Installation and continuous manufacturing process for a long, thin composite element

Abstract

Installation (100) for the continuous manufacture of a longline composite element (FE) comprising a bundle of multifilament fibers impregnated with a composition based on a polymerizable material, characterized in that the installation (100) comprises N stages (STAGE 1, STAGE 2) for manufacturing a composite element, with N greater than or equal to 2 and a translational drive device (D) configured to drive the bundle of multifilament fibers in translation to successively carry out the passage through the N stages, each stage (STAGE 1, STAGE 2) comprising, in the direction of advancement of the bundle of multifilament fibers: - at least one module (110, 120, 130) for preparing multifilament fibers impregnated with polymerizable material; - at least one calibration nozzle (116, 126);and - at least one radiation device (117, 118, 127) disposed downstream of the calibration nozzle (116, 126) and through which the multifilament fibers impregnated with polymerizable material pass and configured to carry out partial or total polymerization to form a composite monostrand (E2, EF). Figure for the abbreviation: Fig 2;

Description

Title of the invention: Installation and method for the continuous manufacturing of a long, thin composite element

[0001] The present invention relates to the field of continuous manufacturing of long-line composite materials made by impregnating multifilamentary fibers with a polymerizable composition.

[0002] More particularly, the present invention relates to an installation and a method for manufacturing composites in the form of monostrands comprising continuous, unidirectional multifilamentary fibers embedded in a polymerizable resin.

[0003] The present invention relates more particularly, but not exclusively, to the manufacture of glass resin composite monostrands, acronym "CVR", exhibiting high mechanical properties.

[0004] Such long, thin composite materials can be used as composite reinforcements, particularly for reinforcing semi-finished products or finished rubber articles such as tires for vehicles, for example pneumatic or non-pneumatic, or in applications for reinforcing concrete, snowmobile tracks, tubular structures, etc.

[0005] We know of document EP 1 174 250 - Al which describes a continuous manufacturing process for single-strand CVR comprising the following steps:

[0006] - to create a rectilinear arrangement of glass fibers and to train this arrangement in a direction of advancement;

[0007] - degas the fiber arrangement by the action of a vacuum in a vacuum chamber;

[0008] - upon exiting the vacuum chamber, after degassing, passing through a chamber resin-filled impregnation device so as to impregnate said fiber arrangement with a resin in liquid state to obtain an impregnated material containing the fibers and the resin;

[0009] - passing said impregnated material through a calibration die having a cross-section of predefined surface and shape, to impose on it a single-strand form; and

[0010] - downstream of the calibration line, in an irradiation chamber, stabilize, so to lidicate the monostrand by photopolymerization of the resin in a UV and / or IR radiation device

[0011] Experience shows, however, that the single-strand CVRs described can still be improved.

[0012] Generally, with reference to [Fig. 1], a device 1 for manufacturing a single strand of glass-resin composite comprises a spool 10 containing glass fibers 11 in the form of multifilaments and continuously unwound by drive along arrow F by a training means (not shown), so as to achieve a rectilinear arrangement 12 of these fibers 11.

[0013] The arrangement 12 then passes through a vacuum chamber 13 disposed between an inlet tube 13a and an outlet tube 13b and an impregnation chamber 14 downstream of the outlet tube 13b and filled with an impregnation composition 15 based on a curable resin. The device 1 further includes a calibration die 16 at the outlet of the impregnation chamber 14 so as to form a single strand 17 and a radiation device 18 comprising, for example, a protective tube 18a through which the composite single strand 17 flows and a plurality of in-line UV irradiators 18b to obtain a polymerized single strand 19. The radiation device 18 further includes a nitrogen injection system (not shown).

[0014] Reference can be made in this regard to document FR 3 009 226 - B1 which describes a process for manufacturing a single strand of glass-resin composite using this type of manufacturing device.

[0015] However, the core polymerization of the impregnated monostrand by UV lamps is not satisfactory.

[0016] French patent document FR 3 117 061 - B1 is also known, describing a process and apparatus for manufacturing multifilament fiber composites comprising means for arranging multifilament fibers in the form of several individual strands, a vacuum chamber and an impregnation chamber through which all the individual strands are passed, a plurality of partial polymerization dies through which the impregnated strands are passed, a calibration die capable of forming a single strand from the impregnated individual strands, and a UV and / or IR radiation device in which the final polymerization of the single strand is carried out. Each polymerization die comprises an annular lamp with LEDs directed axially with respect to the impregnated strand and a reflector for directing the radiation emitted by the LEDs radially towards the impregnated strand.

[0017] In this document, the fibers, distributed in several strands, are introduced into the impregnation chamber by passing them through different orifices in a separating plate and exit through orifices passing through an exit plate, such that the strands travel linear and parallel paths from one plate to the other, parallel to the longitudinal axis of the device. The number of orifices corresponds to the number of strands that make up the bundle.

[0018] Such a solution is particularly radially bulky since the cross-section of the impregnation chamber is directly proportional to the number of individual strands composing the multifilament bundle and therefore to the diameter of the final single strand. The radius of the individual strands increases with the square root of the number of individual strands. It is therefore not possible to increase the diameter of the final single strand without increase the radial footprint of the manufacturing device.

[0019] Moreover, such a solution presents a risk of fouling of the reflectors and LEDs in the polymerization lines, which greatly degrades the performance of the manufacturing device.

[0020] Thus, there is a need to remedy the aforementioned drawbacks.

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

[0022] The present invention relates to a continuous manufacturing installation for a long-slender composite element comprising a bundle of multifilamentary fibers impregnated with a composition based on a polymerizable material.

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

[0024] Each stage comprises, in the direction of advancement of the multifilament fiber bundle: - at least one module for preparing multifilament fibers impregnated with polymerizable material; - at least one calibration nozzle; and - at least one radiation device disposed downstream of the calibration nozzle and through which the multifilament fibers impregnated with polymerizable material circulate and configured to carry out partial or total polymerization to form a composite monostrand.

[0025] Thus, each manufacturing stage of a composite monostrand includes a degassing chamber, an impregnation chamber, in order to impregnate only the multifilament fibers necessary to carry out the partial or final polymerization step.

[0026] Such an installation makes it easy to add additional preparation modules, and more generally manufacturing stages of a composite monostrand in order to increase the diameter of the final composite strand.

[0027] Instead of taking all the fibers and impregnating them at the same time, only those required for the layer to be polymerized will be impregnated. This allows the size of the vacuum and impregnation chamber to be reduced, which is directly proportional to the number of fibers and therefore to the final diameter of the single strand.

[0028] Such an installation also makes it possible to replace and / or add polymerization devices in order to increase the cross-section of the composite monostrand final.

[0029] Such a staged polymerization makes it possible to obtain a composite monostrand with a diameter between 10mm and 30mm with a rate between 10m / min and 50m / min, for example 30m / min.

[0030] Moreover, such an installation allows access to the calibration nozzles and the radiation devices, which are not surrounded by impregnated fibers unlike the prior art known, which facilitates their replacement or maintenance if needed.

