

[0103] For example, in the step of manufacturing a main strand, the impregnated single strand is partially polymerized in a first radiation device to form a main strand of polymerizable material.

[0104] For example, during the manufacturing stage of a second single strand:

[0105] - the main single strand is associated with additional multifilament fibers coming from at least one additional impregnated multifilament fiber preparation module to form a first intermediate single strand;

[0106] - said first intermediate monostrand is polymerized in an additional radiation device configured to carry out a partial or intermediate polymerization of the first intermediate monostrand and to form a pre-polymerized monostrand or second intermediate monostrand; and

[0107] - said second intermediate monostrand is polymerized in a final radiation device located downstream of the additional polymerization radiation device configured to carry out complete or final polymerization of said second intermediate monostrand and form a final composite monostrand.

[0108] Other aims, characteristics and advantages of the invention will appear on reading the following description, given solely by way of non-limiting example, and made with reference to the appended drawings in which:

[0109] [Fig. l] very schematically represents an installation for manufacturing a composite element according to the state of the art;

[0110] [Fig.2] very schematically represents an installation for manufacturing a composite element according to a first embodiment of the invention

[0111] [Fig.3] very schematically represents an installation for manufacturing a composite element according to a second embodiment of the invention; and

[0112] [Fig.4] is a flowchart illustrating certain steps in the process of manufacturing a composite element by an installation according to Figure 2.

[0113] Figure 2 schematically illustrates an installation 100 for manufacturing a very long, elongated EF composite element.

[0114] By "elongated composite element" is meant a very long composite element comprising a bundle of multifilament fibers embedded in a composition based on a polymerizable material, which is manufactured continuously from one or more supply reels of multifilament fibers Fi_0 to form a bundle which is driven in translation along the arrow F to successively impregnate its fibers with polymerizable material and polymerize the material as the bundle moves.

[0115] By “multifilament fiber” is meant a fiber which comprises several elementary filaments Fi arranged side by side to form a bundle whose elementary fibers are unidirectional while being substantially parallel to each other.

[0116] Multifilament fibers can be chosen from the group consisting of glass, carbon, silica, ceramic, flax, hemp, basalt, cellulose, etc. fibers. These multifilament fibers are used to produce elongated composites made by impregnating the multifilament fibers with a polymerizable composition.

[0117] The polymerizable material may be of the thermosetting type, preferably thermocrosslinkable, preferably of the vinylester type. By polymerizable material is meant a material comprising, by weight, more than 50%, preferably more than 75%, of organic matter, preferably more than 95% of organic matter.

[0118] Thus, this material may be a thermopolymerizable polymeric material, for example based on unsaturated polyester, polyepoxide, phenolic derivative, or aminoplast. Preferably, the polymerizable material is crosslinked.

[0119] For example, the polymerizable material is a resin that can be crosslinked by ionizing radiation, and the final polymerization can be easily triggered and controlled by means of an ionizing treatment, for example of the UV type.

[0120] The glass transition temperature Tg of the polymerizable material is preferably greater than or equal to 130°C, for example greater than 170°C, preferably greater than or equal to 180°C.

[0121] In the example illustrated in the figures, the composite element EF is a single strand comprising multifilament fibers embedded in a polymerizable material, such as a thermosetting resin.

[0122] The EF composite monofilament can take any known form, it can be, for example, a cylindrical monofilament of large diameter, for example between 10mm and 30mm or a cylindrical monofilament of small diameter, for example between 0.5mm and 2.5mm.

[0123] The elementary filaments, for example, each have an average diameter of between 5pm and 30pm.

[0124] The installation of the invention allows, of course, the manufacture of single strands of circular, rectangular, oval, elliptical, tubular, etc. cross section.

[0125] As illustrated in FIG. 2, the manufacturing installation 100 comprises, in the direction of advancement of the bundle of multifilament fibers according to the arrow F, a first stage STAGE 1 for manufacturing a main composite monostrand E2, a second stage STAGE 2 for manufacturing a final composite monostrand EF and a translational drive device D according to the arrow F configured to drive the bundle of multifilament fibers in translation to successively carry out the passage in the first and second stages STAGE 1, STAGE 2. The second stage STAGE 2 is here a final stage.

[0126] The drive device D is, for example, of the type comprising a motorized traction drum allowing the composite element to be wound around its axis or comprising two motorized drums facing each other, being spaced apart by a corresponding distance at least equal to the thickness of the composite element and which rotate in opposite directions to drive the composite element EF, by friction, in a translational movement, making it pass into the space situated between the two drums.

