Production process for a shaped thermoplastic composite, shaped thermoplastic composite and production system for a shaped thermoplastic composite.

Abstract

The invention relates to a method (100) for producing a shaped thermoplastic composite (10), said method comprising a pultrusion process and comprising: - a feeding step (110), supplying fibers (12) in a direction A of a pultrusion path, - a wetting step (120) of the fibers (12), which includes passing the fibers through a thermoplastic composition (14), - a heating step (130), which includes the polymerization (131) of the thermoplastic composition (14) having impregnated the fibers to form a heated thermoplastic composite (16) having a first section (S1), - a shaping step (140), by a shaping device (17) having a second section (S2), and the second section (S2) being smaller than the first section (S1), to obtain a heated thermoplastic composite (18) having a second section (S2).and - a cooling step (150) to produce a shaped thermoplastic composite (10). Figure to be published with the abbreviation: FIGURE 1,

Description

Title of the invention: Method for producing a shaped thermoplastic composite, shaped thermoplastic composite and system for producing a shaped thermoplastic composite. Field of invention

[0001] The present invention relates to the field of thermoplastic composites, and more precisely to the field of reinforcing elements.

[0002] This invention relates to a novel method for producing a shaped thermoplastic composite, a shaped thermoplastic composite and a system for producing a shaped thermoplastic composite. Description of the state of the art

[0003] Reinforcing elements are commonly used to reinforce structures in several sectors such as automotive, transportation, aeronautics, aerospace, photovoltaics, construction and building, and / or wind energy applications.

[0004] Reinforcing elements in the form of composite reinforcing elements are known to date.

[0005] Typically, a composite reinforcing element comprises a matrix (usually a polymer matrix comprising a thermosetting polymer) and fibers (in the form of a fibrous substrate). Such composite reinforcing elements are often produced by a pultrusion process.

[0006] Conventional pultrusion processes involve drawing a bundle of fibers through a pultrusion die to wet the fibers, impregnating them by passing them through a resin bath or into an injection box, curing the resin, and cooling the impregnated bundle to form a composite profile at the outlet of said die.

[0007] The pultrusion process makes it possible to obtain profiles of constant section with good mechanical properties. The profile is completely formed when it leaves the pultrusion die. In the case of thermosetting resins, the profile can also no longer be modified once it has left the die.

[0008] This technique requires having a complete tool for each section of profile that one wishes to manufacture, from the impregnation zone to the exit of the die.

[0009] In addition, thermosetting polymers have other disadvantages such as long cycle times, high energy consumption, low recyclability of the materials used, the toxicity of certain components and the emission of gold compounds. volatile organic compounds. Another disadvantage of thermosetting materials is volume shrinkage after curing, which affects dimensional stability and surface appearance after molding and requires specific treatment.

[0010] It is also known to manufacture a reinforcing element with resin comprising a thermoplastic polymer. Advantageously, the reinforcing element comprising a thermoplastic polymer can be successively heated and cooled to change or modify the geometry of the thermoplastic polymer.

[0011] However, successive heatings reduce thermal stability and degrade certain characteristics of the reinforcing element such as folding resistance, flexural strength, and may result in retention and delamination.

[0012] Pultrusion processes with thermoplastic polymer can include melting the polymer, impregnating the fibers and calibrating by cooling, without a polymerization reaction. However, the fiber impregnation rate is low and inhomogeneous. In fact, due to the high viscosity of thermoplastic resins, sufficient and homogeneous impregnation of the fibers is difficult to achieve to date. This is because, on the one hand, the viscosity of the resin generates very high levels of pressure that cause fiber breakage (which can cause mechanical failures, in particular fiber delamination, and weaken the final composite material), and on the other hand, the low homogeneity (resin-rich areas and fiber-rich areas) leads to the creation of passages for the resin, which weakens the composite. These problems are accentuated by the use of resins with high melting temperatures.

[0013] To solve this problem, international patent application WO2017219143 proposes as a solution a method for pultrusion of a beam comprising a first die having a tapered channel portion and heated to achieve the desired viscosity, a vacuum cavity to remove air, and a second die having a tapered channel portion also heated to increase the impregnation of the fibers. However, heating, impregnation and shaping are carried out at the same time. According to this method, many volatile compounds are produced, and this therefore increases the porosity of the composite, volatile compounds remaining trapped in the composite. In addition, this method requires being fed with a preform comprising a polymer and fibers without polymerization, and consequently the same disadvantages as above are reproduced (mechanical failures, delamination of the fibers and weakening of the final composite material).

[0014] Finally, other techniques have been developed, and in particular reactive pultrusion. This technology uses reactive thermoplastic monomers with a very low viscosity, which makes it possible to impregnate a large quantity of fibers. In this case, the profile generally comes out with the final shape of the pultrusion die, integrating an impregnation zone followed by the polymerization zone having the shape of the desired profile, so that the composite leaves the die in its final form, generally in the solid state. The polymerization zone therefore also acts as a calibration zone.

[0015] Although these techniques attempt to calibrate composites (thermoset or thermoplastic), the composites generally exhibit shrinkage. The polymerization reaction also leads to significant shrinkage. The shrinkage results in a loss of pressure in the pultrusion die during the process. This loss of pressure induces relatively high porosity, which results in reduced mechanical properties, a greater amount of residual monomers, greater water absorption, loss of electrical conductivity and chemical resistance. This is because a greater amount of gas and air is present in the composite, which degrades its qualities. In addition, some polymers exhibit high water absorption under humid conditions, which can lead to dimensional changes, internal stresses, delamination, and significant changes in the matrix properties.

[0016] Therefore, there is a need for solutions for generating a shaped thermoplastic composite with reduced porosity. Summary of the invention

[0017] The following constitutes a simplified summary of selected aspects, embodiments, and examples of the present invention in order to provide a basic understanding of the invention. However, this summary does not constitute a complete overview of all aspects, embodiments, and examples of the invention. The sole purpose of the summary is to present selected aspects, embodiments, and examples of the invention in a concise form as an introduction to the more detailed description of the aspects, embodiments, and examples of the invention that follows the summary.

[0018] The invention aims to overcome the drawbacks of the prior art. In particular, the invention provides a method for producing a shaped thermoplastic composite, said method comprising a pultrusion process and comprising:

[0019] - a feeding step, by a fiber feeding device, said step feeder supplying fibers in one direction of a pultrusion path;

[0020] - a step of wetting the fibers, by an impregnation device, which comprises passing the fibers through a thermoplastic composition, said thermoplastic composition being a thermoplastic resin or a thermoplastic resin precursor and comprising at least 50% by weight of monomers;

[0021] - a heating step, by a heating device, which comprises the polymer rization of the thermoplastic composition having impregnated the fibers to form a heated thermoplastic composite having a first section;

[0022] - a step of shaping the heated thermoplastic composite, by pulling the thermoplastic composite heated through a shaping device, the shaping device having a second section, and the second section being smaller than the first section, to obtain a heated thermoplastic composite having a second section;

[0023] - a cooling step, by a cooling device, at a temperature cooling temperature below a glass transition temperature of the heated thermoplastic composite having the second section to produce a shaped thermoplastic composite.

[0024] The advantage of this process is that it results in a shaped thermoplastic composite with reduced porosity compared to those obtained with current conventional processes. Indeed, the developed process allows pressure to be applied to the thermoplastic composite during production, which reduces the porosity. Advantageously, this pressure is applied to the heated thermoplastic composite, which facilitates the application of pressure. Consequently, the shaped thermoplastic composite has reduced porosity, which improves its mechanical and chemical properties.

[0025] In addition, thanks to the process, both chemical shrinkage and thermal shrinkage are taken into account, which further reduces porosity.

[0026] In addition, the process improves surface qualities, such as a smoother and less rough surface, which facilitates other treatments such as coating.

[0027] Consequently, the method according to the invention improves the electrical conductivity, chemical and / or mechanical resistance of shaped thermoplastic composites, while making it possible to reduce water absorption, alkaline attacks, dimensional changes, and modifications in the matrix.

[0028] Advantageously, thanks to the process, the production of volatile compounds is reduced, and they are not trapped in the shaped thermoplastic composite.

[0029] According to other optional elements of the method according to the invention, it may optionally comprise one or more of the following characteristics, alone or in combination:

[0030] - the pultrusion process is a reactive pultrusion process, which improves the mechanical and / or chemical properties,

[0031] - the feeding step and the wetting step are carried out in such a way that the shaped thermoplastic composite comprises at least 60% by volume of fibers, which thus improves the mechanical and / or chemical properties of the shaped thermoplastic composite,

[0032] - the cooling step takes place at the same time as the shaping step, which saves time while taking into account thermal shrinkage, for example,

[0033] - the method comprises a discharge step before the shaping step, which helps reduce porosity and reduce the presence of air and volatile compounds in the heated thermoplastic composite, which further reduces porosity.

[0034] According to another aspect, the present invention also relates to a shaped thermoplastic composite obtainable, preferably obtained, by the method according to the invention. A shaped thermoplastic composite according to the invention has a reduced porosity which makes it possible to obtain better mechanical and / or chemical properties, better water absorption (here, better water absorption means that the water absorption is lower), and better electrical conductivity. Advantageously, the shaped thermoplastic composite according to the invention may have a porosity of less than or equal to 10%, relative to the total volume of the shaped thermoplastic composite.