[0031] Impregnated multifilament fibers can be in the form of single strands or fiber bundles.

[0032] Vacuum chambers and impregnation chambers can, for example, be fitted with lids to facilitate cleaning and the placement of multifilament fibers.

[0033] By "long-length composite element" is meant a long-length composite element comprising a bundle of multifilament fibers embedded in a composition based on a polymerizable material, which is manufactured continuously from several multifilament fiber feed reels to form a bundle which is driven in translation to successively achieve the impregnation of its fibers with polymerizable material and the polymerization of the material as the bundle moves.

[0034] By “multifilament fiber”, we understand a fiber which comprises several elementary filaments arranged side by side to form a bundle whose elementary fibers are unidirectional by being substantially parallel to each other.

[0035] Multifilament fibers can be chosen from the group consisting of glass, carbon, silica, ceramic, flax, hemp, basalt, cellulose fibers, etc. These multifilament fibers are used to make long-strand composites made by impregnating the multifilament fibers with a polymerizable composition.

[0036] The polymerizable material may be of the thermosetting type, preferably thermo-crosslinkable, preferably of the vinylester type. By polymerizable material is meant a material comprising, by weight, more than 50%, preferably more than 75%, of organic matter and even more preferably more than 90% of organic matter.

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

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

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

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

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

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

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

[0044] The drive device is, for example, of the type comprising a motorized traction drum allowing the composite element to be wound around its axis or comprising two motorized drums facing each other, 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, by making it pass through the space located between the two drums.

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

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

[0047] Advantageously, the first manufacturing stage of the main composite monostrand comprises, in the direction of advancement of the multifilament fiber bundle: - a feeding device comprising, for example, several elementary filament feed reels to form a multifilament fiber bundle; - a vacuum chamber or degassing chamber arranged for example between an inlet nozzle and a separation nozzle; - an impregnation chamber downstream of the vacuum chamber and in particular of the separation nozzle and filled with an impregnation composition based on a polymerizable material; - a first calibration die at the outlet of the impregnation chamber to form a first monostrand impregnated with polymerizable material; and - a first radiation device configured to partially polymerize or completely the first monostrand impregnated with polymerizable material and to form a main composite monostrand.

[0048] By "partial polymerization or pre-polymerization", it is understood that the degree of polymerization of the impregnated multifilament fibers has reached between 0.5% and 5% of the complete polymerization.

[0049] By way of non-limiting example, the degree of radiation can be evaluated using a measuring instrument of the "DSC" type, an acronym for "Differential Scanning Calorimetry" in Anglo-Saxon terms.

[0050] The so-called “complete” or “final” polymerization of the composite is obtained when the degree of polymerization of the polymerizable material is close to 100%, preferably greater than or equal to 95% of the complete polymerization.

[0051] For example, the second manufacturing stage of the composite monostrand comprises, in the direction of advancement of the multifilament fiber bundle: - at least one module for preparing additional or secondary impregnated multifilament fibers, - a second calibration die configured to receive additional multifilament fibers from the additional impregnated multifilament fiber preparation module, for example in the form of a single strand or a bundle, and the main composite single strand so as to form a first intermediate single strand; and at least - a final radiation device located downstream of the calibration line, through which the first intermediate monostrand passes and configured to achieve a complete or final polymerization of said first intermediate monostrand and form a final composite monostrand.

[0052] Alternatively, an additional radiation device could be added downstream of the second calibration channel and upstream of the final radiation device. The additional radiation device is configured to perform a partial or intermediate polymerization of the first intermediate strand and to form a second pre-polymerized strand or second intermediate strand.

[0053] According to yet another embodiment, a second supplementary radiation device could be added, positioned between the first supplementary radiation device and the final radiation device. The second supplementary radiation device comprises an additional light source, for example, an ultraviolet light source.

[0054] According to another embodiment, the installation comprises a third stage for manufacturing the final composite monostrand and the second stage is configured to manufacture a second intermediate composite monostrand, the second stage comprising, in the direction of advancement of the multifilament fibers: - at least one module for preparing additional or secondary impregnated multifilament fibers, - a second calibration die configured to receive the additional multifilament fibers from the additional impregnated multifilament fiber preparation module and the main composite monostrand so as to form a first intermediate monostrand; and at least - a first intermediate radiation device located downstream of the second calibration channel and configured to carry out a partial or intermediate polymerization of the first intermediate single strand and to form a second intermediate single strand.

[0055] The second floor here forms an intermediate floor and the third floor here forms a final floor.

[0056] For example, the third stage comprises, in the direction of advancement of the multifilament fibers: - at least one module for preparing additional or secondary impregnated multifilament fibers, - a third calibration die configured to receive the additional multifilament fibers from the additional impregnated multifilament fiber preparation module and the second intermediate monofilament so as to form a third intermediate monofilament; and at least - a final radiation device located downstream of the third calibration channel, through which the third intermediate monostrand passes and configured to achieve a complete or final polymerization of said third intermediate monostrand and form a final composite monostrand.

[0057] Alternatively, the third stage could comprise, between the third calibration die and the final irradiation device, a first additional irradiation device located downstream of the third calibration die and configured to perform a partial or intermediate polymerization of the third intermediate monostrand and to form a pre-polymerized monostrand. In this case, the final irradiation device is configured to perform a complete or final polymerization of said pre-polymerized monostrand and to form a final composite monostrand.

[0058] According to yet another variant, a second supplementary radiation device could be added in the third stage, positioned between the first supplementary radiation device and the final radiation device. The second supplementary radiation device comprises an additional light source, for example, an ultraviolet light source.

[0059] For example, the first radiation device comprises a first source luminous with ultraviolet radiation.

[0060] According to one embodiment, in which the last stage comprises a final radiation device and at least one first additional radiation device disposed upstream of said final radiation device, the final radiation device comprises at least one final infrared light source advantageously to complete the polymerization of the pre-polymerized impregnated multifilament fiber bundle.

[0061] Preferably, the final light source is configured to emit only infrared radiation, with a wavelength between Ipm and 3pm.

[0062] According to one embodiment, in which the last stage comprises only a final radiation device, the final radiation device comprises a final light source configured to emit both infrared and ultraviolet radiation.

[0063] For example, the first ultraviolet light source and / or the additional light source and / or the final light source may comprise a plurality of light-emitting diodes, acronym LEDs, preferably directed radially towards the impregnated multifilament fibers, preferably via reflectors

[0064] Alternatively, the first light source and / or the additional light source and / or the final light source could comprise a plurality of mercury vapor lamps configured to emit at least one broad-spectrum ultraviolet UV radiation, and one infrared radiation.

[0065] The use of protective tubes makes it possible to protect the radiation sources from vapors and possible splashes.

[0066] Furthermore, the use of LEDs can reduce the release of styrene vapors, reduce fouling of the protective tube, and reduce variations in light intensity over time, which allows for a more constant polymerization of the multifilament fiber bundle.