[0127] As illustrated, the first stage STAGE 1 of manufacturing the main composite monostrand E2 comprises, in the direction of advancement of the bundle of multifilament fibers according to arrow F:

[0128] - a supply device 1 1 1 comprising here a plurality of reels 1 12 for supplying elementary filaments Fi_0 to form a bundle of multifilament fibers EO,

[0129] - a vacuum chamber 113 or degassing chamber arranged between an inlet nozzle 113a and a separation nozzle 113b;

[0130] - an impregnation chamber 114 downstream of the vacuum chamber 113 and in particular of the separation nozzle 113b and filled with an impregnation composition 115 based on a polymerizable material;

[0131] - a calibration die 116 at the outlet of the impregnation chamber 114 so as to form a first single strand E1 impregnated with polymerizable material; and

[0132] - a first radiation device 117 through which circulates the first single strand E1 impregnated with polymerizable material and configured to carry out a partial or complete polymerization of the first impregnated single strand E1 and to form a main composite single strand E2.

[0133] Each reel 112 is used to feed a multifilament fiber. If stage 1 comprises nine multifilament fibers, the feed device 111 comprises nine reels. As illustrated, the second stage STAGE 2 for manufacturing the final composite monostrand EF comprises, in the direction of advancement of the bundle of multifilament fibers according to arrow F: two modules 120, 130 for preparing additional or secondary impregnated multifilament fibers ES1, ES2, in the form of a bundle or monostrand. The two additional modules 120, 130 are arranged in parallel;

[0134] - a second calibration die 126 configured to receive the additional multifilament fibers ES1, ES2 and the main composite single strand E2 so as to form a first intermediate single strand E3;

[0135] - an additional radiation device 127 located downstream of the second calibration die 126, through which the first intermediate monostrand E3 circulates and configured to carry out a partial or intermediate polymerization to form a first pre-polymerized monostrand E4 or second intermediate monostrand; and

[0136] - a final radiation device 118 located downstream of the additional radiation device 127, through which the first pre-polymerized monostrand E4 circulates and configured to carry out a complete or final polymerization of said monostrand E4 and form a final composite monostrand EF.

[0137] Alternatively, one could provide only one module or more than two additional or secondary impregnated multifilament fiber preparation modules.

[0138] Generally, the additional radiation device 127 is located downstream of the first radiation device 117 and upstream of the final radiation device 118.

[0139] Alternatively, it could be provided that the second stage STAGE 2 does not include the additional radiation device 127. In this case, the final radiation device 118 is located directly downstream of the second calibration die 126 and through which the first intermediate monostrand E3 circulates. The final radiation device 118 is thus configured to carry out a complete or final polymerization of said first intermediate monostrand E3 and form a final composite monostrand EF.

[0140] The additional modules 120, 130 for preparing additional impregnated multifilament fibers ES1, ES2 are functionally identical to the main module 110 for preparing the impregnated multifilament fiber bundle E1.

[0141] Generally, each additional module 120, 130 comprises a supply device 121, 131 comprising several reels 122, 132 for supplying elementary filaments Fi_l, Fi_2 to respectively form the multifilament fibers ES1, ES2.

[0142] Each additional module 120, 130 further comprises a vacuum chamber 123, 133 arranged between an inlet nozzle 123a, 133a and a separation nozzle 123b, 133b and an impregnation chamber 124,

[0143] 134 downstream of vacuum chamber 123, 133 and in particular of separation nozzle 123b, 133b, filled with an impregnation composition 125,

[0144] 135 based on a polymerizable material coming from an external reservoir (not shown) via an inlet pipe 124a, 134a, and comprising a heating device 124b, 134b. The impregnation chamber 123, 133 is delimited by the separation nozzle 123b, 133b of the vacuum chamber 123, 133 and by a final outlet die 124c, 134c.

[0145] The additional multifilament fibers ES1, ES2 are directed towards the main single strand E2 through the second calibration die 126 so as to form the first intermediate single strand E3 impregnated with polymerizable material and whose main single strand E2 has already undergone partial or complete polymerization in the first radiation device 117.

[0146] The vacuum chamber 113 and the impregnation chamber 114 of the first stage STAGE 1, the first calibration die 116, the first radiation device 117, the second calibration die 126, the additional radiation device 127 and the final radiation device 118 are, here, arranged along the same axis corresponding to the longitudinal axis X-X' of the installation 100. Each vacuum chamber 113, 123, 133 is, in a manner known per se, delimited by an inlet nozzle 113a, 123a, 133a, rigid, provided with a through orifice and a separation nozzle 113b, 123b, 133b, rigid, also provided with a through orifice located axially opposite the orifice of the inlet plate.

[0147] Alternatively, it could be provided that the inlet nozzle is provided with a plurality of through-orifices and that the separation nozzle is provided with a plurality of through-orifices. Each through-orifice receives one or more fibers.

