Functionalized textiles

Abstract

Described herein is a functionalized textile comprising a fiber fabric and a binder having a glass transition temperature of about 75° C. or less, wherein the binder comprises up to about 5% by weight of the functionalized textile.

Description

[Technical field]

[0001] The present invention relates to functionalized fabrics comprising glass and / or carbon fibers, particularly functionalized fabrics for reinforcing structural components such as wind turbine components. [Background technology]

[0002] It is known to use glass and / or carbon fibers to form reinforced fiber fabrics to strengthen structural components such as wind turbine blades or related components (eg, spar caps).

[0003] Structural parts containing woven reinforcing fibers (reinforced structural parts) are often formed by stacking the reinforcing fiber fabric in layers in a mold, filling the mold with resin, and curing the resin to form the part. This can be a time-consuming process.

[0004] The use of wind and wind turbines is gaining more attention as the search for alternative energy sources continues. As interest in generating more energy from the wind grows, technological advances in the art have allowed for an increase in the size of wind turbine blades. Increasing the size of wind turbine blades also increases the time required to fabricate the wind turbine blades.

[0005] It is desirable to provide improved production efficiencies for reinforced structural components, such as wind turbine blades. Summary of the Invention

[0006] The present invention most generally provides a functionalized textile comprising a fiber fabric and a binder having a glass transition temperature of up to about 75° C., the binder comprising up to about 5% by weight of the functionalized textile.

[0007] In one aspect, the present invention provides a functionalized textile comprising: Fiber fabrics, and binder particles having a glass transition temperature of up to about 75° C.; Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; The binder particles comprise up to about 5% by weight (e.g., from about 0.1% to about 3.5% by weight) of the functionalized fabric, and optionally the functionalized fabric comprises from about 2 to about 20 g / m 2 The present invention provides a functionalized textile comprising binder particles of

[0008] In one aspect, the present invention provides a functionalized textile comprising: Fiber fabrics, and binder particles having a glass transition temperature of up to about 75° C.; Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; The binder particles constitute up to about 5% by weight (e.g., about 0.1% to about 3.5% by weight) of the functionalized fabric, the binder particles being attached to a surface of the fiber fabric, and optionally the functionalized fabric has an average mass of about 2 to about 20 g / m 2 The present invention provides a functionalized textile comprising binder particles of

[0009] In one aspect, the present invention provides a functionalized textile comprising: Fiber fabrics, and binder particles having a glass transition temperature of up to about 75° C.; The fiber fabric includes first fibers oriented in a first direction and second fibers oriented in a second direction, the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; the binder comprises up to about 5% by weight of the functionalized fabric; The functionalized textile is provided having a surface on which at least a portion of the binder is present that has an average gloss value of about 65 G.U. or less.

[0010] In one aspect, the present invention provides a textile stack comprising at least two layers of the functionalized textile described herein.

[0011] In one aspect, the invention provides a molded part comprising a woven stack as described herein.

[0012] In one aspect, the present invention is a process for fabricating a functionalized textile, the process comprising: providing a fiber fabric comprising first fibers oriented in a first direction and second fibers oriented in a second direction, the first fibers comprising glass fibers and / or carbon fibers, the second fibers comprising glass fibers and / or carbon fibers, and the second direction being within a range of 0 to 90 degrees of the first direction; The present invention provides a process comprising: applying binder particles having a glass transition temperature of up to about 75° C. to a fibrous fabric; and adhering the binder particles to the fibrous fabric to provide a functionalized fabric, wherein the binder is applied to the fibrous fabric in an amount such that the binder comprises up to about 5% by weight of the functionalized fabric.

[0013] In one aspect, the present invention is a process for fabricating a functionalized textile, the process comprising: providing a fiber fabric comprising first fibers oriented in a first direction and second fibers oriented in a second direction, the first fibers comprising glass fibers and / or carbon fibers, the second fibers comprising glass fibers and / or carbon fibers, and the second direction being within a range of 0 to 90 degrees of the first direction; applying a binder having a glass transition temperature of up to about 75° C. to a fiber fabric to provide a functionalized fabric; and applying a binder to the fiber web; the binder is applied to the fiber fabric in an amount such that the binder comprises up to about 5% by weight of the functionalized fabric; The process provides that the functionalized textile has a surface on which at least a portion of the binder is present that has an average gloss value of about 65 G.U. or less.