[0035] Another aspect of the present invention relates to a use of a shaped thermoplastic composite according to the invention in applications in the automotive, transport, nautical, railway, sport, aeronautics, aerospace industry, photovoltaic, IT, construction and building, telecommunications and / or wind energy sectors. Indeed, having a shaped thermoplastic composite with reduced porosity is of particular interest in these sectors.

[0036] According to another aspect, the present invention relates to a shaping device adapted to reduce a first section of a heated thermoplastic composite to a second section to form a shaped thermoplastic composite having a second section, said second section being smaller than the first section and the shaped thermoplastic composite comprising at least 60% by volume of fibers. A shaping device according to the invention makes it possible to reduce the porosity of the thermoplastic composite and consequently to obtain better qualities. Advantageously, the shaping device is also adaptable and can be implemented in any pultrusion or reactive pultrusion system for thermoplastics. The shaping device according to the invention may comprise at least one inlet and at least one outlet, the outlet being smaller than the inlet, thus applying pressure.

[0037] According to another aspect, the present invention relates to a system for producing a shaped thermoplastic composite, comprising:

[0038] - a fiber supply device, configured to supply fibers in a direction of a pultrusion path,

[0039] - an impregnation device, configured to wet fibers through a com thermoplastic position, said thermoplastic composition being a thermoplastic resin or a thermoplastic resin precursor and comprising at least 50% by weight of monomers,

[0040] - a heating device, configured to cause the polymerization of the com thermoplastic position having impregnated the fibers to form a heated thermoplastic composite having a first section,

[0041] - a shaping device, configured to shape the thermo composite heated thermoplastic composite having a second section, the shaping device having a second section, and the second section being smaller than the first section, to provide a heated thermoplastic composite having a second section, the shaping device facing the previous device,

[0042] - a cooling device, configured at a cooling temperature in below a glass transition temperature of the heated thermoplastic composite having the second section to produce a shaped thermoplastic composite.

[0043] The system according to the invention makes it possible to produce a shaped thermoplastic composite having reduced porosity.

[0044] According to other optional elements of the system according to the invention, it may optionally comprise one or more of the following characteristics, alone or in combination:

[0045] - it comprises an empty space, a vacuum or an air space,

[0046] - the empty space, vacuum or air space is arranged between the heating device and the shaping device,

[0047] - the shaping device comprises at least one input and at least one output, the outlet facing the cooling device. Brief description of the drawings

[0048] The foregoing and other objects, features and advantages of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

[0049] [Fig-1] [Fig.l] represents a functional diagram of a method according to a mode of realization of the invention.

[0050] [Fig.2] [Fig.2] represents a schematic view of a system according to one embodiment of the invention.

[0051] [Fig.3] [Fig.3] represents field gradient microscopy images of a shaped thermoplastic composite.

[0052] Several aspects of the present invention are described by reference to block diagrams and / or schematic diagrams of methods and devices according to embodiments of the invention.

[0053] In the figures, the functional diagrams and / or the principle diagrams show the architecture, the functionality and the possible implementation of devices or systems or methods, according to several embodiments of the invention.

[0054] For this purpose, each box in the functional diagrams or the block diagrams can represent a system, a device, a module which comprises several executable instructions to implement the specified logical function(s).

[0055] In some implementations, the functions associated with the box may appear in a different order than shown in the drawings.

[0056] For example, two boxes presented in succession may be executed substantially simultaneously, or boxes may sometimes be executed in reverse order, depending on the functionality involved.

[0057] Each box of the block diagrams or schematic diagrams, and combinations of boxes in the block diagrams or schematic diagrams, may be implemented by special systems that perform the specified functions or actions or perform combinations of specific equipment and computer instructions. Detailed description

[0058] Exemplary embodiments of the invention will now be described.

[0059] By "polymer" is meant either a copolymer, a homopolymer, or a block copolymer. The term "copolymer" means a polymer grouping together several different monomer units and the term "homopolymer" means a polymer grouping together identical monomer units. By "block copolymer" is meant a polymer comprising one or more uninterrupted blocks of each of the distinct polymer species, the polymer blocks being chemically different from each other and being linked together by a covalent bond. These polymer blocks are also called polymer blocks.

[0060] The expression “polymer composite”, within the meaning of the invention, designates a multi-component material comprising at least two immiscible components among which at least one component is a polymer and the other component may for example be a fibrous reinforcement.

[0061] By "fibrous reinforcement" or "fibrous substrate" or "fibers" is meant, within the meaning of the invention, several fibers, unidirectional fibers or braids, or a continuous filament mat, fabrics, felts, or non-wovens which can take the form of strips, sheets, braids, rovings or pieces.

[0062] The term "matrix" may refer to a material that serves as a binder and can transfer forces to the fibrous reinforcement. The term "polymer matrix" includes polymers, but may also include other compounds or materials. Thus, the term "(meth)acrylic polymer matrix" refers to any type of acrylic and methacrylic compounds, polymers, oligomers, copolymers or block copolymers. However, it would not depart from the scope of the invention if the (meth)acrylic polymer matrix comprised up to 10% by weight, preferably less than 5% by weight of other non-acrylic monomers, selected for example from the following group: butadiene, isoprene, styrene, substituted styrene such as α-methylstyrene or tert-butylstyrene, cyclosiloxanes, vinylnaphthalenes and vinylpyridines.

[0063] The term "initiator" or "precursor", within the meaning of the invention, may refer to a compound which can start / initiate the polymerization of a monomer or monomers.

[0064] The term “polymerization”, within the meaning of the invention, may refer to the process of transforming a monomer or a mixture of monomers into a polymer.

[0065] The term “monomer”, within the meaning of the invention, may refer to a molecule which can undergo polymerization.

[0066] For the purposes of the invention, the term "thermoplastic polymer" may designate a polymer which is generally solid at room temperature, which may be crystalline, semi-crystalline or amorphous, and which softens upon an increase in temperature, in particular after having exceeded its glass transition temperature (Tg), and fluid at a higher temperature, and / or which may exhibit a clear melt upon passing its so-called melting temperature (Tf) (when it is semi-crystalline), and which becomes solid again when the temperature drops below its melting point and below its glass transition temperature.This also applies to thermoplastic polymers slightly crosslinked by the presence of multifunctional monomers or oligomers in the formulation of the (meth)acrylate “syrup”, in mass percentage preferably less than 10%, preferably less than 5% and more preferably less than 2%, which can be thermoformed when heated above the softening temperature.

[0067] The term "thermoplastic composition" may refer to a thermoplastic syrup or a thermoplastic resin or a thermoplastic resin precursor.

[0068] The term “thermosetting polymer” can refer to a plastic material that transforms irreversibly by polymerization.

[0069] The term “(meth)acrylic monomer” can refer to any type of acrylic and methacrylic monomer.

[0070] The term "(meth)acrylic polymer" may refer to a polymer essentially comprising (meth)acrylic monomers which represent at least 50% by weight or more of the (meth)acrylic polymer.

[0071] The term “PMMA”, within the meaning of the invention, may refer to homopolymers and methyl methacrylate (MMA) copolymers, the weight ratio between MMA and PMMA preferably being at least 70% by weight for the MMA copolymer.

[0072] The term "reinforcing element", as used herein, may refer to an element used within / with a structure in order to reinforce it, support it, solidify it, consolidate it, improve its mechanical properties (reinforcement, tension, stretching, etc.), its thermal, electrical and / or chemical properties.

[0073] The term "rebar" may refer to a reinforcing bar that is used as a tensioning device in reinforced concrete and reinforced masonry structures to strengthen and support the concrete under tension. A rebar significantly increases the tensile strength of the concrete or structure.

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

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

[0076] In the following description, "shape" may refer to a shape, preferably a geometric shape, such as a circular, tubular, conical, pyramidal, parallelepiped, rectangular, square, trapezoidal shape, with at least one section.

[0077] The term "section" may be defined by a dimension in thickness, diameter, width, slope, or by an area such as an area or perimeter, or even a volume. For example, a section may correspond to the shape cut along a transverse plane.

[0078] The term "about," as used herein, may provide for a degree of variability in a value or range, e.g., within 10%, within 5%, or within 1% of a stated value or stated limit of a range.

[0079] As mentioned, the current production of thermoplastic composites does not take into account the porosity or the various shrinkages occurring during polymerization or heating and cooling operations. This results in the production of thermoplastic composites with high porosity which consequently induces reduced quality in terms of mechanical and chemical resistance, electrical conductivity and sensitivity to water. There is a need for a new process for generating a shaped thermoplastic composite with reduced porosity and consequently better qualities.

[0080] According to a first aspect, the invention relates to a method for producing a shaped thermoplastic composite, said method comprising a pultrusion process. Preferably, the pultrusion process is a pultrusion process reactive.

[0081] In particular, as illustrated in Figures 1 and 2, a method 100 for producing a shaped thermoplastic composite 10 according to the invention will comprise the following steps: a feeding step 110; a wetting step 120; a heating step 130; a shaping step 140; a cooling step 150.

[0082] As shown in [Fig.l], the method according to the invention comprises a feeding step 110. The step is preferably implemented by a fiber feeding device 11, illustrated for example in [Fig.2].