[0148] The bundle of multifilament fibers is introduced into the corresponding vacuum chamber 1 13 , 123, 133 by passing it through the orifice(s) of the inlet nozzle 1 13a, 123a, 133a and exits through the through orifice(s) of the separation nozzle 1 13b, 123b, 133b.

[0149] Each vacuum chamber 1 13 , 123, 133 is connected to a vacuum pump (not shown) which maintains a pressure level of approximately 0.2 bar, ideally 0.1 bar in the corresponding vacuum chamber 1 13,

[0150] 123, 133, despite the passage of the bundle of multifilament fibers through the orifices having a diameter greater than those of the bundle of multifilament fibers which passes through them.

[0151] The vacuum chambers 1 13, 123, 133 allow the bundle of multifilament fibers passing through them to be degassed by the action of the vacuum and thus to reinforce the effectiveness of the subsequent impregnation and above all to guarantee the absence of bubbles inside the final composite monostrand.

[0152] After passing through the vacuum chamber 1 13 , 123, 133, the bundle of multifilament fibers enters the impregnation chamber 1 14,

[0153] 124, 134 which is completely full of polymerizable impregnation material, therefore devoid of air.

[0154] Each impregnation chamber 114, 124, 134 is an airtight enclosure, delimited by the separation nozzle 113b, 123b, 133b and the final outlet die 116, 124c, 134c, rigid, also provided with one or more through orifices located axially opposite the orifice(s) of the separation nozzle. Each impregnation chamber 114, 124, 134 is supplied with polymerizable material 115, 125, 135 coming from an external reservoir (not shown) via an inlet pipe 114a, 124a, 134a, here located in the upper part of said impregnation chamber 114, 124, 134. Alternatively, the inlet pipe could be provided in the lower part.

[0155] Each impregnation chamber 114, 124, 134 may also comprise, for example on its lower part, a discharge pipe (not shown) for the polymerizable material.

[0156] Each impregnation chamber 114, 124, 134 is completely filled with polymerizable material so that the bundle of multifilament fibers exiting the vacuum chamber 113, 123, 133 and passing through it along a linear path is completely impregnated with polymerizable material.

[0157] Each impregnation chamber 114, 124, 134 is associated with a heating device 114b, 124b, 134b configured to heat the polymerizable material to a temperature between 50°C and 95°C, preferably between 60°C and 80°C.

[0158] Thus, the impregnated multifilament fibers exit the corresponding impregnation chamber 1 14, 124, 134 at a temperature between 50°C and 95°C, preferably between 60 and 80°C before passing through the radiation devices 1 17, 127, 1 18.

[0159] As illustrated in FIG. 2, the feed device 111, the vacuum chamber 113 and the impregnation chamber 114 together form a first module 110 for preparing impregnated multifilament fibers, the feed device 121, the vacuum chamber 123 and the impregnation chamber 124 together form a second module 120 for preparing impregnated multifilament fibers and the feed device 131, the vacuum chamber 133 and the impregnation chamber 134 together form a third module 130 for preparing impregnated multifilament fibers. The modules 120, 130 are additional or secondary modules for preparing impregnated multifilament fibers E1, E1, E2.

[0160] The first and second calibration dies 116, 126 are, here, in the form of a calibration nozzle configured to shape the multifilament fibers exiting the impregnation chamber 114, 124, 134 to form a single strand of impregnated multifilament fibers E1, E3.

[0161] Alternatively, any other device could be provided allowing the shaping of impregnated multifilament fibers before polymerization in the corresponding radiation devices 1 17, 127.

[0162] The first radiation device 1 17 comprises a first ultraviolet radiation light source 1 17a, with the acronym UV.

[0163] The first ultraviolet radiation light source 1 17a comprises, for example, a plurality of light-emitting diodes (not shown), acronym LED, preferably directed radially towards the first impregnated single strand El, with or without reflectors to optimize the irradiation.

[0164] The first ultraviolet light source 1 17a with LEDs is configured to emit only monochromatic ultraviolet radiation, the available wavelengths of which are as follows: 365nm, 385nm, 395nm, 405nm, and more generally between 200nm and 405nm.

[0165] In a non-limiting manner, the first radiation device 117 may comprise a protective tube (not referenced) for the impregnated multifilament fibers E1 which enter the first radiation device 117. The protective tube is, for example, made of quartz or glass and which allows the passage of ultraviolet rays, through which the single strand circulates during formation, this tube may be traversed by a current of inert gas, preferably nitrogen.

[0166] The first 1 17a LED ultraviolet light source therefore makes it possible to emit radial and direct radiation onto the first impregnated single strand El, with or without an intermediate element, such as one or more reflectors.

[0167] Alternatively, the first ultraviolet light source 117a could comprise a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet radiation (UV), infrared radiation, and visible light.

[0168] The use of LEDs can reduce styrene vapors, reduce fouling of the protection tube, and reduce variations in light intensity, which allows for more consistent polymerization of multifilament fibers.