[0067] Furthermore, LEDs have a longer lifespan and lower or similar energy consumption than mercury vapor lamps and can reduce the release of styrene vapors into the atmosphere.

[0068] The final radiation device is distinct from the first radiation device and the additional radiation device.

[0069] The exposure time of the impregnated multifilament fiber bundle to the first UV light source is between 0.2 s and 2 s.

[0070] The power of the first UV light source is between 1000 Watts and 3000 Watts.

[0071] According to another variant, the final light source may comprise the combination of a plurality of mercury vapor lamps configured to emit at least one broad-spectrum ultraviolet UV radiation, and one infrared radiation and of an infrared radiation device configured to emit only infrared radiation with a wavelength of infrared radiation between Ipm and 3pm.

[0072] According to another variant, the final light source may comprise a combination of a plurality of light-emitting diodes, acronym LEDs, and a plurality of mercury vapor lamps configured to emit at least broad-spectrum ultraviolet radiation, and infrared radiation.

[0073] According to yet another variant, the final light source may comprise a combination of mercury vapor UV lamps, LEDs and infrared radiation.

[0074] According to one embodiment, in which the last stage includes a final radiation device and at least one first additional radiation device disposed upstream of said final radiation device, the exposure time of the intermediate single strand to the additional UV light source is between 0.5s and 9s.

[0075] In this case, the power of the additional UV light source is between 1.1 kW and 98 kW.

[0076] In this case, the exposure time of the pre-polymerized monostrand to the final IR light source is between 2.6s and 23s and the power of the final IR light source is between 2.2kW and 98kW.

[0077] In the case where the last stage comprises only a final radiation device, the exposure time of the pre-polymerized monostrand to the final light source is between 4s and 12s and the power of the final light source is between 8.7kW and 130kW.

[0078] Such an installation is particularly advantageous for manufacturing a composite monofilament from a bundle of large-diameter multifilament fibers, ranging from 10 mm to 30 mm. Indeed, because the large-diameter multifilament fiber bundle retains heat for a longer period, it is not necessary to complete the polymerization immediately after partial polymerization by the UV light source. Multifilament fiber bundles can then be added to the main multifilament fiber bundle before proceeding with the final polymerization by UV and IR rays.

[0079] Furthermore, at the end of the process, at the exit of the final radiation device, thanks to the large diameter of the final composite monostrand, the polymerization could end thanks to the exothermic effect of the monostrand.

[0080] Advantageously, the module for preparing additional or secondary impregnated multifilament fibers includes a feeding device for forming multifilament fibers, in the form of a bundle or monofilament, a vacuum chamber or degassing chamber and an impregnation chamber downstream of the vacuum chamber and filled with an impregnation composition based on a polymerizable material.

[0081] For example, the second manufacturing stage of the final composite monofilament comprises two additional modules arranged in parallel. Alternatively, the second manufacturing stage could comprise only one module or more than two additional modules.

[0082] Advantageously, each manufacturing stage of the composite monostrand includes a heating device associated with the corresponding impregnation chamber and configured to heat the polymerizable material present in said impregnation chamber to a temperature between 50°C and 95°C, preferably 60°C to 80°C.

[0083] According to a second aspect, the invention relates to a continuous manufacturing process for a long, slender composite element comprising a bundle of multifilament fibers impregnated with a composition based on a polymerizable material, comprising the following successive steps: - manufacturing of a main single strand in a first manufacturing stage; and at least - manufacturing of a second single strand in a second manufacturing stage.

[0084] Advantageously, each manufacturing stage of a composite monofilament includes a step of preparing impregnated multifilament fibers comprising the following successive steps: - feeding of elementary filaments to form multifilament fibers, - degassing of the multifilament fibers in a vacuum chamber, - impregnation of multifilament fibers with a composition based on a polymerizable material contained in an impregnation chamber filled with said composition, and - calibration of impregnated multifilament fibers, via a calibration die in order to form a monostrand impregnated with polymerizable material.

[0085] For example, during the manufacturing step of a main strand, the impregnated strand is partially polymerized in a first radiation device to form a main strand of polymerizable material.

[0086] For example, during the manufacturing step of a second monofilament: - the main monostrand is associated with additional multifilament fibers from at least one additional impregnated multifilament fiber preparation module to form a first intermediate monostrand; - said first intermediate monostrand is polymerized in an additional radiation device configured to perform partial polymerization or intermediate of the first intermediate monostrand and to form a pre-polymerized monostrand or second intermediate monostrand; and - said second intermediate monostrand is polymerized in a final radiation device located downstream of the additional polymerization radiation device configured to achieve a complete or final polymerization of said second intermediate monostrand and form a final composite monostrand.

[0087] Other objects, features and advantages of the invention will become apparent from the following description, given solely by way of non-limiting example, and made with reference to the accompanying drawings in which:

[0088] [Fig.1] represents, very schematically, a manufacturing installation for a composite element according to the state of the art;

[0089] [Fig.2] represents very schematically an installation for manufacturing a composite element according to a first embodiment of the invention;

[0090] [Fig.3] represents, very schematically, an installation for manufacturing a composite element according to a second embodiment of the invention; and

[0091] [Fig.4] is a flowchart illustrating some steps in the manufacturing process of a composite element by an installation according to [Fig.2].

[0092] Fig. 2 schematically illustrates an installation 100 for manufacturing a long, elongated EF composite element.

[0093] By "long-line composite element" is meant a long-length 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 multifilament fiber feed reels Fi_0 to form a bundle which is driven in translation along the arrow F to successively achieve the impregnation of its fibers with polymerizable material and the polymerization of the material as the bundle moves.

[0094] By “multifilament fiber” is understood a fiber which comprises several elementary filaments arranged side by side to form a bundle whose elementary fibers are unidirectional by being substantially parallel to each other.

[0095] Multifilament fibers can be chosen from the group consisting of glass, carbon, silica, ceramic, flax, hemp, basalt, cellulose fibers, etc. These multifilament fibers are used to make long-strand composites made by impregnating the multifilament fibers with a polymerizable composition.

[0096] The polymerizable material may be of the thermosetting type, preferably thermo-crosslinkable, preferably of the vinylester type. By polymerizable material is meant a material comprising, by weight, more than 50%, preferably more than 75%, of organic matter, preferably more than 95% of organic matter.

[0097] Thus, this material can be a thermopolymerizable polymeric material, for example based on unsaturated polyester, polyepoxide, phenolic derivative, or aminoplast. Preferably, the polymerizable material is cross-linked.

[0098] For example, the polymerizable material is a resin crosslinkable by ionizing radiation, the final polymerization being able to be easily triggered and controlled by means of an ionizing treatment, for example of the UV type.

[0099] 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.

[0100] In the example illustrated in the figures, the composite element EF is a monostrand comprising multifilamentary fibers embedded in a polymerizable material, such as a thermosetting resin.

