System for the continuous manufacturing of an elongate composite part having a circular cross-section

Abstract

A system for the continuous manufacturing of an elongate composite part (EF) that has a circular cross-section (100) and comprises a bundle of multifilament fibers impregnated with a composition based on a polymerizable material, the system (100) comprising a device (120) for mechanically deforming a monofilament (E2) that has been pre-polymerized in a first radiation device (117) located upstream of a second radiation device (118) in the direction of travel of the bundle of multifilament fibers, the mechanical deforming device (120) being configured to deform the pre-polymerized monofilament (E2) and to impart a circular shape to the cross-section of the pre-polymerized monofilament (E2).

Description

[0001] DESCRIPTION

[0002] TITLE: Installation for the continuous production of an elongated composite element with a circular section

[0003] The present invention relates to the field of reinforcements based on composite materials.

[0004] More particularly, the present invention relates to the continuous manufacture of elongated composite materials produced by impregnation of a polymerizable composition of multifilament fibers.

[0005] More particularly, the present invention relates to an installation for manufacturing composites in the form of single strands comprising continuous, unidirectional multifilament fibers embedded in a polymerizable resin.

[0006] 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.

[0007] 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 concrete reinforcement applications.

[0008] Generally, with reference to figure 1, a device 1 for manufacturing a single strand of glass-resin composite comprises one or more reels 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 an arrangement 12 of these fibers 11.

[0009] The arrangement 12 then passes through a vacuum chamber 13 arranged between an inlet nozzle 13a and a separation nozzle 13b and an impregnation chamber 14 downstream of the separation nozzle 13b and filled with impregnation composition 15 based on a curable resin. The device 1 further comprises a calibration die

[0010] 16 at the outlet of the impregnation chamber 14 so as to obtain a single strand 17 and a radiation device 18 comprising, for example, a protection tube 18a through which the composite single strand circulates

[0011] 17 and a plurality of UV irradiators 18b in line in order to obtain a polymerized monostrand 19.

[0012] 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:

[0013] - making an arrangement of glass fibers and driving this arrangement in a direction of advancement;

[0014] - degas the fiber arrangement by the action of vacuum in a vacuum chamber;

[0015] - at the outlet of the vacuum chamber, after degassing, pass 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 impregnation containing the fibers and the resin;

[0016] - passing said impregnated material through a calibration die having a predefined surface section and shape, to impose a single-strand shape on it; and

[0017] - 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.

[0018] Traditionally, known composite monostrands have a circular cross-section and are composed of continuous glass fibers impregnated with a polymerizable material, preferably photo-polymerizable.

[0019] However, in practice, the final geometry of the composite monofilament section is not perfectly circular, but rather slightly elliptical. This elliptical shape is a consequence of current manufacturing facilities and processes in which the composite monofilament emerges from the sizing die coated with a polymerizable material that is still in a liquid state before final polymerization. The composite monofilament therefore still has the possibility of modifying its geometry before final polymerization sets its shape.

[0020] In some applications, a slight deformation of the elliptical geometry does not pose any problems, for example in concrete reinforcement applications. However, in other applications, particularly in vehicle tires, it is necessary, before introducing the composite monofilament into the tire, to pass it through circular shaping dies. This can cause problems with jamming or even breakage of the composite monofilament if its cross-section is not sufficiently circular.

[0021] Composite monofilaments with circular cross-section have the same physical properties in all directions, whereas those with elliptical cross-section are anisotropic.

[0022] Thus, there is a need to address the above-mentioned drawbacks.

[0023] The invention aims to improve the circularity of the section of a composite monostrand, while maintaining a high production speed, between 80m / min and 200m / min, preferably between 100m / min and 120m / min.

[0024] Furthermore, the present invention aims to adapt easily to existing composite monostrand manufacturing installations.

[0025] 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, the installation comprising, in the direction of advance of the bundle of multifilament fibers:

[0026] - a feeding device configured to form a bundle of multifilament fibers;

[0027] - a degassing chamber for the multifilament fiber bundle;

[0028] - an impregnation chamber filled with a composition based on a polymerizable material and configured to impregnate said degassed bundle of multifilament fibers with said composition and form an impregnated single strand, said impregnation chamber being located downstream of the degassing chamber in the direction of advancement of the bundle of multifilament fibers; and

[0029] - a first radiation device through which the single strand impregnated with polymerizable material circulates and configured to carry out a partial polymerization of the impregnated single strand to form a pre-polymerized single strand; and at least

[0030] - a second radiation device, separate and distinct from the first radiation device configured to form a final composite monostrand, and

[0031] - a translational drive device configured to drive the bundle of multifilament fibers in translation and to apply tension to said bundle of multifilament fibers.