[0169] Furthermore, LEDs have a longer lifespan and lower or similar energy consumption than mercury vapor lamps and release less styrene vapors into the atmosphere.

[0170] The first radiation device 117 is configured to partially or completely polymerize the first impregnated monostrand El and deliver a main composite monostrand E2.

[0171] By "partial polymerization or pre-polymerization" is meant that the degree of polymerization of the impregnated multifilament fibers has reached between 0.5% and 5% of complete polymerization.

[0172] The exposure time of the impregnated multifilament fiber bundle E l to the first UV light source is between 0.2s and 2s.

[0173] The power of the first UV light source is between 100W and 3000W.

[0174] The additional radiation device 127 comprises an additional ultraviolet radiation light source 127a, with the acronym UV, arranged after the second calibration nozzle 127 and upstream of the final radiation device 118.

[0175] In one example, the additional ultraviolet radiation light source 127a of the additional radiation device 127 comprises a plurality of LEDs configured to emit only ultraviolet radiation of wavelength between 365nm and 405nm.

[0176] Alternatively, it could be provided that the additional ultraviolet radiation light source 127a of the additional radiation device 127 comprises a plurality of mercury vapor lamps configured to emit broad spectrum UV ultraviolet radiation combined with at least infrared radiation.

[0177] The additional radiation device 127 is configured to partially polymerize or pre-polymerize the first intermediate monostrand E3 and deliver a pre-polymerized monostrand E4.

[0178] The exposure time of the first intermediate single strand E3 to the additional UV light source 127a is between 0.5 s and 9 s.

[0179] The power of the additional UV light source 127a is between 1.1kW and 98kW.

[0180] The final radiation device 118 is distinct from the first radiation device 117 and the additional radiation device 127 to form a final composite single strand EL.

[0181] The final radiation device 1 18 comprises a final light source configured to terminate the polymerization of the first pre-polymerized monostrand E4.

[0182] The so-called “complete” or “final” polymerization of the composite is obtained when the degree of polymerization of the polymerizable material is close to 100%, preferably greater than or equal to 95%.

[0183] For example, the final light source is configured to emit at least one infrared radiation 1 18a, acronym IR, and comprises, for example, a plurality of infrared lamps (not shown), preferably directed radially towards the pre-polymerized single strand E4.

[0184] When the second stage comprises an additional radiation device 127, the final light source 118a is configured to emit only infrared radiation, with a wavelength between 1 pm and 3 pm. For glass fibers, a final IR source with a wavelength equal to 1 pm will be preferred.

[0185] The exposure time of the first pre-polymerized single strand E4 to the final light source 1 18a IR is between 2.6s and 23s.

[0186] The power of the final IR light source 1 18a is between 2.2kW and 98kW. Alternatively, when the second stage does not include an additional radiation device 127, the final light source 1 18a is configured to emit a combination of ultraviolet and infrared radiation.

[0187] Such an installation is particularly advantageous for manufacturing an EF composite monofilament from a bundle of large diameter multifilament fibers, between 10mm and 30mm. Indeed, because the bundle of large diameter multifilament fibers retains heat for longer, it is not necessary to immediately complete the polymerization after the partial polymerization by the UV light source. It is then possible to add multifilament fibers to the main monofilament before carrying out the final polymerization by a UV and infrared light source.

[0188] Alternatively, it could be provided to add a second additional radiation device (not shown) located between the final radiation device 118 and the first additional radiation device 127 and comprising a third ultraviolet light source.

[0189] In this case, it could be provided that the additional ultraviolet radiation light source 127a of the first additional radiation device 127 comprises a plurality of LEDs configured to emit only ultraviolet radiation of wavelength between 365nm and 405nm and that the third ultraviolet radiation light source comprises a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet radiation, infrared radiation and visible light.

[0190] Alternatively, it could be provided that the additional ultraviolet radiation light source 127a of the first additional radiation device 127 comprises a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet radiation UV, infrared radiation and visible light and that the third ultraviolet radiation light source comprises a plurality of LEDs configured to emit only ultraviolet radiation with a wavelength between 365nm and 405.

[0191] Alternatively, it could also be provided that the additional ultraviolet radiation light source 127a of the first additional radiation device 127 and the third ultraviolet radiation light source each comprise a plurality of LEDs configured to emit only ultraviolet radiation with a wavelength between 365nm and 405nm.

[0192] In the embodiment illustrated in Figure 3, in which the same elements bear the same references, the installation 101 for manufacturing a composite monostrand EF differs only from the embodiment illustrated in Figure 2 by the fact that the installation 101 comprises a third stage STAGE 3 for manufacturing a composite monostrand.