[0083] The step 110 of feeding fibers 12 makes it possible to supply fibers 12 in a direction A of a pultrusion path. The fibers 12 may consist of several fibers, unidirectional rovings or a mat of continuous filaments, fabrics, felts or nonwovens which may take the form of strips, sheets, braids, rovings or pieces. The fibrous material of the composite may have various shapes and dimensions, namely one-dimensional, two-dimensional or three-dimensional.

[0084] The one-dimensional shape corresponds to long linear fibers. The fibers may be discontinuous or continuous. The fibers may be arranged randomly or parallel to each other, in the form of a continuous filament. A fiber is defined by its aspect ratio, which is the ratio of the length to the diameter of the fiber. Preferably, the fibers used in the present invention are long fibers or continuous fibers. The fibers may have an aspect ratio of at least 1000, preferably at least 1500, more preferably at least 2000, advantageously at least 3000, and more preferably at least 5000, even more preferably at least 6000, even more preferably at least 7500 and most preferably at least 10,000.

[0085] The two-dimensional shape corresponds to fibrous mats or reinforcements or bundles of fibers, non-woven or woven, which can also be braided. Even if the two-dimensional shape has a certain thickness and, therefore, in principle a third dimension, it is considered to be two-dimensional according to the present invention.

[0086] The three-dimensional shape corresponds for example to non-woven fibrous mats or reinforcements or stacked or folded fiber bundles or mixtures thereof, an assembly of the two-dimensional shape in the third dimension.

[0087] The origins of the fibrous material can be natural or synthetic. As natural material, we can mention plant fibers, wood fibers, animal fibers or mineral fibers.

[0088] Natural fibers are, for example, sisal, jute, hemp, linen, cotton, coconut fibers and banana fibers. Animal fibers are, for example, wool or hair.

[0089] As synthetic material, mention may be made of polymer fibers chosen from fibers of thermosetting polymers, thermoplastic polymers, polyamide (aliphatic or aromatic), polyester, polyvinyl alcohol, polyolefins, polyurethanes, polyvinyl chloride, polyethylene, unsaturated polyesters, epoxy resins and vinyl esters, and / or carbon fibers, or mixtures thereof.

[0090] The mineral fibers can also be chosen from glass fibers, in particular of type E, R or S2, boron fibers, basalt fibers or silica fibers.

[0091] The fibrous substrate of the present invention may be chosen from plant fibers, wood fibers, animal fibers, mineral fibers, synthetic polymer fibers, glass fibers and carbon fibers, and mixtures thereof.

[0092] Preferably, the fibrous substrate is chosen from mineral fibers. Better still, the fibrous substrate is chosen from glass fibers or carbon fibers.

[0093] The fibers of the fibrous substrate may have a diameter of between 0.005 pm and 100 pm, preferably between 1 pm and 50 pm, better still between 5 pm and 30 pm and advantageously between 10 pm and 25 pm.

[0094] Preferably, the fibers of the fibrous substrate of the present invention are chosen from continuous fibers (which means that the aspect ratio does not necessarily apply as for long fibers) for the one-dimensional shape, or from long or continuous fibers for the two- or three-dimensional shape of the fibrous substrate.

[0095] The method according to the invention may comprise a step 120 of wetting the fibers 12. The step is preferably implemented by an impregnation device 13. The wetting step makes it possible to impregnate the fibers 12 with the thermoplastic composition 14, in other words the penetration of the thermoplastic composition into the fibers.

[0096] The step of wetting the fibers may comprise passing the fibers through a thermoplastic composition 14. For example, the fibers are guided through a bath or injection chamber comprising the thermoplastic composition. The thermoplastic composition may be a thermoplastic resin or a thermoplastic resin precursor and comprise at least 50% by weight of monomers of the thermoplastic composite. The thermoplastic composition may comprise a polymer and a monomer.

[0097] Preferably, the monomer of the thermoplastic composite is chosen from alkylacrylic monomers, alkylmethacrylic monomers, hydroxyalkylacrylic monomers and hydroxyalkylmethacrylic monomers, and mixtures of these.

[0098] Preferably, the polymer of the thermoplastic composite is selected from all types of acrylic and methacrylic compounds, polymers, oligomers, copolymers or block copolymers. However, it would not depart from the scope of the invention if the (meth)acrylic polymer matrix comprised up to 10% by weight, preferably less than 5% by weight of other non-acrylic monomers, selected for example from the following group: butadiene, isoprene, styrene, substituted styrene such as α-methylstyrene or tert-butylstyrene, cyclosiloxanes, vinylnaph-thalenes and vinylpyridines.

[0099] The thermoplastic composition according to the invention may comprise between 10% by weight and 50% by weight of a (meth)acrylic polymer (PI) and between 50% by weight and 90% by weight of a (meth)acrylic monomer (MI). Preferably, the thermoplastic composition comprises between 10% by weight and 40% by weight of a (meth)acrylic polymer (PI) and between 60% by weight and 90% by weight of a (meth)acrylic monomer (MI), and better still between 10% by weight and 30% by weight of a (meth)acrylic polymer (PI) and between 70% by weight and 90% by weight of a (meth)acrylic monomer (MI).

[0100] The dynamic viscosity of the thermoplastic composition is in a range from 10 mPa*s to 10,000 mPa*s, preferably from 20 mPa*s to 7,000 mPa*s, and advantageously from 20 mPa*s to 5,000 mPa*s and more advantageously from 20 mPa*s to 2,000 mPa*s and even more advantageously between 20 mPa*s and 1,000 mPa*s. The viscosity of the thermoplastic composition can be easily measured with a rheometer or a viscometer. The dynamic viscosity is measured at 25°C. If the thermoplastic composition has Newtonian behavior, meaning that it does not exhibit shear thinning, the dynamic viscosity is independent of shear in a rheometer or of the speed of the spindle in a viscometer. If the thermoplastic composition has non-Newtonian behavior, meaning that it exhibits shear thinning, the dynamic viscosity is measured at a shear rate of 1 s<-l> at 25 °C.

[0101] As regards the thermoplastic composition of the invention, it comprises a (meth)acrylic monomer (MI) and a (meth)acrylic polymer (PI). Once polymerized, the (meth)acrylic monomer (MI) is transformed into a (meth)acrylic polymer (P2) comprising the monomer units of the (meth)acrylic monomer (MI) and other possible monomers.

[0102] Preferably, the dynamic viscosity of the (meth)acrylic MCI composition is also in a range from 10 mPa*s to 10,000 mPa*s, preferably from 20 mPa*s to 7,000 mPa*s, and advantageously from 20 mPa*s to 5,000 mPa*s and more advantageously from 20 mPa*s to 2,000 mPa*s and even more advantageously between 20 mPa*s and 1000 mPa*s.

[0103] As regards the (meth)acrylic polymer (PI), mention may be made of poly(alkyl methacrylates) or poly(alkyl acrylates). According to a preferred embodiment, the (meth)acrylic polymer (PI) is poly(methyl methacrylate) (PMMA).

[0104] According to one embodiment, the homo- or copolymer of methyl methacrylate (MMA) comprises at least 70%, preferably at least 80%, advantageously at least 90% and more advantageously at least 95% by weight of methyl methacrylate.

[0105] According to another embodiment, the PMMA is a mixture of at least one homopolymer and at least one copolymer of MMA, or a mixture of at least two homopolymers or two copolymers of MMA having a different average molecular weight, or a mixture of at least two copolymers of MMA having a different monomer composition.

[0106] The methyl methacrylate (MMA) copolymer comprises from 70% to 99.9% by weight of methyl methacrylate and from 0.1% to 30% by weight of at least one monomer containing at least one ethylenic unsaturation which can copolymerize with methyl methacrylate.

[0107] These monomers are well known, and mention may be made in particular of acrylic and methacrylic acids and alkyl (meth)acrylates in which the alkyl group contains from 1 to 12 carbon atoms. As examples, mention may be made of methyl acrylate and ethyl, butyl or 2-ethylhexyl (meth)acrylate. Preferably, the comonomer is an alkyl acrylate in which the alkyl group contains from 1 to 4 carbon atoms.

[0108] According to a first preferred embodiment, the methyl methacrylate (MMA) copolymer comprises from 80% to 99.9%, advantageously from 90% to 99.9% and more advantageously from 90% to 99.9% by weight of methyl methacrylate, and from 0.1% to 20%, advantageously from 0.1% to 10% and more advantageously from 0.1% to 10% by weight of at least one monomer containing at least one ethylenic unsaturation which can copolymerize with methyl methacrylate. Preferably, the comonomer is chosen from methyl acrylate and ethyl acrylate, and mixtures thereof.

[0109] The weight average molecular weight of the (meth)acrylic polymer (PI) must be high, which means greater than 50,000 g / mol and preferably greater than 100,000 g / mol.

[0110] Weight average molecular mass can be measured by size exclusion chromatography (SEC).

[0111] The (meth)acrylic polymer (PI) is completely soluble in the monomer (meth)acrylic (MI) or in the mixture of (meth)acrylic monomers. This increases the viscosity of the (meth)acrylic monomer (MI) or the mixture of (meth)acrylic monomers. The resulting solution is a liquid composition generally called "syrup" or "prepolymer". The dynamic viscosity value of liquid (meth)acrylic syrup is between 10 mPa.s and 10,000 mPa.s. The viscosity of the syrup can easily be measured with a rheometer or viscometer. The dynamic viscosity is measured at 25 °C.