[0032] The installation comprises a device for mechanically deforming the pre-polymerized monostrand arranged between the first radiation device and the second radiation device in the direction of advancement of the bundle of multifilament fibers, said device for mechanically deforming the pre-polymerized monostrand being configured to plastically deform the pre-polymerized monostrand and give a circular shape to the section of said pre-polymerized monostrand to form a deformed monostrand.

[0033] Thus, the mechanically deformed single strand circulates through the second radiation device in order to carry out a final polymerization of said deformed single strand to form a final composite single strand.

[0034] The second radiation device is configured to perform final polymerization of the pre-polymerized monostrand.

[0035] By "partial polymerization or pre-polymerization" is meant that the degree of polymerization of the radiation-impregnated multifilament fiber bundle has reached between 35% and 65% of complete polymerization.

[0036] By way of non-limiting example, the degree of polymerization can be evaluated using a measuring instrument of the “DSC” type, an acronym for “Differential Scanning Calorimetry” in English terms. The pre-polymerization step makes it possible to obtain a pre-polymerized, non-sticky single strand, capable of no longer deforming in the free state while being malleable to be deformed under mechanical stress.

[0037] 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 total polymerization.

[0038] The device for mechanically deforming the pre-polymerized single strand is configured to plastically deform the pre-polymerized single strand and obtain a deformed single strand.

[0039] By "plastic deformation" we mean a non-reversible deformation.

[0040] Thanks to the mechanical deformation device, it is possible to give a circular shape to the section of the single strand before final polymerization.

[0041] The circularity of the section of a composite monostrand is therefore improved, while maintaining a high production speed, between 80m / min and 200m / min, preferably between 100m / min and 120m / min.

[0042] Alternatively, it could be envisaged to add a third light source with ultraviolet radiation placed between the device for mechanical deformation of the pre-polymerized single strand and the final radiation device.

[0043] 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 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.

[0044] By “multifilament fiber” is meant a fiber which comprises several elementary filaments arranged side by side to form a bundle whose elementary fibers are unidirectional while being substantially parallel to each other.

[0045] 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.

[0046] 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 and even more preferably more than 90% of organic matter, preferably more than 95%.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] For example, the final composite element is a single strand comprising multifilament fibers embedded in a polymerizable material, such as a thermosetting resin.

[0051] The final composite monofilament can take the form of a cylindrical monofilament with a diameter between 0.2mm and 2.5mm, preferably between 0.7mm and 1.1mm.

[0052] The elementary filaments each have, for example, an average diameter of between 5 μm and 30 μm. The drive device is, for example, of the type comprising a motorized traction drum for winding the composite element around its axis or comprising two motorized drums facing each other, 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.

[0053] Advantageously, the mechanical deformation device comprises at least one set of two shaping members located one above the other in a direction perpendicular to the direction of advancement of the fibers, for example vertically one above the other, on either side of the pre-polymerized single strand to be deformed, one of the shaping members comprises a first annular groove of semi-circular section and the other of the shaping members comprises a second annular groove of semi-circular section matching in shape with the first annular groove. Said annular grooves face each other in the direction perpendicular to the direction of advancement of the fibers, for example vertically, and together define a passage of circular section for receiving the pre-polymerized single strand.

[0054] The vertical positioning of the two grooves, one in relation to the other, is done by the contact of the two shaping members on cylindrical parts dedicated to this purpose.

[0055] Advantageously, the mechanical deformation device comprises a fixed structure and the two shaping members are each movable in rotation around a transverse axis of rotation fixed to the fixed structure.

[0056] The transverse axis of rotation is perpendicular to the direction of advancement of the multifilament fiber bundle.

[0057] For example, the transverse axis of rotation is perpendicular to the vertical axis.

[0058] According to one embodiment, the two shaping members are fixed in translation relative to the fixed structure. According to another embodiment, the mechanical deformation device comprises a system for absorbing variations in diameter of the pre-polymerized single strand associated with one or each shaping member. Said system is integral with the fixed structure and the axis of rotation of the corresponding shaping member.

[0059] For example, the system for absorbing diameter variations comprises at least two longitudinal plates integral with the fixed structure and parallel to each other on either side of the corresponding shaping member.

[0060] Each plate comprises a longitudinal fin cut from said plate, connected at one of its ends to said plate and separated from the rest of the corresponding plate by a slot.