[0193] In this embodiment, the first stage STAGE 1 is identical to the first stage STAGE 1 described with reference to Figure 2 and the second stage STAGE 2 differs from the second stage STAGE 2 described with reference to Figure 2 only by the fact that it does not include a final radiation device which is found in the last stage STAGE 3. The second stage STAGE 2 here forms an intermediate stage.

[0194] Thus, the first pre-polymerized single strand E4 exiting the first intermediate radiation device 127 forms a second intermediate single strand which enters the third stage STAGE 3.

[0195] As illustrated in Figure 3, the third stage STAGE 3 of manufacturing the final composite monostrand EF comprises, in the direction of advancement of the bundle of multifilament fibers according to arrow F:

[0196] - a second series of two modules 140, 150 for preparing additional or secondary impregnated multifilament fibers ES3, ES4. The two additional modules 140, 150 are arranged in parallel; T1

[0197] - a third calibration die 136 configured to receive the additional multifilament fibers ES3, ES4 and the first pre-polymerized monostrand E4 or second intermediate monostrand so as to form a third intermediate monostrand E5;

[0198] - a second additional radiation device 137 located downstream of the second calibration die 126, through which the third intermediate monostrand E5 circulates and configured to carry out a partial or intermediate polymerization to form a second pre-polymerized monostrand E6; and

[0199] - a final radiation device 118 located downstream of the second additional radiation device 137, through which the second pre-polymerized monostrand E6 circulates and configured to carry out a complete or final polymerization of said monostrand E6 and form a final composite monostrand EF.

[0200] Alternatively, it could be provided that the third stage does not include an additional radiation device so that the final radiation device is configured to achieve complete or final polymerization of the third intermediate monostrand E5.

[0201] Alternatively, one or more than two additional or secondary impregnated multifilament fiber preparation modules could be provided.

[0202] The second series of additional modules 140, 150 for preparing additional impregnated multifilament fibers ES3, ES4 is functionally identical to the first series of additional modules 120, 130 for preparing additional impregnated multifilament fibers ES1, ES2.

[0203] The full description of each of these modules will not be repeated so as not to make the description too heavy.

[0204] Generally, each additional module 140, 150 of the second series of additional modules comprises a supply device 141, 151 comprising here several reels 142, 152 for supplying elementary filaments Fi_3, Fi_4 to form respectively multifilament fibers ES3, ES4. Each additional module 140, 150 of the second series of additional modules further comprises a vacuum chamber 143, 153 arranged between an inlet nozzle 143a, 153a and a separation nozzle 143b, 153b and an impregnation chamber 144, 154 downstream of the vacuum chamber 143, 153 and in particular of the separation nozzle 143b, 153b, filled with an impregnation composition 145, 155 based on a polymerizable material coming from an external reservoir (not shown) via an inlet nozzle 144a, 154a, and comprising a heating device 144b, 154b.The impregnation chamber 144, 154 is delimited by the separation nozzle 143b, 153b and by a final outlet die 144c, 154c.

[0205] The additional multifilament fibers ES3, ES4 are directed towards the pre-polymerized single strand E4 through the third calibration die 136 so as to form the third intermediate single strand E5 impregnated with polymerizable material and of which the first pre-polymerized single strand E4 or second intermediate single strand has already undergone partial or complete polymerization in the first additional radiation device 127.

[0206] The second additional polymerization radiation device 137 is distinct from the first radiation device 117, the first additional radiation device 127 and the final radiation device 118.

[0207] The first radiation device 117 and the final radiation device 118 are identical to those described with reference to FIG. 2 and will not be further described here.

[0208] The second additional radiation device 137 comprises an additional ultraviolet radiation light source 137a, with the acronym UV, arranged after the third calibration nozzle 137 and upstream of the final radiation device 118.

[0209] In one example, the second additional ultraviolet light source 137a of the additional radiation device 137 comprises a plurality of LEDs configured to emit only ultraviolet radiation of wavelength between 365nm and 405nm. Alternatively, it could be provided that the second additional ultraviolet light source 137a of the additional radiation device 137 comprises a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet radiation, UV radiation.

[0210] The additional radiation device 137 is configured to partially polymerize or pre-polymerize the third intermediate monostrand E5 and deliver a second pre-polymerized impregnated monostrand E6.

[0211] The exposure time of the third intermediate single strand E5 E5 to the second additional UV light source 137a is between 0.5 s and 9 s.

[0212] The power of the second additional UV light source 137a is, here, between 1.1kW and 98kW.

[0213] The installation has been described with reference to two or three stages of manufacturing composite monofilaments. Generally, the installation comprises N stages of manufacturing a composite monofilament, with N greater than or equal to two. Each stage of manufacturing a composite monofilament comprises an impregnation chamber, in order to impregnate only the multifilament fibers necessary to carry out the partial or final polymerization step.