[0014] In one aspect, the present invention provides a process for making a molded part, comprising: stacking multiple layers of the functionalized fabric described herein; forming a shaped stack of a plurality of stacked fabric layers; heating the fabric stack at a temperature up to about 150° C. to provide a molded part.

[0015] In one aspect, the present invention provides a roll of functionalized fabric as described herein.

[0016] The inventors have discovered that the present invention provides a functionalized fabric that offers improved production efficiencies for reinforced structural components, such as wind turbine blades and related components.

[0017] The inventors have found that applying a small amount of binder particles to a fiber fabric, as described herein, can be advantageous (e.g., less than 5 wt. % (e.g., less than 3.5 wt. % or 0.1-3.5 wt. %) of the total weight of the functionalized fabric, and / or from about 2 to about 30 g / m 2 of the functionalized fabric). 2 (For example, about 2 to about 20 g / m 2) provides functionalized fabrics having discrete binder particles attached to a surface of a fiber fabric (e.g., of attached binder particles having a maximum axial length of up to about 1 mm), the resulting functionalized fabrics having excellent handleability and providing improved production efficiency for reinforced structural parts such as wind turbine blades.

[0018] The inventors have found that the functionalized textiles described herein can be stacked to form textile stacks, and that the binders of the functionalized textiles can adhere the textile layers of the textile stacks to one another to form consolidated textile stacks that exhibit excellent adhesion. The inventors have also found that the functionalized textiles, textile stacks and consolidated textile stacks described herein can be easily molded, and that the molded textiles or textile stacks retain their molded shape (e.g., after removal from a mold).

[0019] The inventors have surprisingly found that the binders described herein (e.g., binder particles) can be added in small amounts (e.g., less than 5 wt. % (e.g., less than 3.5 wt. % or 0.1 to 3.5 wt. %) of the total weight of the functionalized textile and / or from about 2 to about 30 g / m 2 of the functionalized textile. 2 (For example, about 2 to about 20 g / m 2 It has been found that fibrous fabrics, including functionalized fabrics, having a surface comprising a glass transition temperature of up to about 75° C. and an average gloss value of about 65 G.U. or less (e.g., from about 25 G.U. to about 65 G.U. or from about 25 G.U. to about 65 G.U.), can be stacked and molded (i.e., pre-formed) prior to being incorporated into a reinforcing structural component.

[0020] It has been found that by providing the functionalized textiles described herein, the rate at which reinforced structural parts, such as wind turbine blades, can be fabricated is surprisingly increased. The functionalized textiles described herein have also been found to exhibit excellent handling properties, in particular, the functionalized textiles can be rolled, cut, and stacked without the binders detaching. Even more surprisingly, the inventors have found that the functionalized textiles described herein can provide increased production efficiency for reinforced structural parts, such as wind turbine blades, without adversely affecting the mechanical properties of the textile or the final part.

[0021] The present invention includes combinations of the aspects, embodiments and preferred features described herein, except where such combinations are expressly not permitted or explicitly avoided. [Brief description of the drawings]

[0022] BRIEF DESCRIPTION OF THE DRAWINGS Embodiments and experiments illustrating the principles of the present invention are described with reference to the accompanying drawings. [Figure 1] 1 is a graph showing particle size distributions of different binder particles that may be applied to a fiber fabric to make a functionalized fabric as described herein. [Diagram 2] 1 is a 3D microscope produced image of a functionalized fabric described herein. [Figure 3a] FIG. 2 is a schematic diagram of a cross section of a fiber stack. [Figure 3b] FIG. 2 is a schematic diagram of a cross section of a fiber stack. [Figure 4a] 1 is a 3D microscope produced image of a functionalized fabric described herein. [Figure 4b] FIG. 4b is a graph showing the binder particle size distribution on the surface of the functionalized textile shown in FIG. 4a. [Figure 5a] 1 is a 3D microscope produced image of a functionalized fabric described herein. [Figure 5b]FIG. 5b is a graph showing the binder particle size distribution at the surface of the functionalized textile shown in FIG. 5b. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Aspects and embodiments of the present invention will now be described with reference to the accompanying drawings, and further aspects and embodiments will be apparent to those skilled in the art.