[0101] The composite EF monostrand can take any known shape, it can be, for example, a cylindrical monostrand of large diameter, for example between 10mm and 30mm or a cylindrical monostrand of small diameter, for example between 0.5mm and 2.5mm.

[0102] The elementary filaments each have, for example, an average diameter between 5pm and 30qm.

[0103] The installation of the invention allows, of course, the manufacture of single strands with circular, rectangular, oval, elliptical, tubular, etc. cross-sections.

[0104] As illustrated in [Fig.2], the manufacturing installation 100 comprises, in the direction of advancement of the multifilament fiber bundle along arrow F, a first stage STAGE 1 for manufacturing a main composite monostrand E2, a second stage STAGE 2 for manufacturing a final composite monostrand EF and a translational drive device D along arrow F configured to drive the multifilament fiber bundle in translation to successively carry out the passage through the first and second stages STAGE 1, STAGE 2. The second stage STAGE 2 is here a final stage.

[0105] The drive device D is, for example, of the type comprising a motorized traction drum allowing the composite element to be wound around its axis or comprising two motorized drums facing each other, 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, by making it pass through the space located between the two drums.

[0106] As illustrated, the first stage STAGE 1 for manufacturing the main composite monostrand E2 comprises, in the direction of advancement of the multifilament fiber bundle according to arrow F:

[0107] - a power supply device 111 comprising here a plurality of coils 112 feeding elementary filaments Fi_0 to form a multifilament fiber bundle E0,

[0108] - a vacuum chamber 113 or degassing chamber disposed between an inlet nozzle 113a and a separation nozzle 113b;

[0109] - an impregnation chamber 114 downstream of a vacuum chamber 113 and in particular of the separation nozzle 113b and filled with an impregnation composition 115 based on a polymerizable material;

[0110] - a calibration die 116 at the outlet of the impregnation chamber 114 in such a way to form a first monostrand El impregnated with polymerizable material; and

[0111] - a first radiation device 117 through which the first monostrand El impregnated with polymerizable material and configured to achieve partial or complete polymerization of the first impregnated monostrand El and to form a main composite monostrand E2.

[0112] Each reel 112 provides power to one multifilament fiber. If stage 1 has nine multifilament fibers, the power supply device 111 has nine reels.

[0113] As illustrated, the second stage STAGE 2 for manufacturing the final composite monostrand EF comprises, in the direction of advancement of the multifilament fiber bundle according to arrow F:

[0114] - two modules 120, 130 for preparing impregnated multifilament fibers Additional or secondary ESI, ES2, in the form of a bundle or single strand. The two additional modules 120, 130 are arranged in parallel;

[0115] - a second calibration die 126 configured to receive multifilament fibers additional comments ESI, ES2 and the main composite monostrand E2 so as to form a first intermediate monostrand E3;

[0116] - an additional radiation device 127 located downstream of the second calibration die 126, through which the first intermediate monostrand E3 passes and is configured to perform partial or intermediate polymerization to form a first pre-polymerized monostrand E4 or second intermediate monostrand; and

[0117] - a final radiation device 118 located downstream of the radiation device additional 127, through which the first pre-polymerized monostrand E4 circulates and is configured to carry out a complete or final polymerization of said monostrand E4 and form a final composite monostrand EF.

[0118] Alternatively, it could be envisaged that a single module or more than two pre- modules preparation of additional or secondary impregnated multifilament fibers.

[0119] In general, the additional radiation device 127 is located downstream of the first radiation device 117 and upstream of the final radiation device 118.

[0120] Alternatively, the second stage STAGE 2 could be provided for without the additional radiation device 127. In this case, the final radiation device 118 is located directly downstream of the second calibration die 126 and through which the first intermediate monostrand E3 passes. The final radiation device 118 is thus configured to carry out a complete or final polymerization of said first intermediate monostrand E3 and form a final composite monostrand EF.

[0121] The additional modules 120, 130 for preparing additional impregnated multifilament fibers ESI, ES2 are functionally identical to the main module 110 for preparing the impregnated multifilament fiber bundle EL

[0122] Generally, each additional module 120, 130 includes a feeding device 121, 131 comprising several reels 122, 132 for feeding elementary filaments Fi_1, Fi_2 to form respectively the multifilament fibers ESI, ES2.

[0123] Each additional module 120, 130 further comprises a vacuum chamber 123, 133 disposed between an inlet nozzle 123a, 133a and a separation nozzle 123b, 133b and an impregnation chamber 124, 134 downstream of the vacuum chamber 123, 133 and in particular of the separation nozzle 123b, 133b, filled with an impregnation composition 125, 135 based on a polymerizable material from an external reservoir (not shown) via an inlet pipe 124a, 134a, and comprising a heating device 124b, 134b. The impregnation chamber 123, 133 is delimited by the separation nozzle 123b, 133b from the vacuum chamber 123, 133 and by a final outlet die 124c, 134c.

[0124] The additional multifilament fibers ESI, ES2 are directed towards the main single strand E2 through the second calibration die 126 so as to form the first intermediate single strand E3 impregnated with polymerizable material and of which the main single strand E2 has already undergone partial or complete polymerization in the first radiation device 117.

[0125] The vacuum chamber 113 and the impregnation chamber 114 of the first floor FLOOR 1, the first calibration dynasty 116, the first radiation device 117, the second calibration dynasty 126, the additional radiation device 127 and the final radiation device 118 are, here, arranged along the same axis corresponding to the longitudinal axis X-X' of the installation 100.

[0126] Each vacuum chamber 113, 123, 133 is, in a manner known per se, delimited by an inlet nozzle 113a, 123a, 133a, rigid, having a through orifice and a separation nozzle 113b, 123b, 133b, rigid, also having a through orifice located axially opposite the orifice of the inlet plate.

[0127] Alternatively, the inlet nozzle could be provided with a plurality of through-holes and the separation nozzle could be provided with a plurality of through-holes. Each through-hole receiving one or more fibers.

[0128] The multifilament fiber bundle is introduced into the corresponding vacuum chamber 113, 123, 133 by passing it through the orifice(s) of the inlet nozzle 113a, 123a, 133a and exiting through the through orifice(s) of the separation nozzle 113b, 123b, 133b.

[0129] Each vacuum chamber 113, 123, 133 is connected to a vacuum pump (not shown) which maintains a pressure level of approximately 0.2 bar, ideally 0.1 bar in the corresponding vacuum chamber 113, 123, 133, despite the passage of the multifilament fiber bundle through the orifices having a diameter greater than those of the multifilament fiber bundle which passes through them.

[0130] The vacuum chambers 113, 123, 133 allow the multifilament fiber bundle passing through them to be degassed by the action of the vacuum and thus to enhance the effectiveness of the subsequent impregnation and above all to guarantee the absence of bubbles inside the final composite monostrand.

[0131] After passing through the vacuum chamber 113, 123, 133, the multifilament fiber bundle enters the impregnation chamber 114, 124, 134 which is totally full of polymerizable impregnation material, therefore devoid of air.