[0214] Such an installation makes it easy to add additional preparation modules, and more generally stages for manufacturing a composite monostrand in order to increase the diameter of the final composite strand. Such an installation also makes it possible to replace and / or add polymerization devices in order to increase the production speed.

[0215] Such staged polymerization makes it possible to obtain a composite single strand with a diameter between 10mm and 30mm.

[0216] Furthermore, such an installation makes it possible to leave access to the calibration nozzles and to the radiation devices, which are not surrounded by impregnated fibers unlike the known prior art, which facilitates their replacement or maintenance if necessary. The vacuum chambers 113, 123, 133, 143, 153 and the impregnation chambers 114, 124, 134, 144, 154 according to the invention are preferably provided with covers in order to facilitate cleaning and the installation of the multifilament fibers.

[0217] Such an installation allows easy integration of protective tubes inside the radiation devices.

[0218] As illustrated in Figure 4, the flowchart illustrates the steps of a method 200 for manufacturing an EF composite element by the installation according to Figure 2.

[0219] The manufacturing method 200 comprises a first step 210 of manufacturing a main single strand E2 in a first manufacturing stage STAGE 1 and a second stage 220 of manufacturing a final single strand EF in a second manufacturing stage STAGE 2.

[0220] The first step 210 of manufacturing a main single strand E2 comprises the following successive steps:

[0221] - a step 211 of feeding elementary filaments to form a bundle of multifilament fibers E0,

[0222] - a step 212 of degassing, in a vacuum chamber 113, the bundle of multifilament fibers E0,

[0223] - an impregnation step 213 during which the bundle of multifilament fibers E0 is impregnated with a composition based on a polymerizable material contained in an impregnation chamber 114 filled with said composition,

[0224] - a calibration step 214, via a first calibration die 116 at the outlet of the impregnation chamber 114 so as to form a first single strand E1 impregnated with polymerizable material; and

[0225] - a first polymerization step 215 during which the first single strand E1 impregnated with polymerizable material circulates through a first radiation device 117 with a view to partial or complete polymerization of the first impregnated single strand E1 and to form a main composite single strand E2.

[0226] As illustrated, the second step 220 of manufacturing a final monostrand EF comprises the following successive steps: - two parallel steps 230, 240 of preparing additional or secondary impregnated multifilament fibers ES1, ES2,

[0227] - a calibration step 224, via a second calibration die 126 located at the outlet of the first radiation device 117 of the first stage STAGE 1, during which a first intermediate single strand E3 is produced comprising the additional multifilament fibers ES1, ES2 and the main composite single strand E2; and

[0228] - an additional polymerization step 225 during which the first intermediate monostrand E3 circulates through an additional radiation device 127 for the purpose of partial or complete polymerization of said first intermediate monostrand E3 to form a pre-polymerized monostrand E4, and

[0229] - a final polymerization step 226 during which the pre-polymerized single strand E4 circulates through a final radiation device 118 for the purpose of final polymerization of said pre-polymerized single strand E4 to form a final single strand EF.

[0230] Each step 230, 240 of preparing the additional or secondary impregnated multifilament fibers ES1, ES2 comprises a step 231, 241 of feeding elementary filaments to form a bundle of multifilament fibers, a step 232, 242 of degassing, in a vacuum chamber 123, 133 of the bundle of multifilament fibers and a step 233, 243 of impregnation during which the rectilinear bundle of multifilament fibers is impregnated with a composition based on a polymerizable material contained in an impregnation chamber 124, 134 filled with said composition.

[0231] Alternatively, one could provide only one or more than two additional or secondary impregnated multifilament fiber preparation steps.

[0232] After passing through the vacuum chamber 113, the bundle of multifilament fibers E0 enters the impregnation chamber 114 which is completely full of polymerizable impregnation material, therefore free of air. The impregnation chamber 114 is supplied with polymerizable material 115 coming from an external reservoir (not shown) via an inlet pipe 114a, here located in the upper part of said impregnation chamber 114.

[0233] The impregnation chamber 114 is completely filled with polymerizable material so that the bundle of multifilament fibers exiting the vacuum chamber 113 and passing through it in a linear path is completely impregnated with polymerizable material.

[0234] The impregnation chamber 114 is associated with a heating device 114b configured to heat the polymerizable material to a temperature between 50°C and 95°C, preferably between 60°C and 80°C.

[0235] Thus, the impregnated multifilament fibers exit the impregnation chamber 1 14 at a temperature between 50°C and 95°C, preferably between 60°C and 80°C. before passing through the first radiation device 1 17.

[0236] During the first polymerization step 225, the single strand impregnated with polymerizable material E1 is partially or completely polymerized to form a main single strand E2 using the first radiation device 117 comprising a first ultraviolet radiation light source 117a, with the acronym UV.