[0024] Described herein is a functionalized textile comprising a fiber fabric and binder particles, the binder particles being attached to a surface of the fiber fabric and having a glass transition temperature of about 75° C. or less, the binder particles constituting up to about 5% by weight of the functionalized textile.

[0025] Also described herein is a functionalized textile comprising a fiber fabric and a binder (e.g., binder particles), the binder having a glass transition temperature of about 75° C. or less and constituting up to about 5% by weight of the functionalized textile, the functionalized textile having a surface comprising the binder, the surface having an average gloss value of about 65 G.U. or less.

[0026] Textiles Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction; The first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction.

[0027] The first fibers of the fiber weave may be referred to as warp fibers. The first fibers may be arranged side by side and substantially parallel to each other. The second fibers of the fiber weave may be referred to as weft fibers. The second fibers may be arranged side by side and substantially parallel to each other.

[0028] In an embodiment, the fiber fabric includes first fibers oriented in a first direction and second fibers oriented in a second direction, and the second direction is within 0 degrees to 90 degrees of the first direction, e.g., within about 10 degrees to about 90 degrees of the first direction, within about 20 degrees to about 90 degrees of the first direction, within about 30 degrees to about 90 degrees of the first direction, within about 40 degrees to about 90 degrees of the first direction, within about 45 degrees to about 90 degrees of the first direction, within about 60 degrees to about 90 degrees of the first direction, within about 70 degrees to about 90 degrees of the first direction, within about 80 degrees to about 90 degrees of the first direction, within about 85 degrees to about 90 degrees of the first direction, within about 88 degrees to about 90 degrees of the first direction, or within about 90 degrees of the first direction.

[0029] In an embodiment, the fiber fabric may be a unidirectional fabric or a multiaxial fabric, such as a biaxial fabric.

[0030] In an embodiment, the fiber fabric is a unidirectional fabric. A fiber fabric that is a unidirectional fabric can include a second fiber oriented in a second direction, where the second direction is oriented in a direction greater than 0 degrees to the first direction. For example, a unidirectional fabric can include a first fiber oriented in a first direction and a second fiber oriented in a second direction, where the second direction is at about 0 degrees to about 90 degrees to the first direction, for example, within about 45 degrees to about 90 degrees to the first direction, within about 60 degrees to about 90 degrees to the first direction, within about 70 degrees to about 90 degrees to the first direction, within about 80 degrees to about 90 degrees to the first direction, within about 85 degrees to about 90 degrees to the first direction, within about 88 degrees to about 90 degrees to the first direction, or within about 90 degrees to the first direction. In a unidirectional fabric, the first fibers can comprise more than about 90% by weight of the fabric, such as more than about 92% by weight of the fabric, or at least about 95% by weight of the fabric. In a unidirectional fabric, the second fibers can comprise up to about 10% by weight of the fabric, such as up to about 8% by weight, or up to about 5% by weight. In a unidirectional fabric, the second direction can be substantially perpendicular to the first direction, the first fibers can comprise more than 92% by weight of the fabric, and the second fibers can comprise up to about 8% by weight of the fabric. In an embodiment, the fabric is a unidirectional fabric, the second direction is substantially perpendicular to the first direction, and the weight ratio of the first fibers to the second fibers is in the range of 15:1 to 25:1.