[0112] Advantageously, the liquid (meth)acrylic composition or syrup does not contain any additional solvent deliberately added.

[0113] With regard to the (meth)acrylic monomer (MI), the monomer is selected from alkylacrylic monomers, alkylmethacrylic monomers, hydroxyalkylacrylic monomers and hydroxyalkylmethacrylic monomers, and mixtures thereof.

[0114] Preferably, the (meth)acrylic monomer (MI) is chosen from the monomers hydroxyalkylacrylics, hydroxyalkylmethacrylic monomers, alkylacrylic monomers, alkylmethacrylic monomers and mixtures thereof, the alkyl group containing from 1 to 22 linear, branched or cyclic carbon atoms, the alkyl group preferably containing from 1 to 12 linear, branched or cyclic carbon atoms.

[0115] Better still, the (meth)acrylic monomer (MI) is chosen from alkylacrylic monomers or alkylmethacrylic monomers and mixtures thereof, the alkyl group containing from 1 to 22 linear, branched or cyclic carbon atoms, the alkyl group preferably containing from 1 to 12 linear, branched or cyclic carbon atoms.

[0116] Advantageously, the (meth)acrylic monomer (MI) is chosen from methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, methacrylic acid, acrylic acid, n-butyl acrylate, isobutyl acrylate, n-butyl methacrylate, isobutyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, isobornyl acrylate, isobornyl methacrylate, hydroxyethyl acrylate and hydroxyethyl methacrylate, and mixtures thereof.

[0117] More advantageously, the (meth)acrylic monomer (MI) is chosen from methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, methacrylic acid, acrylic acid, n-butyl acrylate, isobutyl acrylate, n-butyl methacrylate, isobutyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, isobornyl acrylate, isobornyl methacrylate, and mixtures thereof.

[0118] According to a preferred embodiment, at least 50% by weight and preferably at least less than 60% by weight of the (meth)acrylic monomer (MI) is methyl methacrylate.

[0119] According to a first more preferred embodiment, at least 50% by weight, preferably at least 60% by weight, better still at least 70% by weight, advantageously at least 80% by weight and even more advantageously 90% by weight of the monomer (MI) is a mixture of methyl methacrylate with optionally at least one other monomer.

[0120] With regard to the (meth)acrylic monomer (M2), the monomer is multifunctional. Preferably, the (meth)acrylic monomer (M2) is chosen from compounds comprising at least two (meth)acrylic functions. The (meth)acrylic monomer (M2) may also be chosen from mixtures of at least two compounds (M2a) and (M2b) each respectively comprising at least two (meth)acrylic functions.

[0121] The (meth)acrylic monomer (M2) may be chosen from 1,3-butylene glycol dimethacrylate; 1,4-butanediol dimethacrylate; 1,6-hexanediol diacrylate; 1,6-hexanediol dimethacrylate; diethylene glycol dimethacrylate; dipropylene glycol diacrylate; ethoxylated bisphenol A diacrylate (10); ethoxylated bisphenol A dimethacrylate (2); ethoxylated bisphenol A diacrylate (3); ethoxylated bisphenol A dimethacrylate (3); ethoxylated bisphenol A diacrylate (4); ethoxylated bisphenol A dimethacrylate (4); ethoxylated bisphenol A dimethacrylate; ethoxylated bisphenol dimethacrylate (10); ethylene glycol dimethacrylate; polyethylene glycol diacrylate (200); polyethylene glycol diacrylate (400); polyethylene glycol dimethacrylate (400); polyethylene glycol dimethacrylate (400); polyethylene glycol diacrylate (600); polyethylene glycol dimethacrylate (600);polyethylene glycol diacrylate 400; propoxylated neopentyl glycol diacrylate (2); tetraethylene glycol diacrylate; tetraethylene glycol dimethacrylate; tricyclodecanedimethanol diacrylate; tricyclodecanedimethanol dimethacrylate; triethylene glycol diacrylate; triethylene glycol dimethacrylate; tripropylene glycol diacrylate; ethoxylated trimethylolpropane triacrylate (15); ethoxylated trimethylolpropane triacrylate (3); ethoxylated trimethylolpropane triacrylate (6); ethoxylated trimethylolpropane triacrylate (9); ethoxylated pentaerythritol triacrylate 5; ethoxylated trimethylolpropane triacrylate (20); propoxylated glyceryl triacrylate (3); trimethylolpropane triacrylate; propoxylated glyceryl triacrylate (5,5); pentaerythritol triacrylate; propoxylated glyceryl triacrylate (3); propoxylated trimethylolpropane triacrylate (3); trimethylolpropane triacrylate;trimethylolpropane trimethacrylate; tris(2-hydroxyethyl) isocyanurate triacrylate; ditrimethylolpropane tetraacrylate; dipentaerythritol pentaacrylate; te-; ethoxylated pentaerythritol tetraacrylate (4); pentaerythritol tetraacrylate; dipentaerythritol hexaacrylate; 1,10-decanediol diacrylate; 1,3-butylene glycol diacrylate; 1,4-butanediol diacrylate; 1,9-nonanediol diacrylate; 2-(2-vinyloxyethoxy)ethyl acrylate; 2-butyl-2-ethyl-1,3-propanediol diacrylate; 2-methyl-1,3-propanediol diacrylate; 2-methyl-1,3-propanediyl ethoxyacrylate; 3-methyl-1,5-pentanediol diacrylate; alkoxylated cyclohexanedimethanol diacrylate; alkoxylated hexanediol diacrylate; cyclohexanedimethanol diacrylate; ethoxylated cyclohexanedimethanol diacrylate; diethylene glycol diacrylate; dioxane glycol diacrylate; ethoxylated dipentaerythritol hexaacrylate; ethoxylated glycerol triacrylate; ethoxylated neopentyl glycol diacrylate; hydroxypivalyl hydroxypivalate diacrylate; neopentyl glycol diacrylate;poly(tetramethylene glycol) diacrylate; polypropylene glycol 400 diacrylate; polypropylene glycol 700 diacrylate; propoxylated ethoxylated bisphenol A diacrylate (6); propoxylated ethylene glycol diacrylate; propoxylated pentaerythritol tetraacrylate (5); and propoxylated trimethylolpropane triacrylate. ;

[0122] Preferably, the (meth)acrylic monomer (M2) is chosen from ethylene glycol dimethacrylate, neopentyl glycol diacrylate, neopentyl glycol dimethacrylate, 1,4-butanediol dimethacrylate, 1,4-butanediol diacrylate, 1,3-butylene glycol diacrylate, 1,3-butylene glycol dimethacrylate, triethylene glycol dimethacrylate and triethylene glycol diacrylate, or mixtures thereof.

[0123] The (meth)acrylic monomer (M2) may be present in the (meth)acrylic composition MCI between 0.01 and 10 phr by weight, preferably is present between 0.1 and 9.5 phr per 100 parts of a liquid (meth)acrylic syrup, better still between 0.1 and 9 phr, better still between 0.1 and 8.5 phr and advantageously between 0.1 and 8 phr.

[0124] In a first preferred embodiment, the (meth)acrylic monomer (M2) is present in the (meth)acrylic composition MCI between 0.01 and 9 phr and is chosen from compounds comprising two (meth)acrylic functions.

[0125] In a second preferred embodiment, the (meth)acrylic monomer (M2) is present in the (meth)acrylic composition MCI between 0.01 and 9 phr and is chosen from mixtures of compounds comprising two (meth)acrylic functions.

[0126] In a third preferred embodiment, the (meth)acrylic monomer (M2) is present in the (meth)acrylic composition MCI between 0.01 and 9 phr and is chosen from mixtures of compounds comprising at least two (meth)acrylic functions.

[0127] In a fourth preferred embodiment, the (meth)acrylic monomer (M2) is present in the (meth)acrylic composition MCI between 0.01 and 9 phr and is chosen among the mixtures of compounds comprising at least two (meth)acrylic functions. At least one compound of the mixture comprises only two (meth)acrylic functions and represents at least 50% by weight of the mixture of methacrylic monomer (M2), preferably at least 60% by weight. The other compound of the mixture comprises more than two (meth)acrylic functions.

[0128] According to another embodiment of the wetting step, the thermoplastic composition may be a thermoplastic resin precursor.

[0129] A precursor or an initiator (Ini) can start the polymerization of the (meth)acrylic monomers (MI) and (M2), and it is chosen from among the radical initiators.

[0130] Preferably, the initiator (Ini) is activated by heat.

[0131] The radical initiators (Ini) can be chosen from compounds comprising a peroxy group or compounds comprising an azo group and preferably among compounds comprising a peroxy group.

[0132] Preferably, the compound comprising a peroxy group comprises from 2 to 30 carbon atoms.

[0133] Preferably, the compound comprising a peroxy group is chosen from diacyl peroxides, peroxyesters, peroxydicarbonates, dialkyl peroxides, peroxyacetals, hydroperoxide or peroxyketal.