[0061] For example, the slot has two opposite surfaces, for example vertical, spaced apart by a clearance, for example vertical, so as to give the fin flexibility in the direction perpendicular to the direction of advancement of the fiber bundle, for example vertical, and thus absorb any variation in diameter of the pre-polymerized single strand.

[0062] Each longitudinal fin further comprises a transverse orifice for receiving the axis of rotation of said shaping member. The transverse orifices of the plates face each other.

[0063] The diameter variation absorption system allows the shaping members to move in translation along the vertical axis when the diameter of the pre-polymerized single strand increases, for example due to an impregnation or pre-polymerization defect. This thus prevents the mechanical deformation device from jamming or even breaking.

[0064] Each longitudinal fin may comprise a plurality of slats extending along the longitudinal axis, parallel to each other and spaced from each other in the direction perpendicular to the direction of advancement, for example vertically, so as to increase the rigidity of the longitudinal fin.

[0065] Alternatively, any other system for absorbing variations in the diameter of the single strand could be provided, such as a return member secured to the fixed structure and the axis of rotation of the corresponding shaping member.

[0066] The rollers are tensioned or preloaded by the absorption system, i.e. it pushes the shaping rollers onto each other with a defined force, which guarantees the correct geometry of the circular section passage receiving the pre-polymerized single strand, while allowing the shaping rollers to be separated in the event of a problem.

[0067] Thus, the shaping members touch each other with a certain force given by the deformation of the fins during preload. This ensures the vertical position of the shaping members. The shaping members only move apart if the preload is exceeded when there is a large diameter defect on the single strand.

[0068] According to one embodiment, the shaping members each have the shape of a roller of generally cylindrical shape.

[0069] For example, one of the shaping members, for example the lower roller, comprises a cylindrical outer surface provided with two annular shoulders delimiting between them the second annular groove of semi-circular section.

[0070] For example, the other of the shaping members, for example the upper roller, comprises a cylindrical outer surface provided with an annular central shoulder comprising, on its outer surface, the first annular groove.

[0071] For example, the two annular shoulders of one of the shaping members each comprise an axial surface inclined obliquely in order to delimit between them a V-shape allowing the pre-polymerized monostrand to be guided in the second annular groove.

[0072] For example, the cylindrical outer surface of the other of the shaping members is provided with two annular end shoulders, on either side of the annular central shoulder.

[0073] The other of the shaping members comprises, for example, a first annular groove delimited transversely between a first end shoulder and the central shoulder and a second annular groove delimited transversely between the central shoulder and the second end shoulder.

[0074] In other words, the central shoulder lies transversely between the two annular grooves.

[0075] For example, each annular groove of the other of the shaping members faces vertically a shoulder of one of the shaping members.

[0076] According to one embodiment, the installation comprises a heating device associated with the 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.

[0077] Alternatively, it could be provided that the installation does not include such a heating device.

[0078] According to another embodiment, the mechanical deformation device comprises at least two or more sets of two shaping members located one above the other in a direction perpendicular to the direction of advancement of the beam, for example vertically and on either side of the pre-polymerized single strand to be deformed, said sets being arranged in series in the direction of advancement of the beam.

[0079] According to one embodiment, the first radiation device comprises a first light source which combines ultraviolet radiation, acronym UV, and infrared radiation, acronym IR.

[0080] The exposure time of the impregnated single strand to the first light source with combined ultraviolet / infrared radiation is between 0.1 s and 1.5 s, preferably between 0.4 and 0.7 s.

[0081] The power of the first light source with combined UV and infrared radiation is between 2kW and 14kW, preferably between 4kW and 7kW.

[0082] According to another embodiment, the first light source comprises a plurality of light-emitting diodes configured to emit only monochromatic ultraviolet radiation with a wavelength between 200nm and 405nm, preferably between 365nm and 405nm.

[0083] According to another embodiment, the first light source comprises a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet (UV) radiation, infrared radiation, and visible light.

[0084] According to one embodiment, the second radiation device comprises a second light source with ultraviolet and infrared radiation or infrared radiation alone to complete the polymerization of the deformed single strand.

[0085] The exposure time of the deformed single strand to the second light source combining ultraviolet and infrared rays is between 1 s and 6 s, preferably between 1.5 s and 3 s.

[0086] The power of the second UV and infrared light source is between 100kW and 60kW, preferably between 20kW and 40kW

[0087] According to a variant, the second light source comprises a plurality of light-emitting diodes, acronym LED, preferably directed radially towards the deformed single strand, the available wavelengths of which are between 200nm and 405nm, preferably between 365nm and 405nm. In this case, the LEDs are combined with infrared radiation.