[0031] In an embodiment, the fiber fabric is a biaxial fabric. In the biaxial fabric, the second direction may be within 20 degrees to 90 degrees of the first direction, for example, the second direction may be within about 30 degrees to about 90 degrees of the first direction, the second direction may be within about 40 degrees to about 90 degrees of the first direction, the second direction may be within about 45 degrees to about 90 degrees of the first direction, the second direction may be within about 60 degrees to about 90 degrees of the first direction, within about 70 degrees to about 90 degrees of the first direction, within about 80 degrees to about 90 degrees of the first direction, within about 85 degrees to about 90 degrees of the first direction, within about 88 degrees to about 90 degrees of the first direction, or within about 90 degrees of the first direction. In an embodiment, the fiber fabric is a biaxial fabric, and the second direction is at about 25-75 degrees from the first direction, e.g., about 45 degrees from the first direction. In an embodiment, the fiber fabric is a biaxial fabric, and the second direction is at least about 45 degrees from the first direction. In an embodiment, the fiber fabric is a biaxial fabric, and the second direction is substantially perpendicular to the first direction. In an embodiment, the fiber fabric is a biaxial fabric, and the second fibers comprise more than 5% by weight of the fiber fabric. In an embodiment, the fiber fabric is a biaxial fabric, and the second fibers can comprise at least about 10% by weight of the fiber fabric, e.g., at least about 15% by weight, at least about 20% by weight, or at least about 25% by weight of the fiber fabric.

[0032] In an embodiment, at least the first fiber or the second fiber comprises, consists essentially of, or consists of glass fibers.

[0033] In an embodiment, both the first fiber and the second fiber comprise, consist essentially of, or consist of glass fibers.

[0034] In embodiments, the glass fibers comprise at least about 50% by weight of the woven fibers described herein, e.g., at least about 60% by weight of the woven fibers, at least about 70% by weight of the woven fibers, at least about 80% by weight of the woven fibers, at least about 90% by weight of the woven fibers, or at least about 95% by weight of the woven fibers.

[0035] As used herein, the term "glass fiber" is used to refer to a plurality of continuous glass filaments (the term "continuous" as used herein is used to refer to a fiber / filament whose length is many times longer than its diameter, e.g., at least about 5000 times longer than its diameter, e.g., at least about 10000 times longer than its diameter). The glass fibers used in the woven fabrics described herein may be provided as glass fiber strands (or tows). The glass fibers may be formed by a continuous manufacturing process in which molten glass passes through holes in a "bushing" and the stream of molten glass formed thereby solidifies into filaments / fibers. The glass fibers described herein (e.g., the glass fibers of the first fiber and / or the second fiber) may include a sizing agent on their surface, e.g., a sizing agent applied to the glass fibers during the formation of the fibers. The sizing agent may include components that facilitate the formation of the glass fibers and / or their use in matrix resins, such as film formers, lubricants, coupling agents (to promote compatibility between the glass fibers and resins used to form composite articles including the hybrid woven fabrics described herein). In some embodiments, the glass fibers of the first and / or second fibers include a polyester-compatible sizing or an epoxy-compatible sizing.

[0036] As used herein, the term "fiberglass strand" or "fiberglass tow" refers to a bundle of continuous glass filaments. In embodiments, a fiberglass strand or tow is a bundle of glass filaments without any twists.

[0037] In an embodiment, the fiberglass strands or fiberglass tows are provided from fiberglass direct rovings, which are made of continuous, untwisted (i.e., substantially parallel, or parallel) bundles of glass filaments that are combined into a single strand (as the glass filaments are formed) and wound onto a bobbin.

[0038] Any suitable glass reinforcing fibers may be employed as the first or second fibers, for example, fibers made from E-glass, E-CR-glass (such as Advantex™ glass fibers available from Owens Corning), C-glass, H-glass, S-glass, and AR glass types may be used.

[0039] In embodiments, the glass fibers referred to herein (e.g., the first fibers that may be glass fibers and / or the second fibers that may be glass fibers) have a linear mass density in the range of about 50 tex to about 5000 tex, e.g., about 200 tex to about 4800 tex, about 300 tex to about 2500 tex, about 300 tex to about 2400 tex, or about 600 tex to about 1200 tex.

[0040] The term "carbon fiber" is used herein to refer to a plurality of continuous carbon filaments (the term "continuous" is used herein to refer to a fiber / filament whose length is many times longer than its diameter, e.g., at least about 5000 times longer than its diameter, e.g., at least about 10000 times longer than its diameter). The carbon fibers used in the woven fabrics described herein may be provided as carbon fiber tows (or strands), which are bundles of continuous carbon filaments. The carbon fibers described herein (e.g., the carbon fibers of the first fiber and / or the second fiber) may include a sizing agent on their surface, e.g., a sizing agent applied to the carbon fibers during the formation of the fibers. The sizing agent may include components that facilitate the formation of the carbon fibers and / or their use in matrix resins, such as film formers, lubricants, coupling agents (to promote compatibility between the carbon fibers and resins used to form composite articles including the hybrid woven fabrics described herein). In some embodiments, the carbon fibers include a polyester compatible sizing agent or an epoxy compatible sizing agent.