[0134] The initiator (Ini) is selected from diisobutyryl peroxide, cumyl peroxyneodecanoate, di(3-methoxybutyl) peroxydicarbonate, 1,1,1,3-tetramethylbutyl peroxyneodecanoate, cumyl peroxyneoheptanoate, di-n-propyl peroxydicarbonate, tert-amyl peroxyneodecanoate, di-sec-butyl peroxydicarbonate, diisopropyl peroxydicarbonate, di(4-tert-butylcyclohexyl) peroxydicarbonate, di(2-ethylhexyl) peroxydicarbonate, tert-amyl peroxyneodecanoate, tert-butyl peroxyneodecanoate, di-n-butyl peroxydicarbonate, peroxydicarbonate dicetyl peroxydicarbonate, di-myristyl peroxydicarbonate, 1,1,1,3-tetramethylbutyl peroxypivalate, tert-butyl peroxyneoheptanoate, tert-amyl peroxypivalate, tert-butyl peroxypivalate, di(3,5,5-trimethylhexanoyl) peroxide, dilauroyl peroxide, didecanoyl peroxide, 5-dimethyl-2,5-di(2-ethylhexanoylperoxy)hexane,1,1,1,3-tetramethylbutyl peroxy-2-ethylhexanoate, tert-amyl peroxy-2-ethylhexanoate, dibenzoyl peroxide, tert-butyl peroxy-2-ethylhexanoate, tert-butyl peroxydiethylacetate, tert-butyl peroxyisobutyrate, 1,1-di(tert-butylperoxy)-3,3,5-trimethylcyclohexane, 1,1-di(tert-amylperoxy)cyclohexane, 1,1-di(tert-butylperoxy)cyclohexane, tert-amyl peroxy-2-ethylhexylcarbonate, tert-amyl peroxyacetate, tert-butyl peroxy-3,5,5-trimethylhexanoate, 2,2-di(tert-butylperoxy)butane, peroxyi- , tert-butyl peroxypropylcarbonate, tert-butyl peroxy-2-ethylhexylcarbonate, tert-amyl peroxybenzoate, tert-butyl peroxyacetate, butyl 4-di(tert-butylperoxy)valerate, tert-butyl peroxybenzoate, di-tert-amyl peroxide, dicumyl peroxide, di(2-tert-butylperoxyisopropyl)benzene, 5-dimethyl-2,5-di(tert-butylperoxy)hexane, tert-butyl cumyl peroxide, 5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3, di-tert-butyl peroxide, 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxonane, 2,2'-azobisisobutyronitrile (AIBN), 2,2'-azodi(2-methylbutyronitrile), razobisisobutyramide, 2,2'-azobis(4-dimethylvaleronitrile), l,r-azodi(hexahydrobenzonitrile) or 4'-azobis(4-cyanopentanoic acid).

[0135] Preferably, the initiator (Ini) is chosen from cumyl peroxyneodecanoate, di(3-methoxybutyl) peroxydicarbonate, 1,1,1,3-tetramethylbutyl peroxyneodecanoate, cumyl peroxyneoheptanoate, di-n-propyl peroxydicarbonate, tert-amyl peroxyneodecanoate, di-sec-butyl peroxydicarbonate, diisopropyl peroxydicarbonate, di(4-tert-butylcyclohexyl) peroxydicarbonate, di(2-ethylhexyl) peroxydicarbonate, tert-amyl peroxyneodecanoate, tert-butyl peroxyneodecanoate, di-n-butyl peroxydicarbonate, dicetyl peroxydicarbonate, dimyristyl, 1,1,1,3-tetramethylbutyl peroxypivalate, tert-butyl peroxyneoheptanoate, tert-amyl peroxypivalate, tert-butyl peroxypivalate, di(3,5,5-trimethylhexanoyl) peroxide, dilauroyl peroxide, didecanoyl peroxide, 5-dimethyl-2,5-di(2-ethylhexanoylperoxy)hexane or 1,1,1,3-peroxy-2-ethylhexanoate,3-tetramethylbutyl. ,

[0136] The thermoplastic composition may comprise between 0.1 phr and 5 phr of an initiator (Ini) to start the polymerization of the (meth)acrylic monomer (MI) and the (meth)acrylic comonomer (M2).

[0137] The method 100 according to the invention may comprise a heating step 130. Preferably, the heating step is implemented by a heating device 15. The heating step makes it possible to trigger and initiate the polymerization 131 of the thermoplastic composition 14 which has impregnated the fibers 12 to form a heated thermoplastic composite 16 having a first section SL

[0138] Heating also increases the space between molecules, which increases the flexibility of the heated thermoplastic composite to facilitate the next shaping step. As explained, a thermoplastic composite has the specificity of generally being solid at room temperature and softening during a temperature increase, in particular after exceeding its glass transition temperature (Tg) or melting temperature (Tf), and becoming solid again when the temperature drops below its melting point and below its glass transition temperature. Thanks to the heating step, polymerization takes place, which increases the partial pressure and ensures greater fluidity and flexibility; thus, the heated thermoplastic composite will be more deformable.

[0139] The heating step comprises heating by convection, conduction, IR (infrared (including NIR and MIR (near and mid infrared)), microwave, UV (ultraviolet) and / or induction.

[0140] According to one embodiment of the heating step 130, the polymerization can take place at a temperature usually lower than 140°C, preferably lower than 130°C and better still lower than 125°C.

[0141] According to one embodiment of the heating step, the polymerization can take place at a temperature of at least 40°C, preferably at least 50°C and better still at least 60°C.

[0142] Preferably, the polymerization can take place at a temperature between 40°C and 140°C, preferably between 50°C and 130°C, more preferably between 60°C and 125°C.

[0143] Advantageously, the heating step can be implemented continuously or not.

[0144] The heating step and the polymerization make it possible to pass from a thermoplastic composition which has impregnated the fibers (thermoplastic resin or thermoplastic resin precursor) and which is liquid to a heated thermoplastic composite 16.

[0145] The heating step makes it possible to obtain a heated thermoplastic composite 16 with a first section SL

[0146] The first section may have a predetermined thickness or width, and / or diameter (internal or external), or volume or area or perimeter.

[0147] The thermoplastic composite, preferably the heated thermoplastic composite, may have different geometries. The geometry may be tubular, conical, oval, pyramidal, cubic or cuboidal. Preferably, the thermoplastic composite is not limited by its geometry. In addition, the thermoplastic composite, preferably the heated thermoplastic composite, may have a variable dimension, such as thickness, diameter, length, width, height, area, volume, perimeter.

[0148] Preferably, the heated thermoplastic composite is not limited by its dimension, for example by its length.

[0149] The first section of the thermoplastic composite and preferably of the heated thermoplastic composite may have different geometries depending on the geometry of the heated thermoplastic composite. For example, the section may be circular, triangular, square, rectangular, parallelepiped, trapezoidal. Preferably, the section is not limited by its geometry. The first section of the thermoplastic composite and preferably of the heated thermoplastic composite may have a variable dimension depending on the dimension of the heated thermoplastic composite. Preferably, the section is not limited by its dimension.

[0150] For example, if the heated thermoplastic composite is conical, the first section may be circular, elliptical, parabolic or hyperbolic. Preferably, the section is determined with respect to a transverse axis. According to another example, the heated thermoplastic composite may be pyramidal, and in this context the first section may be triangular, or the heated thermoplastic composite may be tubular, and the first section may be parallelepipedal, rectangular, square, trapezoidal. The geometry may influence the polymerization. Thus, depending on the geometry of the thermoplastic composite, a greater amount of monomer may be transformed into polymer and improve the impregnation.

[0151] During the heating step, the resin generally exhibits a high shrinkage, between 5% and 20% (18% on the pure resin), as it polymerizes from a liquid resin to a solid. This shrinkage results in a loss of pressure in the pultrusion process. This loss of pressure induces a relatively high porosity, which results in reduced mechanical properties, a greater amount of residual monomers, greater water absorption, a change in electrical conductivity and chemical resistance of the thermoplastic composite.

[0152] The method according to the invention may comprise a step 140 of heating the heated thermoplastic composite 16. Preferably, the step is implemented by drawing the heated thermoplastic composite 16 through a shaping device 17. The shaping device 17 has a second section S2, and the second section S2 is smaller than the first section SL. The shaping step 140 makes it possible to obtain a heated thermoplastic composite 18 having a second section S2.

[0153] Advantageously, during the shaping step 140, the heated thermoplastic composite 16 passes through the shaping device 17 in which, thanks to the smaller section of the shaping device 17, pressure is applied to the heated thermoplastic composite 16. Preferably, the heated thermoplastic composite 16 is further heated and therefore deformable. Heating the heated thermoplastic composite 16 makes it easier to shape the shaping step 140.

[0154] Preferably, the temperature of the heated thermoplastic composite at the inlet of the shaping device may be between 100°C and 160°C, and preferably above the Tv.

[0155] Advantageously, the duration of the shaping step may be predetermined depending on the thermoplastic composition, the fiber content and / or the first section of the heated thermoplastic composite. For example, the duration of the shaping step may be between 10 seconds and 3 minutes, depending on the pulling speed and the length of the shaping device.