[0088] According to another variant, the second light source could comprise a plurality of mercury vapor lamps, the exposure time of the deformed single strand of which is between 1 s and 4 s, preferably between 1.5 s and 2 s, at a power of between 1 0kW and 60kW, preferably between 20kW and 40kW.

[0089] Alternatively, the second light source could include a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet (UV) radiation, infrared radiation, and visible light. The mercury vapor lamps may be combined with infrared radiation with an infrared radiation wavelength between 1 pm and 3 pm.

[0090] According to yet another variant, it could be provided that the second radiation device comprises a light source with infrared radiation only configured to emit only infrared radiation, with a wavelength between 1 pm and 3 pm.

[0091] In this case, the duration of exposure of the deformed single strand to the second light source combining infrared radiation alone is between 2s and 8s, preferably between 3s and 4s and the power of this second infrared light source is between 10kW and 60kW, preferably between 20kW and 40kW.

[0092] 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:

[0093] [Fig. l] very schematically represents an installation for manufacturing a composite element according to the state of the art;

[0094] [Fig.2] very schematically represents an installation for manufacturing a composite element according to one embodiment of the invention;

[0095] [Fig.3] very schematically represents a mechanical deformation device of the installation of figure 2;

[0096] [Fig.4] illustrates a detailed view of the mechanical deformation device of Figure 3.

[0097] [Fig.5] illustrates a detail view of a mechanical deformation device according to another embodiment.

[0098] Figure 2 schematically illustrates an installation 100 for manufacturing a very long, elongated EF composite element.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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 and even more preferably more than 90% of organic matter, or even more than 95%.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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. The composite single strand EF may take the form of a cylindrical single strand with a diameter of between 0.2 mm and 2.5 mm, preferably between 0.7 mm and 1.1 mm.

[0107] The elementary filaments, for example, each have an average diameter of between 5pm and 30pm.

[0108] 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:

[0109] - a supply device 1 1 1 comprising here one or more reels 1 12 for supplying elementary filaments Fi_0 to form a bundle of multifilament fibers E0,

[0110] - a vacuum chamber 113 or degassing chamber arranged between an inlet nozzle 113a and a separation nozzle 113b;

[0111] - 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;

[0112] - a calibration die 1 16 at the outlet of the impregnation chamber 1 14 so as to obtain a single strand E l impregnated with polymerizable material;

[0113] - a first radiation device 117 through which circulates the single strand E1 impregnated with polymerizable material and configured to carry out a partial or intermediate polymerization to form a pre-polymerized single strand E2;

[0114] - a mechanical deformation device 120 for the pre-polymerized single strand E2 arranged downstream of the first radiation device 117 and configured to give a circular shape to the section of said pre-polymerized single strand E2 and form a deformed single strand E3;

[0115] - a second radiation device 1 18 or final radiation device, distinct from the first radiation device 1 17, through which the deformed monostrand E3 circulates and configured to carry out a final polymerization to form a final composite monostrand EF; and

[0116] - a translational drive device D according to arrow F configured to drive the bundle of multifilament fibers in translation to successively carry out degassing, impregnation of its fibers with polymerizable material and polymerization of the material as the bundle moves.

[0117] The vacuum chamber 113, the impregnation chamber 114, the calibration die 116, the first radiation device 117 and the second radiation device 118 are arranged along the same axis corresponding to the longitudinal axis of the installation 100 in the longitudinal direction X.

[0118] Generally, the fibers are delivered by one or more reels 1 12, called "rovings" in Anglo-Saxon terms. The bundle, coming from the feeding device 1 1 1 , passes through the installation, advancing in the direction of the arrow F, being set in motion by the drive device D located at the output of the device.

[0119] The drive device D is, for example, of the type comprising a motorized traction drum for winding the composite element around its axis or comprising two motorized drums facing each other, 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 located between the two drums. Alternatively, any drive device could be used to set the bundle of multifilament fibers in motion in a direction of advance.

[0120] The vacuum chamber 113 is, in a manner known per se, delimited by a rigid inlet nozzle 113a, provided with a through orifice and a rigid separation nozzle 113b, also provided with a through orifice located axially opposite the orifice of the inlet nozzle 113a.

[0121] The bundle of multifilament fibers E0 is introduced into the vacuum chamber 113 by passing it through the orifice of the inlet nozzle 113a and exiting through the orifice of the separation nozzle 113b.