[0132] Each impregnation chamber 114, 124, 134 is an airtight enclosure, delimited by the separation nozzle 113b, 123b, 133b and the final outlet die 116, 124c, 134c, rigid, also provided with one or more through orifices located axially opposite the orifice(s) of the separation nozzle.

[0133] Each impregnation chamber 114, 124, 134 is supplied with polymerizable material 115, 125, 135 from an external reservoir (not shown) via an inlet pipe 114a, 124a, 134a, here located in the upper part of said impregnation chamber 114, 124, 134. Alternatively, the inlet pipe could be provided in the lower part.

[0134] Each impregnation chamber 114, 124, 134 may also include, for example on its lower part, a drain pipe (not shown) for the polymerizable material.

[0135] Each impregnation chamber 114, 124, 134 is totally filled with polymerizable material so that the bundle of multifilament fibers exiting the vacuum chamber 113, 123, 133 and which passes through it in a linear path is completely impregnated with polymerizable material.

[0136] Each impregnation chamber 114, 124, 134 is associated with a heating device 114b, 124b, 134b configured to heat the polymerizable material to a temperature between 50°C and 95°C, preferably between 60°C and 80°C.

[0137] Thus, the impregnated multifilament fibers exit the corresponding impregnation chamber 114, 124, 134 at a temperature between 50°C and 95°C, preferably between 60 and 80°C, before passing through the radiation devices 117, 127, 118.

[0138] As illustrated in [Fig. 2], the feeding device 111, the vacuum chamber 113, and the impregnation chamber 114 together form a first module 110 for the preparation of impregnated multifilament fibers; the feeding device 121, the vacuum chamber 123, and the impregnation chamber 124 together form a second module 120 for the preparation of impregnated multifilament fibers; and the feeding device 131, the vacuum chamber 133, and the impregnation chamber 134 together form a third module 130 for the preparation of impregnated multifilament fibers. Modules 120 and 130 are additional or secondary modules for the preparation of impregnated multifilament fibers I1, E1, and E1.

[0139] The first and second calibration dies 116, 126 are, here, in the form of a calibration nozzle configured to shape the multifilament fibers exiting the impregnation chamber 114, 124, 134 to form a single strand of impregnated multifilament fibers El, E3.

[0140] Alternatively, any other device could be provided allowing the shaping of impregnated multifilament fibers before polymerization in the corresponding radiation devices 117, 127.

[0141] The first radiation device 117 includes a first ultraviolet radiation light source 117a, acronym UV.

[0142] The first ultraviolet light source 117a comprises, for example, a plurality of light-emitting diodes (not shown), acronym LED, preferably directed radially towards the first impregnated single strand El, with or without reflectors to optimize irradiation.

[0143] The first 117a LED ultraviolet light source is configured to emit only monochromatic ultraviolet radiation, the available wavelengths of which are: 365nm, 385nm, 395nm, 405nm, and more generally between 200nm and 405nm.

[0144] Without limitation, the first radiation device 117 may include a protective tube (not referenced) for the impregnated multifilament fibers El that enter the first radiation device 117. The protective tube is, for example, made of quartz or glass and allows ultraviolet rays to pass through, through which the single strand being formed passes; this tube may be traversed by a current of inert gas, preferably nitrogen.

[0145] The first ultraviolet light source 117a with LEDs therefore makes it possible to emit radial and direct radiation on the first impregnated single strand El, with or without an intermediate element, such as one or more reflectors.

[0146] Alternatively, the first ultraviolet light source 117a could comprise a plurality of mercury vapor lamps configured to emit broad-spectrum ultraviolet radiation, infrared radiation and visible light.

[0147] The use of LEDs can reduce styrene vapors, reduce fouling of the protective tube, and reduce variations in light intensity, which allows for more consistent polymerization of multifilament fibers.

[0148] Moreover, LEDs have a longer lifespan and lower or similar energy consumption to mercury vapor lamps and release less styrene vapor into the atmosphere.

[0149] The first radiation device 117 is configured to polymerize by partially or totally the first impregnated monofilament El and deliver a main composite monofilament E2.

[0150] By "partial polymerization or pre-polymerization" it is understood that the degree of polymerization of the impregnated multifilament fibers has reached between 0.5% and 5% of the complete polymerization.

[0151] The exposure time of the El-impregnated multifilament fiber bundle to the first UV light source is between 0.2s and 2s.

[0152] The power of the first UV light source is between 100W and 3000W.

[0153] The additional radiation device 127 includes an additional ultraviolet radiation light source 127a, acronym UV, disposed after the second calibration nozzle 127 and upstream of the final radiation device 118.

[0154] In one example, the additional ultraviolet light source 127a of the additional radiation device 127 comprises a plurality of LEDs configured to emit only ultraviolet radiation with wavelengths between 365nm and 405nm.

[0155] Alternatively, the additional ultraviolet light source 127a of the additional radiation device 127 could be provided that it comprises a plurality of mercury vapor lamps configured to emit broad-spectrum ultraviolet UV radiation combined at least with infrared radiation.

[0156] The additional radiation device 127 is configured to partially polymerize or pre-polymerize the first intermediate monostrand E3 and deliver a pre-polymerized single strand E4.

[0157] The exposure time of the first intermediate monostrand E3 to the additional UV light source 127a is between 0.5s and 9s.

[0158] The power of the additional UV light source 127a is between LlkWet98kW.

[0159] The final radiation device 118 is distinct from the first radiation device 117 and the additional radiation device 127 to form a final composite monostrand EF.

[0160] The final radiation device 118 includes a final light source configured to complete the polymerization of the first pre-polymerized monostrand E4.

[0161] 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%.

[0162] For example, the final light source is configured to emit at least one infrared radiation 118a, acronym IR, and comprises, for example, a plurality of infrared lamps (not shown), preferably directed radially towards the pre-polymerized monostrand E4.

[0163] When the second stage includes an additional radiation device 127, the final light source 118a is configured to emit only infrared radiation, with a wavelength between Ipm and 3pm. For glass fibers, a final IR source with a wavelength equal to Ipm is preferred.

[0164] The exposure time of the first pre-polymerized monostrand E4 to the final light source 118a IR is between 2.6s and 23s.

[0165] The power of the final light source 118a IR is between 2.2kW and 98kW.

[0166] Alternatively, when the second stage does not include an additional radiation device 127, the final light source 118a is configured to emit a combination of ultraviolet and infrared radiation.

[0167] Such an installation is particularly advantageous for manufacturing a composite EF monofilament from a bundle of large-diameter multifilament fibers, ranging from 10 mm to 30 mm. Indeed, because the large-diameter multifilament fiber bundle retains heat for a longer period, it is not necessary to complete the polymerization immediately after partial polymerization by the UV light source. Multifilament fibers can then be added to the main monofilament before proceeding with the final polymerization by a UV and infrared light source.