[0041] In an embodiment, the carbon fibers have a fiber diameter in the range of about 100 tex to about 5000 tex, for example, about 200 tex to about 5000 tex, about 400 tex to about 5000 tex, about 600 tex to about 5000 tex, about 800 tex to about 5000 tex, about 100 tex to about 4800 tex, about 200 tex to about 4800 tex, 400 tex to about 4800 tex, about 600 tex to about 4800 tex, The linear density is about 800 tex to about 4800 tex, about 100 tex to about 2400 tex, about 200 tex to about 2400 tex, about 400 tex to about 2400 tex, about 100 tex to about 2000 tex, about 200 tex to about 2000 tex, about 400 tex to about 2000 tex, about 600 tex to about 2000 tex, about 800 tex to about 2000 tex, or about 1200 tex.

[0042] In an embodiment, the carbon fibers (if present) are provided by carbon fiber tows (strands of carbon fibers). In an embodiment, the carbon fiber tows have a size ranging from 6K to 50K, e.g., 6K to 24K, or 6K to 12K. For example, the first fiber may be provided from one or more carbon fiber tows having a size ranging from 6K to 50K, e.g., 6K to 24K, or 6K to 12K. The #K designation means that the carbon tow is composed of #×1,000 individual carbon filaments, i.e., a carbon fiber tow having a size of 6K is made of approximately 6000 carbon fiber filaments / fibers.

[0043] In an embodiment, the fibrous fabric is a non-crimp fabric, and the first and second fibers are maintained in their respective orientations by the sutures (the first and second fibers are not woven together, i.e., the non-crimp fabric is a non-woven fabric). Any suitable sutures can be employed. In an embodiment, the sutures are polyester yarns. In an embodiment, the sutures have a linear mass density in the range of about 50 decitex to about 300 decitex. In an embodiment, the sutures form a stitching pattern through the fabric, and the stitching pattern can be selected from a tricot stitching pattern, a symmetric double tricot stitching pattern, an asymmetric double tricot stitching pattern, a symmetric stitching pattern, and an asymmetric stitching pattern. In an embodiment, the sutures form a stitching pattern through the fabric, and the stitching pattern is a tricot stitching pattern. In an embodiment, the sutures define a stitching length, and the stitching length is in the range of about 2 mm to about 7 mm, for example about 3 mm.

[0044] In an embodiment, the fibrous fabric is a woven fabric, for example a plain weave fabric, a warp knit fabric, or a twill weave fabric.

[0045] In an embodiment, the woven fiber fabric consists essentially of, or consists of, glass fibers and / or carbon fibers. In an embodiment, the woven fiber fabric consists essentially of, or consists of, glass fibers and carbon fibers. In an embodiment, the woven fiber fabric consists essentially of, or consists of, glass fibers.

[0046] In an embodiment, the woven fiber fabric comprises glass fibers. In an embodiment, the woven fiber fabric comprises additional fibers in addition to the glass fibers. In an embodiment, the woven fiber fabric comprises additional fibers in addition to the glass fibers and / or carbon fibers. Examples of other fibers that may be included in the woven fiber fabric include polymeric fibers such as PET.

[0047] In an embodiment, the fiber fabric has a thickness of about 200 g / m 2 ~about 2500g / m 2 , for example, about 300 g / m 2 ~About 2000g / m 2 , for example, about 500 g / m2 ~About 1500g / m 2 , for example, about 500 g / m 2 ~Approx. 1300g / m 2 , for example, about 1300 g / m 2 ~about 2500g / m 2 The area weight of the textile fabric may be determined according to ISO 3374.

[0048] In an embodiment, the fiber fabric comprises: first fibers oriented in a first direction; and second fibers oriented in a second direction; The first fibers include glass fibers, the second fibers include glass fibers, the second direction is within 45 degrees to 90 degrees of the first direction, and the first fibers and the second fibers are maintained in their respective orientations by a suture.