[0122] The vacuum chamber 1 13 is connected to a vacuum pump (not shown) which maintains a pressure level of approximately 0. lbar in the vacuum chamber 1 13, despite the passage of the bundle of multifilament fibers EO through the orifice having a diameter greater than that of the bundle of multifilament fibers EO which passes through them.

[0123] The vacuum chamber 1 13 allows the bundle of EO multifilament fibers 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.

[0124] After passing through the vacuum chamber 113, the bundle of multifilament fibers EO enters an impregnation chamber 114 which is completely full of polymerizable impregnation material, therefore free of air.

[0125] The impregnation chamber 114 is an airtight enclosure, delimited by the separation nozzle 113b and a rigid calibration nozzle, also provided with a through orifice located axially opposite the orifice of the separation nozzle 113b.

[0126] The impregnation chamber 114 is supplied with polymerizable material 115 coming from an external reservoir (not shown) via an inlet pipe 115a, here located in the upper part of said impregnation chamber 114.

[0127] The impregnation chamber 114 may also comprise, for example on its lower part, a discharge pipe (not shown) for the polymerizable material.

[0128] 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.

[0129] The impregnation chamber 114 is, here, 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.

[0130] Thus, the impregnated bundle of multifilament fibers leaves 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 radiation devices 1 17, 1 18. Alternatively, such a heating device 1 14b could not be provided.

[0131] The calibration die 116 here comprises a calibration nozzle configured to shape the bundle of multifilament fibers exiting the impregnation chamber 114 to form a single strand of impregnated multifilament fibers E1.

[0132] The first radiation device 1 17 comprises a first light source 1 17a which combines ultraviolet radiation, acronym UV, and infrared radiation, acronym IR.

[0133] The exposure time of the El-impregnated multifilament fiber bundle to the first combined ultraviolet / infrared light source is between 0.1 s and 1.5 s, preferably between 0.4 s and 0.7 s.

[0134] The power of the first light source with combined ultraviolet / infrared radiation is between 2 kW and 14 kW, preferably between 4 kW and 7 kW.

[0135] For example, the first light source comprises a plurality of light-emitting diodes (not shown), acronym LED, preferably directed radially towards the impregnated multifilament fiber bundle E l .

[0136] For example, the power of LEDs is between 2kW and 14 kW, preferably between 4 kW and 7 kW.

[0137] According to yet another variant, the first light source with radiation is configured to emit only monochromatic ultraviolet radiation, for example via LEDs, the available wavelengths of which are as follows: 365, 385, 395, 405nm, and more generally between 200nm and 405nm.

[0138] In a non-limiting manner, the first radiation device 1 17 may comprise a protective tube (not referenced) for the impregnated single strand E1 which enters the first radiation device 1 17. The protective tube is, for example, made of quartz glass, through which the single strand circulates during formation, this tube may be traversed by a current of inert gas, preferably nitrogen. The first ultraviolet radiation light source 1 17a with LEDs therefore makes it possible to emit radial radiation on the impregnated single strand E1, with or without reflectors to optimize the irradiation.

[0139] According to yet another variation, the first light source 117a could comprise a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet (UV) radiation, infrared radiation, and visible light.

[0140] The first radiation device 117 is configured to partially polymerize or pre-polymerize the impregnated single strand E1 and deliver a pre-polymerized impregnated multifilament fiber single strand E2.

[0141] By "partial polymerization or pre-polymerization" is meant that the degree of polymerization of the multifilament fiber bundle has reached between 35% and 65% of complete polymerization.

[0142] The pre-polymerization step makes it possible to obtain a pre-polymerized, non-sticky single strand of fibers, capable of no longer deforming in the free state while being malleable to be deformed under mechanical stress.

[0143] The second radiation device 1 18 or final radiation device comprises a second light source 1 18a with combined ultraviolet and infrared radiation or infrared radiation alone configured to complete the polymerization of the pre-polymerized and deformed impregnated multifilament fiber bundle, called deformed single strand E3.

[0144] Complete 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%.

[0145] The exposure time of the deformed single strand E3 to the second light source combining ultraviolet and infrared rays is between 1 s and 6 s, preferably between 1.5 s and 3 s.

[0146] The power of the second light source with combined UV and infrared radiation is between 10 kW and 60 kW, preferably between 20 kW and 40 kW. According to a variant, the second light source comprises a plurality of light-emitting diodes (not shown), acronym LED, preferably directed radially towards the deformed single strand E3, the available wavelengths of which are between 200 nm and 405 nm, preferably between 365 nm and 405 nm.