[0168] Alternatively, a second supplementary radiation device (not shown) could be added, located between the final radiation device 118 and the first additional radiation device 127 and comprising a third light source with ultraviolet radiation.

[0169] In this case, it could be envisaged that the additional ultraviolet light source 127a of the first additional radiation device 127 comprises a plurality of LEDs configured to emit only ultraviolet radiation with wavelengths between 365nm and 405nm and that the third ultraviolet light source comprises a plurality of mercury vapor lamps configured to emit broad-spectrum ultraviolet UV radiation, infrared radiation and visible light.

[0170] Alternatively, the additional ultraviolet light source 127a of the first additional radiation device 127 could be provided that it comprises a plurality of mercury vapor lamps configured to emit broad-spectrum ultraviolet UV radiation, infrared radiation and visible light and that the third ultraviolet light source comprises a plurality of LEDs configured to emit only ultraviolet radiation with wavelengths between 365nm and 405nm.

[0171] Alternatively, it could also be provided that the additional ultraviolet light source 127a of the first additional radiation device 127 and the third ultraviolet light source each comprise a plurality of LEDs configured to emit only ultraviolet radiation with wavelengths between 365nm and 405nm.

[0172] In the embodiment illustrated in [Fig.3], in which the same elements bear the same references, the installation 101 for manufacturing a single-strand composite EF differs only from the embodiment illustrated in [Fig.2] in that the installation 101 includes a third stage STAGE 3 for manufacturing a single-strand composite.

[0173] In this embodiment, the first stage STAGE 1 is identical to the first stage STAGE 1 described with reference to [Fig.2] and the second stage STAGE 2 differs from the second stage STAGE 2 described with reference to [Fig.2] only in that it does not include a final radiation device which is found in the last stage STAGE 3. The second stage STAGE 2 here forms an intermediate stage.

[0174] Thus, the first pre-polymerized monostrand E4 exiting the first intermediate radiation device 127 forms a second intermediate monostrand which enters the third stage STAGE 3.

[0175] As illustrated in [Fig. 3], the third stage STAGE 3 of single-strand manufacturing The final composite EF comprises, in the direction of advancement of the multifilament fiber bundle according to arrow F:

[0176] - a second series of two modules 140, 150 for preparing multifila- fibers additional or secondary impregnated modules ES3, ES4. The two additional modules 140, 150 are arranged in parallel;

[0177] - a third calibration die 136 configured to receive multifila- fibers additional comments ES3, ES4 and the first pre-polymerized monostrand E4 or second intermediate monostrand so as to form a third intermediate monostrand E5;

[0178] - a second additional radiation device 137 located downstream of the second calibration die 126, through which the third intermediate monostrand E5 passes and is configured to perform partial or intermediate polymerization to form a second pre-polymerized monostrand E6; and

[0179] - a final radiation device 118 located downstream of the second device additional radiation 137, through which the second pre-polymerized monostrand E6 circulates and is configured to carry out a complete or final polymerization of said monostrand E6 and form a final composite monostrand EF.

[0180] Alternatively, it could be provided that the third stage does not include an additional radiation device so that the final radiation device is configured to achieve a complete or final polymerization of the third intermediate single strand E5.

[0181] Alternatively, one could provide for one or more than two additional or secondary impregnated multifilament fiber preparation modules.

[0182] The second series of additional modules 140, 150 for preparation of additional impregnated multifilament fibers ES3, ES4 is functionally identical to the first series of additional modules 120, 130 for preparation of additional impregnated multifilament fibers ESI, ES2.

[0183] The full description of each of these modules will not be repeated in order to avoid making the description too cumbersome.

[0184] Generally, each additional module 140, 150 of the second series of additional modules includes a feeding device 141, 151 comprising here several reels 142, 152 for feeding elementary filaments Fi_3, Fi_4 to form respectively multifilament fibers ES3, ES4.

[0185] Each additional module 140, 150 of the second series of additional modules further comprises a vacuum chamber 143, 153 disposed between an inlet nozzle 143a, 153a and a separation nozzle 143b, 153b and an impregnation chamber 144, 154 downstream of the vacuum chamber 143, 153 and in particular of the separation nozzle 143b, 153b, filled with an impregnation composition 145, 155 based on a polymerizable material from an external reservoir (not shown) via an inlet nozzle 144a, 154a, and comprising a heating device 144b, 154b. The The impregnation chamber 144, 154 is delimited by the separation nozzle 143b, 153b and by a final outlet die 144c, 154c.

[0186] The additional multifilament fibers ES3, ES4 are directed towards the pre-polymerized monostrand E4 through the third calibration die 136 so as to form the third intermediate monostrand E5 impregnated with polymerizable material and of which the first pre-polymerized monostrand E4 or second intermediate monostrand has already undergone partial or complete polymerization in the first additional radiation device 127.

[0187] The second additional polymerization radiation device 137 is distinct from the first radiation device 117, the first additional radiation device 127 and the final radiation device 118.

[0188] The first radiation device 117 and the final radiation device 118 are identical to those described with reference to [Fig.2] and will not be described further here.

[0189] The second additional radiation device 137 includes an additional ultraviolet radiation light source 137a, acronym UV, disposed after the third calibration nozzle 137 and upstream of the final radiation device 118.

[0190] In one example, the second additional ultraviolet light source 137a of the additional radiation device 137 comprises a plurality of LEDs configured to emit only ultraviolet radiation with wavelengths between 365nm and 405nm.

[0191] Alternatively, the second additional ultraviolet light source 137a of the additional radiation device 137 could be provided that it comprises a plurality of mercury vapor lamps configured to emit broad-spectrum ultraviolet radiation, a radiation.

[0192] The additional radiation device 137 is configured to partially polymerize or pre-polymerize the third intermediate monostrand E5 and deliver a second pre-polymerized impregnated monostrand E6.

[0193] The exposure time of the third intermediate monostrand E5 E5 to the second additional UV light source 137a is between 0.5s and 9s.

[0194] The power of the second additional 137a UV light source is, here, between 11kW and 98kW.

[0195] The installation has been described with reference to two or three composite monofilament manufacturing stages. Generally, the installation comprises N composite monofilament manufacturing stages, with N greater than or equal to two. Each composite monofilament manufacturing stage includes an impregnation chamber, so as to impregnate only the multifilament fibers necessary to carry out the poly- partial or final merization.

[0196] Such an installation makes it easy to add additional preparation modules, and more generally, manufacturing stages for a composite monostrand in order to increase the diameter of the final composite strand. Such an installation also makes it possible to replace and / or add polymerization devices in order to increase production speed.

[0197] Such a staged polymerization makes it possible to obtain a composite monostrand with a diameter between 10mm and 30mm.

[0198] Moreover, such an installation allows access to the calibration nozzles and radiation devices, which are not surrounded by impregnated fibers unlike the prior art known, which facilitates their replacement or maintenance if needed.