[0049] In an embodiment, the fiber fabric comprises: first fibers oriented in a first direction; and second fibers oriented in a second direction; The first fibers include glass fibers, the second fibers include glass fibers, the second direction is within 45 degrees to 90 degrees of the first direction, the first fibers and the second fibers are maintained in their respective orientations by a suture, and the glass fibers of the first fibers and / or the second fibers include a polyester-compatible sizing or an epoxy-compatible sizing.

[0050] In an embodiment, the fiber fabric comprises: first fibers oriented in a first direction; and second fibers oriented in a second direction; the first fibers comprise glass fibers and the second fibers comprise glass fibers, the second direction is within 45 degrees to 90 degrees of the first direction, the first fibers and the second fibers are maintained in their respective orientations by a suture, the glass fibers of the first fibers and / or the second fibers comprise a polyester compatible sizing or an epoxy compatible sizing, and the fiber fabric has a weight of about 500 g / m 2~about 2500g / m 2 The area weight ranges from 0.01 to 0.01 mm.

[0051] Binder The functionalized textile includes a binder (e.g., binder particles). The functionalized textile may be described herein as including binder particles. The functionalized textile may be described herein as including a woven fiber fabric having binder particles attached to a surface of the woven fiber fabric.

[0052] In an embodiment, the binder (e.g., binder particles) comprises, consists essentially of, or consists of a resin binder. In an embodiment, the binder (e.g., binder particles) comprises or consists of a thermoplastic resin. In an embodiment, the binder (e.g., binder particles) comprises or consists of a thermoplastic resin selected from an epoxy resin, an acrylate resin, or a polyester resin. In an embodiment, the binder (e.g., binder particles) comprises or consists of a thermoplastic resin selected from an epoxy resin or a polyester resin. In an embodiment, the binder comprises or consists of a resin comprising an epoxy, acrylate, or ester functional group, e.g., a resin comprising an epoxy or ester functional group. In an embodiment, the binder (e.g., binder particles) comprises or consists of a bio-based resin, e.g., a bio-based resin comprising an epoxy, acrylate, or ester functional group, e.g., a bio-based resin comprising an epoxy or ester functional group.

[0053] In an embodiment, the binder (e.g., binder particles) has a glass transition temperature of at most about 75°C, e.g., at most about 70°C, at most about 65°C, at most about 60°C, or at most about 55°C. In an embodiment, the binder has a glass transition temperature of at least about 30°C, e.g., at least about 35°C, or at least about 40°C. In an embodiment, the binder has a glass transition temperature in the range of about 30°C to about 75°C, e.g., about 40°C to about 70°C. The glass transition temperature of the binder can be determined using differential scanning calorimetry (DSC) according to EN ISO 11357-2 (determination of glass transition temperature). The glass transition temperature of the binder can be determined using differential scanning calorimetry (DSC) according to EN ISO 11357-2 (determination of glass transition temperature), the glass transition temperature being determined as the value provided in the second heating cycle. The glass transition temperature of the binder can be determined according to the EN ISO 11357-2 test method by heating the binder at a heating rate of 10 K / min under an air flow of 80 mL / min, heating from -60°C to 120°C. In an embodiment, the glass transition temperature of the binder can be determined according to the EN ISO 11357-2 test method by heating the binder at a heating rate of 10 K / min under an air flow of 80 mL / min, heating from -60°C to 120°C, then holding at 120°C for 5 minutes, then cooling from 120°C to -60°C at a cooling rate of 10 K / min, then holding at -60°C for 5 minutes, then heating again from -60°C to 120°C at a heating rate of 10 K / min, the glass transition temperature being determined as the value provided by the second heating cycle.

[0054] In an embodiment, the binder (e.g., binder particles) has a melting point such that the binder completely melts when exposed to a temperature of up to about 120° C. for at least a suitable time, e.g., the binder completely melts when exposed to a temperature of up to about 110° C. for at least a suitable time, or the binder completely melts when exposed to a temperature of up to about 100° C. for at least a suitable time, or the binder completely melts when exposed to a temperature of up to about 90° C. for at least a suitable time. In an embodiment, the binder has a melting point such that the binder completely melts when exposed to a temperature in the range of about 60° C. to about 120° C., e.g., about 80° C. to about 120° C., for at least a suitable time. A suitable time period may be up to 1 hour, e.g., up to 30 minutes. A suitable time period may be at least about 1 minute, e.g., at least about 5 minutes or at least about 10 minutes.