[0237] The first ultraviolet light source 1 17a is identical to that described with reference to Figure 2 and will not be further described here.

[0238] The exposure time of the first El impregnated monostrand to the first UV light source is between 0.2s and 2s.

[0239] The power of the first UV light source is between 1000Watts and 3000Watts.

[0240] During the additional polymerization step 225, the first intermediate monostrand E3 comprising the additional multifilament fiber bundles ES1, ES2 and the main composite monostrand E2 are polymerized using an additional radiation device 127 comprising an additional ultraviolet radiation light source 127a, with the acronym UV.

[0241] The exposure time of the first intermediate single strand E3 to the additional UV light source is between 0.5s and 9s.

[0242] The power of the additional UV light source is between 1.1kW and 98kW.

[0243] In the final polymerization step 226, the first pre-polymerized monostrand E4 is polymerized using a final radiation device 118 comprising an infrared radiation light source, distinct and separate from the first radiation device 117 and the additional radiation device 127.

[0244] The exposure time of the first pre-polymerized E4 monostrand to the final IR light source is between 2.6s and 23s.

[0245] The power of the final light source 1 18a is between 2.2kW and 98kW.

[0246] The final light source 1 18a is identical to that described with reference to Figure 2 and will not be further described here.

[0247] The installation and the manufacturing method according to the invention can be adapted to both existing installations and new installations.

[0248] The installation and the manufacturing method according to the invention make it possible to obtain composite elements having a cross-section of different sizes and this at a high manufacturing rate.

[0249] For example, for a CVR composite, it is possible to obtain, using the method according to the invention, sections having a diameter of between 10mm and 30mm for a rate of approximately 50m / min.

[0250] Furthermore, the installation and the manufacturing method according to the invention make it easy to add additional preparation modules, and more generally stages for manufacturing a composite monostrand in order to increase the diameter of the final composite strand. Such an installation also makes it possible to replace and / or add polymerization devices in order to increase the production speed. Furthermore, such an installation makes it possible to leave access to the calibration nozzles and the polymerization devices, which are not surrounded by impregnated fibers unlike the known prior art, which facilitates their replacement or maintenance if necessary.

Claims

CLAIMS 1. Installation (100, 101) for the continuous manufacture of an elongate composite element (EF) comprising a bundle of multifilament fibers impregnated with a composition based on a polymerizable material, the installation (100, 101) comprising N stages (STAGE 1, STAGE 2, STAGE 3) for manufacturing a composite element, with N greater than or equal to 2 and a translational drive device (D) configured to drive the bundle of multifilament fibers in translation to successively carry out the passage through the N stages, the first stage (STAGE 1) for manufacturing a main composite monostrand (E2) comprising in the direction of advance of the bundle of multifilament fibers: - a feed device (111) configured to form a bundle of multifilament fibers (E0), a vacuum chamber (113); - an impregnation chamber (114) downstream of the vacuum chamber (113) and filled with an impregnation composition (115) based on a polymerizable material; - a first calibration die (116) at the outlet of the impregnation chamber (114) so ​​as to form a first single strand (El) impregnated with polymerizable material; and - a first radiation device (117) configured to partially or completely polymerize the first single strand (El) impregnated with polymerizable material and to form a main composite single strand (E2), characterized in that the second stage (STAGE2) for manufacturing the composite single strand (E4, EF) comprises, in the direction of advancement of the bundle of multifilament fibers: at least one module (120, 130) for preparing additional impregnated multifilament fibers (ESI, ES2) comprising a feed device (121, 131) for forming a bundle of multifilament fibers, a vacuum chamber (123, 133) and an impregnation chamber (124, 134) downstream of the vacuum chamber (123, 133) and filled with an impregnating composition (125, 135) based on a polymerizable material; - a second calibration die (126) configured to receive the additional multifilament fibers (ES1, ES2) coming from the module (120, 130) for preparing the additional impregnated multifilament fibers and the main composite monostrand (E2) so as to form a first intermediate monostrand (E3); and - at least one additional radiation device (127) located downstream of the second calibration die (126), and through which the first intermediate monostrand (E3) circulates and configured to carry out a partial polymerization of said first intermediate monostrand (E3) to form a first pre-polymerized monostrand (E4).

2. Installation (100) according to claim 1, in which the second stage (STAGE2) comprises a final radiation device (118) located downstream of the additional radiation device (127) and configured to carry out total polymerization of the first pre-polymerized monostrand (E4) and form a final composite monostrand (EF).