[0199] The vacuum chambers 113, 123, 133, 143, 153 and the impregnation chambers 114, 124, 134, 144, 154 according to the invention are preferably equipped with lids to facilitate cleaning and the placement of the multifilament fibers.

[0200] Such an installation allows for easy integration of protective tubes inside the radiation devices.

[0201] As illustrated in [Fig.4], the flowchart illustrates the steps of a process 200 for manufacturing a composite EF element by the installation according to [Fig.2].

[0202] The manufacturing process 200 comprises a first manufacturing step 210 of a main single strand E2 in a first manufacturing stage STAGE 1 and a second manufacturing stage 220 of a final single strand EF in a second manufacturing stage STAGE 2.

[0203] The first step 210 of manufacturing a main monostrand E2 comprises the following successive steps:

[0204] - a step 211 of feeding elementary filaments to form a bundle of E0 multifilament fibers,

[0205] - a step 212 of degassing, in a vacuum chamber 113, the fiber bundle multifilament E0,

[0206] - an impregnation step 213 during which the multifilament fiber bundle E0 is impregnated with a composition based on a polymerizable material contained in an impregnation chamber 114 filled with said composition,

[0207] - a calibration step 214, via a first calibration die 116 at the outlet of the impregnation chamber 114 so as to form a first monostrand El impregnated with polymerizable material; and

[0208] - a first polymerization step 215 during which the first monostrand El impregnated with polymerizable material, it circulates through a first radiation device 117 for the purpose of partial or complete polymerization of the first impregnated monostrand El and to form a main composite monostrand E2.

[0209] As illustrated, the second step 220 of manufacturing a final EF monostrand comprises the following successive steps:

[0210] - two parallel steps 230, 240 of preparation of multifilament fibers im additional or secondary pregnancies ESI, ES2,

[0211] - a calibration step 224, via a second calibration die 126 located in exit of the first radiation device 117 of the first stage STAGE 1, during which a first intermediate monofilament E3 is produced, comprising the additional multifilament fibers ESI, ES2 and the main composite monofilament E2; and

[0212] - an additional polymerization step 225 during which the first intermediate single strand E3 circulates through an additional radiation device 127 for partial or complete polymerization of said first intermediate single strand E3 to form a pre-polymerized single strand E4, and

[0213] - a final polymerization step 226 during which the pre-polymerized monostrand E4 circulates through a final radiation device 118 for the purpose of final polymerization of said pre-polymerized single strand E4 to form a final single strand EF.

[0214] Each step 230, 240 of preparation of the additional or secondary impregnated multifilament fibers ESI, ES2 includes a step 231, 241 of feeding elementary filaments to form a bundle of multifilament fibers, a step 232, 242 of degassing, in a vacuum chamber 123, 133 of the bundle of multifilament fibers and a step 233, 243 of impregnation during which the straight bundle of multifilament fibers is impregnated with a composition based on a polymerizable material contained in an impregnation chamber 124, 134 filled with said composition.

[0215] Alternatively, one could provide for one or more than two preparation steps of the additional or secondary impregnated multifilament fibres.

[0216] After passing through the vacuum chamber 113, the multifilament fiber bundle E0 enters the impregnation chamber 114 which is totally full of polymerizable impregnation material, therefore devoid of air.

[0217] The impregnation chamber 114 is supplied with polymerizable material 115 from an external reservoir (not shown) via an inlet pipe 114a, here located in the upper part of said impregnation chamber 114.

[0218] The impregnation chamber 114 is totally filled with polymerizable material so that the multifilament fiber bundle exiting the vacuum chamber 113 and passing through it along a linear path is completely impregnated with polymerizable material.

[0219] The impregnation chamber 114 is associated with a heating device 114b configured to heat the polymerizable material to a temperature between 50°C and 95°C, preferably between 60°C and 80°C.

[0220] Thus, the impregnated multifilament fibers exit the impregnation chamber 114 at a temperature between 50°C and 95°C, preferably between 60°C and 80°C, before passing through the first radiation device 117.

[0221] During the first polymerization step 225, the monostrand impregnated with polymerizable material El is partially or totally polymerized to form a main monostrand E2 using the first radiation device 117 comprising a first ultraviolet radiation light source 117a, acronym UV.

[0222] The first ultraviolet light source 117a is identical to that described with reference to [Fig.2] and will not be described further here.

[0223] The exposure time of the first impregnated monostrand El to the first UV light source is between 0.2s and 2s.

[0224] The power of the first UV light source is between 1000 Watts and 3000 Watts.

[0225] During the additional polymerization step 225, the first intermediate monostrand E3 comprising the additional multifilament fiber bundles ESI, ES2 and the main composite monostrand E2 is polymerized using an additional radiation device 127 comprising an additional ultraviolet radiation light source 127a, acronym UV.

[0226] The exposure time of the first intermediate monostrand E3 to the additional UV light source is between 0.5s and 9s.

[0227] The power of the additional UV light source is between 1lkW and 98kW.

[0228] During the final polymerization step 226, the first pre-polymerized monostrand E4 is polymerized using a final radiation device 118 comprising an infrared radiation light source, separate and distinct from the first radiation device 117 and the additional radiation device 127.

[0229] The exposure time of the first pre-polymerized monostrand E4 to the final IR light source is between 2.6s and 23s.

[0230] The power of the final light source 118a is between 2.2kW and 98kW.

[0231] The final light source 118a is identical to that described with reference to [Fig.2] and will not be described further here.

[0232] The installation and manufacturing process according to the invention can be adapted to both existing and new installations.

[0233] The installation and manufacturing process according to the invention makes it possible to obtain composite elements having a cross-section of different sizes and this at a high production rate.

[0234] For example, for a CVR composite, the following process can be obtained the invention, sections having a diameter between 10mm and 30mm for a rate of approximately 50m / min.

[0235] Furthermore, the installation and manufacturing process according to the invention make it easy to add additional preparation modules, and more generally, additional manufacturing stages for a composite monostrand in order to increase the diameter of the final composite strand. Such an installation also makes it possible to replace and / or add polymerization devices in order to increase the production speed.

[0236] Moreover, such an installation allows access to the calibration nozzles and polymerization devices, which are not surrounded by impregnated fibers unlike the prior art known, which facilitates their replacement or maintenance if needed.

Claims

Claims

1. Installation (100, 101) for the continuous manufacture of an elongate composite element (EF) comprising a bundle of multifilament fibers impregnated with a composition based on a polymerizable material, characterized in that the installation (100, 101) comprises N stages (STAGE 1, STAGE 2, STAGE 3) for manufacturing a composite element, with N greater than or equal to 2 and a translational drive device (D) configured to drive the bundle of multifilament fibers in translation to successively carry out the passage through the N stages, each stage (STAGE 1, STAGE 2, STAGE 3) comprising, in the direction of advance of the bundle of multifilament fibers: - at least one module (110, 120, 130, 140, 150) for preparing multifilament fibers impregnated with polymerizable material; - at least one calibration nozzle (116, 126, 136);and - at least one radiation device (117, 118, 127, 137) arranged downstream of the calibration nozzle (116, 126, 136) and through which the multifilament fibers impregnated with polymerizable material circulate and configured to carry out partial or total polymerization to form a composite single strand (E2, E5, EF).;

2. Installation (100, 101) according to claim 1, in which the installation comprises at least a first stage (STAGE 1) for manufacturing a main composite monostrand (E2) and a second stage (STAGE2) for manufacturing a composite monostrand (EF).