[0147] According to another variant, the second light source 118a could comprise a plurality of mercury vapor lamps, the exposure time of the deformed single strand of which is between 1 s and 4 s, preferably between 1.5 s and 2 s, at a power of between 10 kW and 60 kW, preferably between 20 kW and 40 kW.

[0148] Alternatively, the second light source 118a could comprise a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet radiation (UV), infrared radiation and visible light and a plurality of lamps with an infrared radiation wavelength between 1 pm and 3 pm.

[0149] According to yet another variant, the second light source could be solely infrared radiation. The second radiation device in this case comprises a solely infrared radiation light source configured to emit only infrared radiation, with a wavelength between 1 pm and 3 pm.

[0150] In this case, the duration of exposure of the deformed single strand E3 to the second light source combining infrared radiation alone is between 2s and 8s, preferably between 3s and 4s and the power of this second infrared light source is between 10kW and 60kW, preferably between 20kW and 40kW.

[0151] Alternatively, a third radiation device with an infrared radiation light source could be provided downstream of the second radiation device.

[0152] The mechanical deformation device 120 of the pre-polymerized single strand E2 is illustrated in detail with reference to FIG. 3. The mechanical deformation device 120 of the pre-polymerized single strand E2 is configured to plastically deform the pre-polymerized single strand E2 and obtain a deformed single strand E3.

[0153] As illustrated, the mechanical deformation device 120 of the pre-polymerized monostrand E2 comprises a fixed structure 121 and two shaping members or rollers 122, 123 integral with said fixed structure 121.

[0154] Each roller 122, 123 is movable in rotation around an axis of rotation 124, 125 secured to said fixed structure 21.

[0155] The rotation axes 124, 125 extend along a transverse axis Y perpendicular to the longitudinal advancement axis X.

[0156] The two rollers 122, 123 are fixed in translation along the vertical axis Z.

[0157] Alternatively, the two rollers can be movable in translation along the vertical axis Z, as will be described with reference to Figure 5.

[0158] The two rollers 122, 123 are aligned on a vertical axis ZI parallel to the vertical axis Z and are opposite in the vertical direction relative to the single strand E2 which passes between said rollers 122, 123.

[0159] Alternatively, the rollers 122, 123 could be aligned along an axis other than vertical, in particular along an axis perpendicular to the direction of advancement of the bundle of multifilament fibers.

[0160] As illustrated, the mechanical deformation device 102 comprises a set of two rollers 122, 123 superimposed here vertically. Alternatively, a plurality of sets of two rollers could be provided arranged in series along the direction of advancement X of the beam.

[0161] One of the rollers, here, the lower roller 123 comprises a cylindrical body having a cylindrical outer surface 123a provided with two annular shoulders 123b, 123c delimiting between them an annular groove 123d of semi-circular section.

[0162] The two annular shoulders 123b, 123c of the lower roller 123 each comprise an axial surface 123e, 123f, here inclined obliquely in order to delimit between them a V shape allowing the pre-polymerized single strand E2 to be guided in the second annular groove 123d.

[0163] The other of the rollers, here the upper roller 122, comprises a cylindrical body having a cylindrical outer surface 122a provided with two annular end shoulders 122b, 122c and an annular central shoulder 122d, together delimiting two annular grooves 122e, 122f, namely a first annular groove 122e between a first end shoulder 122b and the central shoulder 122d and a second annular groove 122f between the central shoulder 122d and the second end shoulder 122c.

[0164] The central shoulder 122d is located transversely between the two annular grooves 122e, 122f.

[0165] Each annular groove 122e, 122f of the upper roller 122 faces a shoulder 123b, 123c of the lower roller 123.

[0166] The central shoulder 122d of the upper roller 122 faces the annular groove 123d of the lower roller 123.

[0167] The central shoulder 122d comprises, on its outer surface, an annular groove 122g of semi-circular section matching in shape with the annular groove 123d of the lower roller 123 and together delimiting a circular passage for receiving the pre-polymerized single strand E2.

[0168] The pre-polymerized single strand E2 is intended to be received between the annular groove 122g of the upper roller and the annular groove 123d of the lower roller 123 in order to deform it plastically, and to give it a circular section.

[0169] The rollers 122, 123 are in radial contact on the cylindrical parts which are located at each end of the roller, namely the outer cylindrical surface of the annular end shoulders 122b, 122c of the upper roller 122 and the cylindrical outer surface 123a of the lower roller 123. This makes it possible to position the two semi-circular sections 122g and 123d along the vertical axis Z and defines the spacing of the U-shaped grooves 123d, 122g.