3. Installation (101) according to claim 1, comprising a third stage (STAGE 3) for manufacturing the final composite monostrand (EF) 4. comprising, in the direction of advancement of the bundle of multifilament fibers: at least one module (140, 150) for preparing additional impregnated multifilament fibers (ES3, ES4), - a third calibration die (136) configured to receive the additional multifilament fibers (ES3, ES4) coming from the module (140, 150) for preparing the additional impregnated multifilament fibers and the first pre-polymerized monostrand (E4) so ​​as to form a third intermediate monostrand (E5); and at least - a final radiation device (118) located downstream of the third calibration die (136), through which the third single strand circulates intermediate (E5) and configured to carry out complete polymerization of said single strand (E5) and form a final composite single strand (EF).

5. Installation (101) according to claim 4, in which the third stage (STAGE 3) comprises, between the third calibration die (136) and the final radiation device (118), a second additional radiation device (137) configured to carry out a partial polymerization of the third intermediate single strand (E5) and to form a pre-polymerized single strand (E6).

6. Installation (100, 101) according to claim 1 or 5, wherein the additional radiation device (127, 137) comprises an additional light source (127a, 137a) with ultraviolet radiation.

7. Installation (100, 101) according to any one of the preceding claims, in which the first radiation device (117) comprises a first light source (117a) with ultraviolet radiation.

8. Installation (100, 101) according to any one of the preceding claims, in which the final radiation device (118) comprises a final light source (118a) configured to emit at least one infrared radiation.

9. Installation (100, 101) according to any one of the preceding claims, in which each stage (STAGE 1, STAGE 2, STAGE 3) for manufacturing the composite monostrand comprises a heating device (114b, 124b, 134b, 144b, 154b) associated with the corresponding impregnation chamber (114, 124, 134, 144, 154) and configured to heat the polymerizable material present in said impregnation chamber (114, 124, 134, 144, 154) to a temperature between 50°C and 95°C, preferably between 60°C and 80°C.

10. Method (200) for the continuous manufacture of an elongated composite element (EF) comprising a bundle of multifilament fibers impregnated with a composition based on a polymerizable material, comprising the following successive steps: - manufacture of a main single strand (E2) in a first stage (STAGE 1) of manufacturing during which a first impregnated monostrand (E1) is polymerized in a first radiation device (117) to form a main composite monostrand (E2); and at least - manufacturing a composite monostrand (E4, EF) in a second manufacturing stage (STAGE 2), each manufacturing stage (STAGE 1, STAGE 2) comprising a step of preparing impregnated multifilament fibers comprising the following successive steps: - feeding of elementary filaments to form a bundle of multifilament fibers, - degassing, in a vacuum chamber (113, 123, 133, 143, 153), the bundle of multifilament fibers, impregnating the bundle of multifilament fibers with a composition based on a polymerizable material contained in an impregnation chamber (114, 124, 134, 154) filled with said composition, and - calibrating the impregnated multifilament fiber bundle, via a calibrating die (116, 126, 136) so as to form a single strand impregnated with polymerizable material, characterized in that during the step of manufacturing the composite single strand (E4, EF), - the main single strand (E2) is associated through a second calibration die (126) with additional multifilament fibers (ES1, ES2) coming from at least one module (120, 130) for preparing additional impregnated multifilament fibers comprising a feed device (121, 131) for forming a bundle of multifilament fibers, a vacuum chamber (123, 133) and an impregnation chamber (124, 134) downstream of the vacuum chamber (123, 133) and filled with an impregnation composition (125, 135) based on a polymerizable material to form a first intermediate single strand (E3); and - said first intermediate single strand (E3) is polymerized in an additional radiation device (127) configured to carry out a partial polymerization of the first intermediate single strand (E3) and to form a second intermediate single strand (E4). 1 1. Method (200) according to claim 10, wherein the second intermediate monostrand (E4) is polymerized in a final radiation device (1 18) located downstream of the additional radiation device (127) configured to carry out complete polymerization of said second intermediate monostrand (E4) and form a final composite monostrand (EF).

12. Method (200) according to claim 10, in which the second intermediate monostrand (E4) is associated through a third calibration die (136) with additional multifilament fibers (ES3, ES4) coming from at least one module (140, 150) for preparing additional impregnated multifilament fibers comprising a feed device (141, 151) for forming a bundle of multifilament fibers, a vacuum chamber (143, 153) and an impregnation chamber (144, 154) downstream of the vacuum chamber (143, 153) and filled with an impregnation composition (145, 155) based on a polymerizable material to form a third intermediate monostrand (E5); and - said third intermediate monostrand (E5) is polymerized in an additional radiation device (137) configured to carry out a partial polymerization of the third intermediate monostrand (E5) and to form a pre-polymerized monostrand (E6); said pre-polymerized monostrand (E6) being polymerized in a final radiation device (118) located downstream of the additional radiation device (137) configured to carry out a complete polymerization of said pre-polymerized monostrand (E6) and to form a final composite monostrand (EF).

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