3. Installation (100, 101) according to claim 2, in which the first stage (STAGE 1) for manufacturing the main composite monostrand (E2) comprises, in the direction of advancement of the bundle of multifilament fibers: - a feed device (111) configured to form a bundle of multifilament fibers (E0), - a vacuum chamber (113); - an impregnation chamber (114) downstream of the vacuum chamber (113) and filled with an impregnation composition (115) based on a polymerizable material; - a first calibration die (116) at the outlet of the impregnation chamber (114) so ​​as to form a first monostrand (El) impregnated with polymerizable material; and - a first radiation device (117) configured to po- partially or completely polymerize the first single strand (El) impregnated with polymerizable material and to form a main composite single strand (E2).

4. Installation (100) according to claim 2 or 3, in which the second stage (STAGE2) for manufacturing the composite monostrand (EF) comprises, in the direction of advancement of the bundle of multifilament fibers: - at least one module (120, 130) for preparing additional impregnated multifilament fibers (ESI, ES2), - a second calibration die (126) configured to receive the additional multifilament fibers (ESI, ES2) coming from the module (120, 130) for preparing the additional impregnated multifilament fibers and the main composite monostrand (E2) so as to form a first intermediate monostrand (E3); and at least one final radiation device (118) located downstream of the second calibration die (126), through which the first intermediate monostrand (E3) circulates and configured to carry out complete polymerization of said monostrand (E3) and form a final composite monostrand (EF).

5. Installation (100) according to claim 4, in which the second stage (STAGE2) comprises an additional radiation device (127) located between the second calibration die (126) and the final radiation device (118) and configured to carry out a partial polymerization of the first intermediate monostrand (E3) and to form a second intermediate monostrand (E4).

6. Installation (101) according to claim 2 or 3, comprising a third stage (STAGE 3) for manufacturing the final composite monostrand (EF) and in which the second stage (STAGE2) is configured to manufacture a second intermediate composite monostrand (E4), the second stage (STAGE2) comprising, in the direction of advancement of the bundle of multifilament fibers: - at least one module (120, 130) for preparing additional impregnated multifilament fibers (ESI, ES2), - a second calibration die (126) configured to receive the bundles of additional multifilament fibers (ESI, ES2) coming from the module (120, 130) for preparing the additional impregnated multifilament fibers and the main composite monostrand (E2) so as to form a first intermediate monostrand (E3); and at least - a first intermediate radiation device (127) located downstream of the second calibration die (126) and configured to carry out a partial polymerization of the first intermediate monostrand (E3) and to form a second intermediate monostrand (E4).

7. Installation (101) according to claim 6, in which the third stage (STAGE 3) comprises, in the direction of advancement of the bundle of multifilament fibers: - at least one module (140, 150) for preparing additional impregnated multifilament fibers (ES3, ES4), - a third calibration die (136) configured to receive the additional multifilament fibers (ES3, ES4) coming from the module (140, 150) for preparing the additional impregnated multifilament fibers and the second intermediate single strand (E4) so ​​as to form a third intermediate single strand (E5); and at least - a final radiation device (118) located downstream of the third calibration die (136)), through which the third intermediate monostrand (E5) circulates and configured to carry out complete polymerization of said monostrand (E5) and form a final composite monostrand (EF).

8. Installation (101) according to claim 7, in which the third stage (STAGE 3) comprises, between the third calibration die (136) and the final radiation device (118), a second additional radiation device (137) configured to carry out a partial polymerization of the third intermediate monostrand (E5) and to form a pre-polymerized monostrand (E6).

9. Installation (100, 101) according to claim 5 or 8, in which the additional radiation device (127, 137) comprises an additional light source (127a, 137a) with ultraviolet radiation.

10. Installation (100, 101) according to claim 3 taken in combination with any one of the preceding claims, in which the first radiation device (117) comprises a first light source (117a) with ultraviolet radiation.

11. An installation (100, 101) according to claim 3 or 7 taken in combination with any one of the preceding claims, wherein the final radiation device (118) comprises a source final light (118a) configured to emit at least one infrared radiation.

12. Installation (100, 101) according to claim 3 or 7 taken in combination with any one of the preceding claims, in which the module (120, 130, 140, 150) for preparing the additional impregnated multi-filament fibers (ES1, ES2, ES3, ES4) comprises a feed device (121, 131, 141, 151) for forming a bundle of multi-filament fibers, a vacuum chamber (123, 133, 143, 153) and an impregnation chamber (124, 134, 144, 154) downstream of the vacuum chamber (123, 133, 143, 153) and filled with an impregnation composition (125, 135, 145, 155) based on a material polymerizable.

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

14. Method (200) for the continuous manufacture of an elongated composite element (EF) comprising a bundle of multifilament fibers impregnated with a composition based on a polymerizable material, comprising the following successive steps: - manufacture of a main single strand (E2) in a first manufacturing stage (STAGE 1); and at least - manufacture of a second single strand (EF) in a second manufacturing stage (STAGE 2).

15. Method (200) according to claim 14, in which each stage (STAGE1, STAGE2) of manufacturing a composite monostrand comprises a step of preparing impregnated multifilament fibers comprising the following successive steps: - feeding elementary filaments to form a bundle of multifilament fibers, - degassing, in a vacuum chamber (113, 123, 133, 143, 153), the bundle of multifilament fibers, - impregnation of the bundle of multifilament fibers with a com- position based on a polymerizable material contained in an impregnation chamber (114, 124, 134, 154) filled with said composition, and - calibrating the impregnated multifilament fiber bundle, via a calibrating die (116, 126, 136) so as to form a single strand impregnated with polymerizable material.

16. The method (200) of claim 15, wherein, in the step of manufacturing a main monostrand (E2), the impregnated monostrand (El) is polymerized in a first radiation device (117) to form a main monostrand (E2) of polymerizable material.

17. Method (200) according to claim 16, wherein during the step of manufacturing a second single strand (EF): - the main single strand (E2) is associated with additional multifilament fibers (ESI, ES2) coming from at least one module (120, 130) for preparing additional impregnated multifilament fibers to form a first intermediate single strand (E3); - said first intermediate monostrand (E3) is polymerized in an additional radiation device (127) configured to carry out a partial polymerization of the first intermediate monostrand (E3) and to form a second intermediate monostrand (E4); and - said second intermediate monostrand (E4) is polymerized in a final radiation device (118) located downstream of the additional radiation device (127) configured to carry out complete polymerization of said second intermediate monostrand (E4) and form a final composite monostrand (EF).

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