[0170] Alternatively, the upper and lower rollers 122, 123 could be reversed. The rollers 122, 123 are advantageously made of a material that is resistant to wear and heat and has little adhesion to the resin.

[0171] The embodiment of Figure 5, in which the same elements bear the same references, differs from the embodiment of Figure 3 only in that one or both shaping members 122, 123 are movable in translation along the vertical axis Z relative to the fixed structure 121.

[0172] The mechanical deformation device 120 comprises, for this purpose, a system 127, 128 for absorbing variations in diameter of the pre-polymerized single strand E2 associated with each shaping member 122, 123.

[0173] Said system 127, 128 is integral with the fixed structure 121 and the rotation axis 124, 125 of the corresponding shaping member 122, 123.

[0174] Said system 127, 128 is deformed (preloaded) when the two rollers touch each other, surfaces 122b and 122c on 123a. This causes the rollers to be pressed against each other with a certain force. This is necessary to give sufficient force to deform the CVR wire.

[0175] As illustrated and, in a non-limiting manner, the system 127, 128 for absorbing variations in diameter comprises two longitudinal plates 127a, 128a integral with the fixed structure 121, parallel to each other on either side of the corresponding shaping member 122, 123.

[0176] Each longitudinal plate 127a, 128a comprises a longitudinal fin 127b, 128b cut out of said plate comprising a transverse orifice 127c, 128c for receiving the rotation axis 124, 125 of the corresponding shaping member 122, 123.

[0177] Said longitudinal fin 127b, 128b is connected at one of its ends to said plate 127a, 128a and separated from the rest of the corresponding plate by a slot having two opposite surfaces, here vertical, spaced apart by a clearance J, here vertical, so as to give the fin 127b, 128b flexibility in the direction perpendicular to the direction of advancement of the fiber bundle, here vertical Z, and thus absorb any variation in diameter of the pre-polymerized single strand E2. The transverse orifices 127c, 127c of the fins face each other.

[0178] The system 127, 128 for absorbing variations in diameter allows the shaping members 122, 123 to move in translation along the vertical axis Z during an increase in diameter of the pre-polymerized single strand E2, for example due to a defect in impregnation or pre-polymerization. This thus prevents the mechanical deformation device 120 from jamming, or even breaking said device.

[0179] As illustrated, and in a non-limiting manner, each longitudinal fin 127b, 128b comprises a plurality of slats 127d, 128d extending along the longitudinal axis X, parallel to each other and spaced vertically from each other so as to increase the rigidity of the longitudinal fin 127b, 128b.

[0180] Alternatively, any other system for absorbing variations in the diameter of the single strand could be provided, such as a return member secured to the fixed structure 121 and to the rotation axis 124, 125 of the corresponding shaping member 122, 123.

[0181] The installation according to the invention makes it possible to continuously produce a deformed composite single strand that does not require post-treatment.

[0182] Such an installation can easily be installed on all existing composite reinforcement production lines.

[0183] Thanks to the mechanical deformation device, it is possible to give a circular shape to the section of the single strand before final polymerization.

[0184] The mechanical deformation device according to the invention is easily installed on a production line of composite monostrand of known circular section, after the first UV lamp.