[0156] As explained, the shaping step includes the application of pressure (resulting from the smaller cross-section of the shaping device) which surprisingly results in a reduction in porosity. Indeed, as illustrated in [Fig. 3], the porosity rate decreased from 5% to 1%, as measured by microscopic (optical) analysis and porosity measurement by a calcination test (ISO 1172). In addition, due to the reduced porosity, less "air" and volatile compounds are present in the thermoplastic composite, and consequently less empty space is present inside the thermoplastic composite, which results in less water absorption and consequently lower electrical conductivity and better chemical resistance.Indeed, with less porosity and less empty space, less water can penetrate inside the thermoplastic composite, and consequently with less water penetration, less water absorption (by weighing). In addition, thanks to the heating step taking place before the shaping step, fewer volatile compounds are trapped in the fibers, which also allows for a reduction in porosity. Furthermore, if the thermoplastic composite is less porous, its conductivity will be better. In addition, the surface appearance improves, for example, becomes shinier and smoother. A better surface appearance is important for an optional coating or varnishing or winding step. In addition, the shaping step helps compensate for the shrinkage effect.

[0157] According to one embodiment, the shaping step can reduce the heated thermoplastic composite by 1% to 15% by volume. Preferably, the shaping step can reduce the heated thermoplastic composite by 2% to 12% by volume and more preferably by 3% to 10% by volume.

[0158] According to another embodiment, the shaping step can reduce the heated thermoplastic composite by 1% to 15% in diameter. Preferably, the shaping step can reduce the heated thermoplastic composite by 2% to 12% in diameter and more preferably by 3% to 10% in diameter.

[0159] According to another embodiment, the shaping step can reduce the heated thermoplastic composite by 1% to 15% in surface area or area. Preferably, the shaping step can reduce the heated thermoplastic composite by 2% to 12% in surface area or area and more preferably by 3% to 10% in surface area or area.

[0160] According to another embodiment, the shaping step can reduce the perimeter of the heated thermoplastic composite by 1% to 15%. Preferably, the shaping step in shape can reduce the perimeter of the heated thermoplastic composite by 2% to 12% and even better by 3% to 10%.

[0161] For example, the shaping device may be configured such that a heated thermoplastic may have a first section such as a diameter of about 13 mm and a second section of about 12.6 mm.

[0162] According to another example, the shaping device may be configured such that the heated thermoplastic composite may have a first section such as a thickness of about 10 mm and a second section of about 9.7 mm in one dimension, while the thickness (width) in the perpendicular dimension remains the same for both sections or is also reduced.

[0163] The invention is not limited to precise values, but applies very advantageously to any type of section values.

[0164] The second section of the heated thermoplastic composite having a second section may have a geometry identical to that of the first section of the heated thermoplastic composite having a first section.

[0165] For example, the first section of the heated thermoplastic composite may be circular, and the second section of the same heated thermoplastic composite having the second section may also be circular after passing through the shaping device, but with a different dimension, such as a second section smaller than the first section, for example in diameter and / or area and / or perimeter.

[0166] Alternatively, the second section of the heated thermoplastic composite with a second section may have a different geometry than the first section of the heated thermoplastic composite with a first section after passing through the shaping device.

[0167] For example, the first section of the heated thermoplastic composite may be circular or tubular, and the second section of the same heated thermoplastic composite with the second section may be square after passing through the forming device, with a different dimension, such as a second section smaller than the first section, for example in area and / or perimeter.

[0168] According to another example, the first section of the heated thermoplastic composite may be parallelepipedal and the second section of the same thermoplastic composite heated with the second section may be rectangular, square or even trapezoidal after passing through the shaping device, with a different dimension, such as a second section smaller than the first section, for example in area and / or perimeter.

[0169] The second section is smaller than the first section in at least one dimension.

[0170] In order to further improve the porosity and properties of the thermo composite heated plastic, the method according to the invention may comprise an evacuation step 135. Preferably, the evacuation step comprises the evacuation of air, the evacuation of volatile compounds, the evacuation of monomers, the evacuation of reactants, other fluids, and / or gaseous compounds. Advantageously, the evacuation step may take place before the shaping step. An evacuation step may be implemented by an air gap (indicated by AIR in [Fig.2]), by a vacuum or by a vacuum space between the pultrusion die and the shaping device. Evacuation may be implemented by applying a vacuum between the pultrusion die and the shaping device. The evacuation step allows degassing before the shaping step.

[0171] The method according to the invention may comprise a cooling step 150. In a particular embodiment, the cooling step may be implemented by a cooling device 19. In addition, the cooling step may be implemented at a given cooling temperature and / or over a given cooling duration.

[0172] According to one embodiment, the cooling temperature and / or the cooling duration may be chosen as a function of the glass transition temperature (Tg) and / or the melting temperature of the heated thermoplastic composite. Preferably, the cooling step takes place at a cooling temperature lower than the glass transition temperature of the heated thermoplastic composite having the second section. For example, the Tg may be lower than 130°C, preferably lower than 120°C and more preferably lower than 110°C. The glass transitions (Tg) of the polymers may be measured with equipment capable of performing a thermomechanical analysis (DMA). A RDAII analyzer "Rheometrics Dynamic Analyzer" offered by Rheometrics Company was used. Thermomechanical analysis accurately measures the viscoelastic changes of a sample as a function of the temperature, stress or strain applied.The device continuously records the deformation of the sample, maintaining the fixed stress, during a controlled temperature variation program. The results are obtained by plotting the modulus of elasticity (G'), the loss modulus (G") and the loss angle as a function of temperature. Tv is the highest temperature value read on the loss angle curve, when the derivative of the loss angle is equal to zero.

[0173] According to another embodiment, the cooling temperature and / or the cooling duration can be chosen as a function of the dimensions of the heated thermoplastic composite, as a function of the heating temperature, as a function of the heating duration, as a function of the heating type, as a function of the section of the thermoplastic composite, as a function of the geometry of the thermoplastic composite, depending on the drawing speed, depending on the length of the cooling device and / or depending on the thermoplastic composition.

[0174] For example, the cooling temperature may be less than or equal to 150°C, preferably less than or equal to 130°C, more preferably less than or equal to 110°C and more preferably less than or equal to 100°C. The cooling temperature may be greater than or equal to 50°C, preferably greater than or equal to 60°C, more preferably greater than or equal to 70°C, more preferably greater than or equal to 80°C. The cooling temperature may be between 50°C and 150°C, preferably between 60°C and 130°C, more preferably between 70°C and 130°C, more preferably between 80°C and 110°C.

[0175] The cooling step 150 makes it possible to produce a shaped thermoplastic composite 10, preferably to produce a shaped thermoplastic composite having the second section. Better still, the cooling step makes it possible to stabilize the geometry, and in particular the section.

[0176] According to a preferred embodiment, the cooling step can take place at the same time as the shaping step. According to another embodiment, the cooling step can take place after the shaping step.

[0177] The method according to the invention may comprise other optional steps 160, such as coating, bending, heating, cooling, cutting, welding, bonding and / or laminating. The optional step may be implemented depending on the shaped thermoplastic composite to be produced. The optional step may also improve the qualities and / or properties of the shaped thermoplastic composite.

[0178] According to another embodiment, the invention relates to a shaped thermoplastic composite 10 obtainable, preferably obtained, by the method according to the invention.

[0179] As explained, a thermoplastic composite shaped according to the invention comprises a polymer matrix and fibers.

[0180] According to one embodiment, the shaped thermoplastic composite may comprise at least 50% by volume of fibers, preferably at least 60% by volume of fibers and better still at least 70% by volume of fibers.

[0181] A shaped thermoplastic composite is preferably obtained from a thermoplastic composite comprising 35% or less by volume of a polymer matrix comprising (meth)acrylic polymers, and at least 65% by volume of fibers. It may also be obtained from a thermoplastic composite comprising from 20% to 30% by volume of a polymer matrix comprising (meth)acrylic polymers, and from 70% to 80% by volume of fibers.

[0182] According to one embodiment, the shaped thermoplastic composite may comprise from 20 to 30% by volume of a polymer matrix and from 60 to 80% by volume of a polymer matrix. volume of fibers.

[0183] Preferably, the polymer matrix may comprise at least 20% by weight of (meth)acrylic polymers, and at least 60% by volume of fibers.

[0184] In addition, said (meth)acrylic polymers can be crosslinked.

[0185] A shaped thermoplastic composite may have different sections, for example circular, elliptical, parabolic or hyperbolic, triangular, oval, parallelepiped. Preferably, the section may be defined by an axis perpendicular to the longitudinal axis of the shaped thermoplastic composite. The shaped thermoplastic composite is not limited by the geometry of the section.

[0186] A shaped thermoplastic composite can have a variable dimension (thickness, diameter, length, width, height).

[0187] A shaped thermoplastic composite is preferably used to produce a reinforcing element for reinforcing a structure. A reinforcing element may, for example, be a panel, a rod, a bar, a rebar, or a sheet. In one embodiment, the shaped thermoplastic composite may comprise several sheets.

[0188] Advantageously, the thermoplastic composite shaped according to the invention meets all the requirements of the standard “Specifications for solid rounded glass fiber reinforced polymer bars for the reinforcement of concrete”.

[0189] Advantageously, a thermoplastic composite shaped according to the invention may have a porosity of less than or equal to 10%, preferably less than or equal to 8%, better still less than or equal to 5% and even better still less than or equal to 1%. The porosity can be measured by optical microscopy analysis and / or by a calcination test. Thanks to its low porosity, the thermoplastic composite shaped according to the invention has better mechanical properties and better thermal quality, better chemical properties and better chemical resistance, better electrical conductivity properties, and less water absorption.