Claims

CLAIMS 1. Installation (100) 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, the installation (100) comprising, in the direction of advance (X) of the bundle of multifilament fibers: - a feed device (111) configured to form a bundle of multifilament fibers (E0); a degassing chamber (113) for the bundle of multifilament fibers (E0); - an impregnation chamber (114) filled with a composition based on a polymerizable material and configured to impregnate said degassed bundle of multifilament fibers (E0) with said composition and form an impregnated single strand (E1), said impregnation chamber (114) being located downstream of the degassing chamber in the direction of advancement of the bundle of multifilament fibers; and - a first radiation device (117) through which the impregnated single strand (E1) of polymerizable material circulates and configured to carry out a partial polymerization of the impregnated single strand (E1) and to form a pre-polymerized single strand (E2); and at least - a second radiation device (118), separate and distinct from the first radiation device (117) configured to form a final composite monostrand (EF), and - a translational drive device (D) configured to drive the bundle of multifilament fibers in translation and to apply tension to said bundle of multifilament fibers, the installation comprising a device (120) for mechanically deforming the pre-polymerized single strand (E2) arranged between the first radiation device (117) and the second radiation device (118) in the direction of advancement of the bundle of multifilament fibers, said device (120) for mechanically deforming the pre-polymerized single strand (E2) being configured to plastically deform the pre-polymerized single strand (E2) and give a circular shape to the section of said single strand (E2) pre-polymerized to form a deformed single strand (E3), characterized in that said mechanical deformation device (120) comprises: - at least one set of two shaping members (122, 123) located one above the other in a direction perpendicular to the direction of advancement of the bundle of multifilament fibers, on either side of the pre-polymerized single strand (E2) to be deformed, one of the shaping members (122) comprising a first annular groove (122g) of semi-circular section and the other of the shaping members (123) comprising a second annular groove (123d) of semi-circular section matching in shape with the first annular groove (122g), said annular grooves (122g, 123d) facing each other and together defining a passage of circular section for receiving the pre-polymerized single strand (E2), - a fixed structure (121), the two shaping members (122, 123) being each movable in rotation around a transverse axis of rotation (124, 125) fixed to the fixed structure (121); and - a system (127, 128) for absorbing variations in the diameter of the pre-polymerized single strand (E2) associated with each shaping member (122, 123), said system (127, 128) being integral with the fixed structure (121) and the axis of rotation (124, 125) of the corresponding shaping member (122, 123).

2. Installation (100) according to claim 1, in which the system (127, 128) for absorbing variations in diameter comprises at least two longitudinal plates (127a, 128a) integral with the fixed structure and parallel to each other on either side of the corresponding shaping member, each longitudinal plate (127a, 128a) comprising a longitudinal fin (127b, 128b) cut out of the corresponding plate (127a, 128a) and provided with a transverse orifice (127c, 128c) for receiving the axis of rotation (124, 125) of the corresponding shaping member, each longitudinal fin (127b, 128b) being connected at one of its ends to the corresponding plate and separated from the rest of the corresponding plate by a slot.

3. Installation (100) according to claim 2, in which each longitudinal fin (127b, 128b) comprises a plurality of slats (127d, 128d) extending along the longitudinal axis (X), parallel to each other and spaced from each other in the direction perpendicular to the direction of advancement.

4. Installation (100) according to any one of claims 1 to 3, in which the shaping members (122, 123) are in radial contact and tensioned by the absorption system.

5. Installation (100) according to any one of the preceding claims, in which the shaping members (122, 123) each have the shape of a roller of generally cylindrical shape.

6. Installation (100) according to claim 5, in which one of the shaping members (123) comprises a cylindrical outer surface (123a) provided with two annular shoulders (123b, 123c) delimiting between them the second annular groove (123d) of semi-circular section.

7. Installation (100) according to claim 5 or 6, in which the other of the shaping members (122) comprises a cylindrical outer surface (122a) provided with an annular central shoulder (122d) comprising, on its outer surface, the first annular groove (122g).

8. Installation (100) according to claim 7, in which the cylindrical outer surface (122a) of the other of the shaping members (122) is provided with two annular end shoulders (122b, 122c), on either side of the annular central shoulder (122d).

9. Installation (100) according to claim 8, in which the other of the shaping members (122) comprises a first annular groove (122e) delimited transversely between a first end shoulder (122b) and the central shoulder (122d) and a second annular groove (122f) delimited transversely between the central shoulder (122d) and the second end shoulder (122c). Tl 10. Installation (100) according to claim 9, in which each annular groove (122e, 122f) of the other of the shaping members (122) faces vertically a shoulder (123b, 123c) of one of the shaping members (123). 1 1. Installation (100) according to any one of the preceding claims, in which the mechanical deformation device (120) comprises at least two sets of two shaping members (122, 123), on either side of the pre-polymerized single strand (E2) to be deformed, said sets being arranged in series in the direction of advance (X) of the bundle.

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

13. Installation (100) according to any one of the preceding claims, in which the first light source (117a) comprises a plurality of light-emitting diodes configured to emit monochromatic ultraviolet radiation with a wavelength between 200nm and 405nm.

14. Installation (100) according to claims 12 and 13, in which the first light source (117a) with ultraviolet radiation further comprises infrared radiation.

15. Installation (100) according to claim 12, in which the first light source (117a) with ultraviolet radiation comprises a plurality of mercury vapor lamps configured to emit broad spectrum ultraviolet radiation UV, infrared radiation and visible light.

16. Installation (100) according to any one of the preceding claims, in which the second radiation device (118) comprises a second light source (118a) with combined ultraviolet and infrared radiation or infrared radiation alone to complete the polymerization of the deformed single strand (E3).

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