[0190] For example, the shaped thermoplastic composite according to the invention may have a water absorption of between 5 and 15% by weight of said shaped thermoplastic composite, whereas the same thermoplastic composite without shaping according to the invention has a water absorption of between 20 and 40%. The water absorption can be measured by weighing (adapted to ASTM D570). The shaped thermoplastic composite according to the invention has a water absorption divided by 2 compared to the same thermoplastic composite without shaping according to the invention. The shaped thermoplastic composite according to the invention has an improvement of between 10% and 50%.

[0191] Advantageously, a thermoplastic composite shaped according to the invention may have a roughness lower than that of the same thermoplastic composite without shaping. shaped. For example, the shaped thermoplastic composite of the invention may be smoother or shinier at its outer surface. The appearance of the surface may be important in case a treatment is applied to the surface of the thermoplastic composite, for example a coating. Indeed, the treatment will be easier with the shaped thermoplastic composites of the invention, for example more penetrating and longer lasting. The appearance may be measured by any method used to date in the art, e.g. by visual measurement.

[0192] According to another aspect, the invention relates to a use of a thermoplastic composite shaped according to the invention in applications in the automotive, transport, nautical, railway, sport, aeronautics, aerospace industry, photovoltaics, IT, construction and building, telecommunications and / or wind energy industries.

[0193] According to another aspect, the invention relates to a shaping device 17. The shaping device is configured to reduce a first section of a thermoplastic composite, preferably a thermoplastic composite according to the invention and more preferably a heated thermoplastic composite according to the invention, to a second section to form a shaped thermoplastic composite, preferably according to the invention, with a second section, said second section being smaller than the first section. The second section is smaller than the first section in at least one dimension, for example diameter and / or perimeter and / or area. In this context, the shaped thermoplastic composite has at least one dimension smaller than that of the heated thermoplastic composite, the dimension being able to be volume, perimeter and / or diameter, for example.

[0194] Advantageously, a shaping device according to the invention comprises at least one inlet and at least one outlet. At least one inlet preferably faces the pultrusion die. At least one outlet preferably faces the cooling die. In addition, the outlet is smaller than the inlet, in at least one dimension; preferably, the section of the outlet is smaller than the section of the inlet.

[0195] According to one embodiment of the invention, the shaping device may comprise a heating device and / or a cooling device. Indeed, depending on the cross-section of the thermoplastic composite or depending on the final shape of the shaped thermoplastic composite, the shaping device may be configured to heat and / or cool the shaped thermoplastic composite for bending or for manipulating the shaped thermoplastic composite.

[0196] The shaping device may comprise a mold, a shaping channel and / or a temperature-adjustable mold.

[0197] A shaping device according to the invention is not limited to a shape by particular or to a particular geometry or dimension. A shaping device may have a shape or geometry or dimension adaptable according to the reduction in section of the thermoplastic composite.

[0198] For example, a shaping device may be conical, pyramidal, or truncated wedge-shaped.

[0199] Furthermore, a shaping device according to the invention is not limited in size. For example, a shaping device may have a variable length, thickness, diameter, width, slope. Preferably, this makes it possible to adapt the shaping device to the thermoplastic composite with the first section to obtain a thermoplastic composite with a second section.

[0200] Advantageously, the sections of the shaping device can also be adjustable and / or adaptable.

[0201] According to a preferred embodiment, the shaping device according to the invention may be configured to be adaptable to a dimension of the thermoplastic composite. Preferably, the shaping device according to the invention may be configured to be adaptable to the heated thermoplastic composite. More preferably, the shaping device according to the invention may be configured to be adaptable to the shrinkage of the resin in the heated thermoplastic composite. The shrinkage may be between 3% and 15%.

[0202] Advantageously, the inlet of the shaping device perfectly matches in dimension the last device of the pultrusion die. For example, if the last pultrusion device in the pultrusion die is a heating device, then the inlet of the shaping device has the same dimensional characteristics as the heating device.

[0203] Preferably, the shaping device is removable. The shaping device may be non-permanently attached to the pultrusion die and preferably to the mold preceding the inlet of the shaping device, such that the heated thermoplastic composite having a first section enters the inlet of the shaping device. Removable attachment corresponds to the ability to be easily detached, removed or disassembled without having to destroy the attachment means, either because there are no attachment means, or because the attachment means can be easily and quickly removed (e.g., notch, screw, tab, lug, clips). For example, by removable, it will be understood that the object is not attached by welding, nor by any other means not intended to allow the object to be detached. This also allows the sections to be varied and to be adaptable to any type of section of the thermoplastic composite.

[0204] For example, the shaping device may be mechanically fixed, by screwing to the mold preceding the entry of the shaping device into the die of pultrusion.

[0205] Alternatively, the shaping device may be irremovably attached to the pultrusion die, for example by welding the inlet of the shaping device to the preceding mold of the pultrusion die.

[0206] According to another variant, the shaping device may be placed at a certain distance from the pultrusion die in order to leave a gap between the pultrusion die and the shrinking die (i.e. the shaping device). The gap may be configured to create a void space allowing degassing before the shaping device and / or a vacuum and / or an air space.

[0207] The shaping device makes it possible to reduce the section of the thermoplastic composite, and even better of the heated thermoplastic composite.

[0208] The shaping device may correspond to a tightening zone.

[0209] The shaping device allows in a particularly advantageous manner, thanks to its section adapted to each type of thermoplastic composite, to apply pressure on the thermoplastic composite in order to reduce the porosity of the thermoplastic composite.

[0210] Advantageously, the shaping device can be controlled and / or moved digitally / automatically or manually controlled.

[0211] According to another aspect, the invention relates to a system 200 for producing a shaped thermoplastic composite. An example of the system is illustrated in [Fig.2],

[0212] A system 200 for producing a shaped thermoplastic composite 10 may comprise:

[0213] - a fiber supply device 11, configured to supply fibers 12 in a direction of a pultrusion path A,

[0214] - an impregnation device 13, configured to wet the fibers 12 through a thermoplastic composition 14, said thermoplastic composition 14 being a thermoplastic resin or a thermoplastic resin precursor and comprising at least 50% by weight of monomers,

[0215] - a heating device 15, configured to cause the polymerization of the thermoplastic composition 14 for forming a heated thermoplastic composite 16 having a first section SI,

[0216] - a shaping device 17, configured to shape the composite heated thermoplastic composite 16 according to a second section S2, the shaping device 17 having a second section, and the second section being smaller than the first section, to provide a heated thermoplastic composite 18 having a second section, the shaping device 17 being fitted to the previous device, the shaping device preferably facing the device previous,

[0217] - a cooling device 19, configured at a cooling temperature below a glass transition temperature of the thermoplastic composite heated with the second section 18 to produce a shaped thermoplastic composite 10.

[0218] Preferably, all devices in the system operate continuously.

[0219] A system 200 according to the invention may comprise a fiber supply device 11. A fiber supply device is configured to supply fibers 12 in a direction of a pultrusion path A.

[0220] A fiber feed device may comprise at least one spool, a reel, a wheel around which fibers are wound. These fibers may be unwound from said spool, said reel, said wheel by one or more redirection and guide means which guide and connect the unwound fibers to assemble the fibers into a bundle.

[0221] This bundle of fibers is pulled, by traction, towards an impregnation device 13.

[0222] The system 200 according to the invention may comprise a pulling device which pulls the fibers in the direction of advance, and preferably on the pultrusion path A. For example, a pulling device may comprise one or more jaws or gripping surfaces, preferably opposed, and actuated so as to drive in the direction A the fibers, the thermoplastic composite, the heated thermoplastic composite. The speed of the device may be configurable.

[0223] The system 200 may comprise an impregnation device 13 configured to wet the fibers 12 through a thermoplastic composition 14, said thermoplastic composition 14 being a thermoplastic resin or a thermoplastic resin precursor and comprising at least 50% by weight of monomers. Preferably, the thermoplastic composition is the thermoplastic composition described above.

[0224] For example, the pulling device may be configured to guide the fibers through one or more baths, one or more injection chambers, one or more soaking tanks, one or more impregnation chambers.

[0225] The impregnation device is configured to receive the fibers and to wet the fibers by capillary absorption or injection so as to ensure complete impregnation of the fibers with the thermoplastic composition, preferably in liquid form.

[0226] According to one embodiment, the impregnation device may comprise a comb, a scraper, a succession of rings of decreasing diameter, a tubular channel, so as to eliminate the excess thermoplastic composition.

[0227] The system according to the invention may comprise a heating device 15 configured to cause the polymerization of the thermoplastic composition 14 for forming a heated thermoplastic composite 16 with a first section SI.

[0228] The heating device may be chosen from conduction, convection, radiation and / or volumetric heating devices.

[0229] The heating device may comprise a mold, an enclosure, a microwave source, an IR (NIR / MIR) source, an air blower, an oven and / or an induction source. Preferably, the heating device comprises an infrared heater or a microwave heater. This ensures sufficiently uniform heating and ensures polymerization of the thermoplastic composition.

[0230] The polymerization makes it possible to obtain a thermoplastic composite having a first section, preferably a solid heated thermoplastic composite with a first section.

[0231] Advantageously, the heating device may comprise one or more IR or thermometer type heating sensors in order to regulate the different heating temperatures and / or a timer, to control the heating duration.

[0232] The system according to the invention may comprise a shaping device 17. Preferably, it is a shaping device as described above.

[0233] A shaping device 17 is configured to shape the heated thermoplastic composite 16 according to a second section S2. The shaping device 17 may have an inlet and an outlet, and preferably the inlet has a first section and the outlet has a second section, and more preferably the second section is smaller than the first section, to provide a heated thermoplastic composite 18 with a second section. The shaping device is configured to apply pressure to the heated thermoplastic composite with a first section to reduce the first section to a second section. Preferably, the pressure is applied across the section of the shaping device, and preferably the second section, which is smaller than the heated thermoplastic composite with a first section.

[0234] Advantageously, the shaping device 17 is adjusted to the preceding device or the preceding mold of the pultrusion die. Preferably, the pultrusion die comprises all the devices before the shaping device. The shaping device can be perfectly adapted, adjusted to the dimensional characteristics of the preceding mold or device. Preferably, the inlet of the shaping device is adapted to the dimensional characteristic of the preceding mold or device. Preferably, the outlet of the shaping device faces the cooling device.

[0235] According to one embodiment, the shaping device is located at a certain distance from the previous mold or device so as to allow degassing and / or applying a vacuum. In this context, the system may comprise an air gap, a vacuum, or an empty space. Preferably, the air gap, the vacuum, or the empty space is disposed between the heating device and the shaping device.

[0236] The system according to the invention may comprise a cooling device 19. The cooling device may be configured at a cooling temperature below the glass transition temperature of the thermoplastic composite heated with the second section 18 to produce a shaped thermoplastic composite 10.

[0237] The cooling device of the system of the invention may be configured to solidify the heated thermoplastic composite with the second section to form a shaped thermoplastic composite.

[0238] Preferably, the cooling device allows the heated thermoplastic composite to be sufficiently cooled so that said heated thermoplastic composite becomes solid and can be removed from the system without deformation.

[0239] Advantageously, said cooling device may be configured to cool the heated thermoplastic composite directly or indirectly, i.e. by direct or indirect contact.

[0240] The cooling device may allow cooling of the heated thermoplastic composite to a cooling temperature allowing the heated thermoplastic composite to transition to a solid state, and thermal shrinkage. The thermal shrinkage may be between 0 and 5%, preferably between 1% and 5%.

[0241] Preferably, the cooling temperature is lower than the glass transition temperature of the thermoplastic composite, and preferably lower than the glass transition temperature of the heated thermoplastic composite. For example, it is less than or equal to 120°C, preferably less than or equal to 110°C.

[0242] In addition, the cooling device is adapted to achieve rapid cooling of the heated thermoplastic composite. This may depend on the length and speed of pulling. Advantageously, only the shape of the shaped heated thermoplastic composite is cooled.

[0243] Advantageously, this may be instantaneous cooling or, alternatively, slow cooling.

[0244] For this purpose, the shaping device may be equipped with a cooling device for actively cooling the heated thermoplastic composite. This may include compressed air.

[0245] Alternatively, the cooling device may be adapted to induce passive cooling or automatic cooling. It may be a mold, a nozzle, a refrigerant circuit, a flow of a cooling fluid and / or a fan.

[0246] Preferably, the system comprises a specific arrangement of the different devices. For example, it is preferable that the feeding device appears before the impregnation device in direction A of the pultrusion path. It is also preferable that the impregnation device appears before the heating device, which appears before the shaping device, which appears before the cooling device.

[0247] Advantageously, a vacuum or an empty space or an air space is arranged between the heating device and the shaping device. This arrangement is particularly advantageous for reducing the porosity of the shaped thermoplastic composite, the volatile compounds, and for improving the mechanical and chemical properties.

[0248] The system according to the invention may comprise other devices such as a bending device, a twisting device, a cutting device, a vacuum device.

[0249] The invention may be subject to numerous variations and applications other than those described above. In particular, unless otherwise indicated, the different structural and functional features of each of the implementations described above should not be considered as combined and / or closely and / or inextricably linked to each other, but rather as mere juxtapositions. Furthermore, the structural and / or functional features of the various embodiments described above may be the subject in whole or in part of any different juxtaposition or any different combination. Examples

[0250] Table 1: Example for a thermoplastic composite rod obtained by the shaping process of the invention and without shaping and comprising 60% of fibers and at least 20% of thermoplastic composition with an acrylic resin. [Tables 1] Parameter Shaping Without shaping External diameter - Section 1 13 mm 13 mm External diameter - Section 2 12.6 mm 12.97 mm Shape rod rod Porosity 1% 5% Water absorption at 50°C after 168 h 0.15% 0.36% Resistance 1100 MPa 1000 MPa

[0251] As shown in Table 1, the thermoplastic composite shaped according to the invention has improved chemical and mechanical properties, and in particular low porosity.

Claims

Claims

1.

2.

3.

4. A method (100) of producing a shaped thermoplastic composite (10), said method comprising a pultrusion process and comprising: - a feeding step (110), by a fiber feeding device (11), said feeding step providing fibers (12) in a direction A of a pultrusion path, - a step of wetting (120) the fibers (12), by an impregnation device (13), which comprises passing the fibers through a thermoplastic composition (14), said thermoplastic composition (14) being a thermoplastic resin or a thermoplastic resin precursor and comprising at least 50% by weight of monomers, - a heating step (130), by a heating device (15), which comprises the polymerization (131) of the thermoplastic composition (14) having impregnated the fibers to form a heated thermoplastic composite (16) having a first section (SI), - a step of shaping (140) the heated thermoplastic composite (16), by drawing the heated thermoplastic composite (16) through a shaping device (17), the shaping device (17) having a second section (S2), and the second section (S2) being smaller than the first section (SI), to obtain a heated thermoplastic composite (18) having a second section (S2), and - a step of cooling (150), by a cooling device (19), to a cooling temperature lower than a glass transition temperature of the heated thermoplastic composite (18) having the second section (S2) to produce a shaped thermoplastic composite (10). A method (100) of producing a shaped thermoplastic composite (10) according to claim 1, characterized in that the pultrusion method is a reactive pultrusion method. A method (100) of producing a shaped thermoplastic composite (10) according to claim 1 or 2, characterized in that the feeding step (110) and the wetting step (120) are carried out such that the shaped thermoplastic composite comprises at least 60% by volume of fibers. A method (100) of producing a shaped thermoplastic composite (10) according to any preceding claim, ca- characterized in that the cooling step (150) takes place at the same time as the shaping step (140).

5. A method (100) of producing a shaped thermoplastic composite (10) according to any preceding claim, characterized in that the method (100) comprises a discharging step (135) before the shaping step (140).

6. Shaped thermoplastic composite (10) obtained by the method (100) according to one of claims 1 to 5.

7. Shaped thermoplastic composite (10) according to the preceding claim, characterized in that it has a porosity less than or equal to 10%, relative to the total volume of the shaped thermoplastic composite (10).

8. Use of a shaped thermoplastic composite (10) according to the preceding claim in applications in the automotive, transport, nautical, railway, sport, aeronautics, aerospace industry, photovoltaics, IT, construction and building, telecommunications and / or wind energy industries.

9. System (200) for producing a shaped thermoplastic composite (10), comprising - a fiber feeder (11), configured to feed fibers (12) in a direction of a pultrusion path A, - an impregnation device (13), configured to wet the fibers (12) through a thermoplastic composition (14), said thermoplastic composition (14) being a thermoplastic resin or a thermoplastic resin precursor and comprising at least 50% by weight of monomers, - a heating device (15), configured to cause polymerization of the thermoplastic composition (14) having impregnated the fibers to form a heated thermoplastic composite (16) having a first section (S1), - a shaping device (17), configured to shape the heated thermoplastic composite (16) according to a second section (S2), the shaping device (17) having a second section (S2),and the second section (S2) being smaller than the first section (S1), to provide a heated thermoplastic composite (18) having a second section (S2), the shaping device (17) facing the previous device, - a cooling device (19) configured at a cooling temperature below a glass transition temperature of the heated thermoplastic composite (18) having the second section (S2) to produce a shaped thermoplastic composite (10).

10. A system (200) for producing a shaped thermoplastic composite (10) according to claim 9, characterized in that it comprises a void space, a vacuum, or an air space.

11. A system (200) for producing a shaped thermoplastic composite (10) according to claim 10, characterized in that the void space, vacuum or air space is disposed between the heating device (15) and the shaping device (17).

12. System (200) for producing a shaped thermoplastic composite (10) according to one of claims 9 to 11, characterized in that the shaping device (17) comprises at least one inlet and at least one outlet, the outlet facing the cooling device (19).

13. System (200) for producing a shaped thermoplastic composite (10) according to claim 9, characterized in that the shaping device (17) configured to reduce the first section (S1) of the heated thermoplastic composite to a second section (S2) to form the shaped thermoplastic composite (10) having a second section (S2), said second section (S2) being smaller than the first section (S1) and the shaped thermoplastic composite (10) comprising at least 60% by volume of fibers.

14. A system (200) for producing a shaped thermoplastic composite (10) according to claim 13, characterized in that the shaping device comprises at least one inlet and at least one outlet, the outlet being smaller than the inlet.

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