[0055] In an embodiment, the binder (e.g., binder particles) has a softening temperature in the range of about 50° C. to about 100° C., e.g., about 60° C. to about 100° C. In an embodiment, the softening temperature may be determined using an oscillatory rheometer employing a heat-cool-heat cycle of heating from 30° C. to 130° C. at a rate of 3° C. / min, cooling to 130° C. to 30° C., and heating to 30° C. to 130° C. at a rate of 3° C. / min, with a binder sample having a thickness of 400 μm and a diameter of 25 mm, at a frequency of 1 Hz, with a deformation of 0.1% in a planar-planar geometry. The softening temperature is measured during the first heat.

[0056] In an embodiment, the binder is applied to the fiber fabric as binder particles. The binder particles before application to the fiber fabric may have a volume average particle size of up to about 1 mm, for example up to about 800 μm, up to about 600 μm, up to about 500 μm, up to about 400 μm, up to about 300 μm, or up to about 200 μm. In an embodiment, the binder particles before application to the fiber fabric have a volume average particle size of more than about 10 μm, for example more than about 20 μm, more than about 30 μm, more than about 40 μm, or more than about 50 μm. In an embodiment, the binder particles before application to the fiber fabric have a volume average particle size in the range of about 10 μm to about 1 mm, for example, about 20 μm to about 600 μm, about 30 μm to about 500 μm, about 40 μm to about 400 μm, or about 50 μm to about 300 μm. The volume average particle size of the binder particles before application to the fiber fabric can be determined using dynamic light scattering techniques on a dispersion of the binder particles. A particle size analyzer such as the Beckman™ LS13320 Particle Size Analyzer can be employed to determine the volume average particle size by laser diffraction according to the ISO 13320 2009 standard (i.e., using dynamic light scattering techniques on a dispersion of the binder particles before application to the fiber fabric). The sample can be analyzed twice as received and after dispersion in air, and the amount of sample is typically about 20 g per test.

[0057] In embodiments, the binder of the functionalized fabric may be described as a binder particle.

[0058] The binder particles applied to the fiber weave can be attached to the surface of the fiber weave such that the functionalized textile includes binder particles attached to the surface. The binder particles applied to the surface of the fiber weave can be attached to the fiber weave to form the functionalized textile. Due to the small amount of binder particles applied to the fiber weave as described herein, the functionalized textile includes a fiber weave having binder particles attached to the fiber weave, where the binder particles form discrete binder particles on the surface of the fiber weave (e.g., as opposed to the binder solidifying to form a large patch or layer on the surface of the fiber weave). As used herein, the terms "discrete binder particles" and "discrete binder particles" refer to binder particles attached to the surface of the fiber weave spaced apart from one another, i.e., there is a surface area of ​​the fiber weave that is free of binder particles around each binder particle. In an embodiment, the binder particles attached to the surface of the fiber weave have a longest axial length of less than about 2 mm, for example less than about 1 mm.

[0059] In an embodiment, the binder particles attached to the surface of the functionalized textile have a size distribution such that at least about 90% by weight of the binder particles attached to the surface of the fibrous fabric have a longest axial length of less than about 2 mm, e.g., less than about 1 mm, less than about 800 μm, less than about 700 μm, less than about 600 μm, or less than about 500 μm. In an embodiment, the binder particles attached to the surface of the functionalized textile have a size distribution such that the binder particles attached to the surface of the fibrous fabric have a longest axial length of at least about 1 μm, at least about 10 μm, or at least about 20 μm. In an embodiment, the binder particles attached to the surface of the functionalized textile have a size distribution such that at least about 90% by weight of the binder particles attached to the surface of the fibrous fabric have a longest axial length of at least about 1 μm, at least about 10 μm, or at least about 20 μm.

[0060] In an embodiment, the binder particles attached to the surface of the functionalized textile fabric have a size distribution such that the binder particles attached to the surface of the textile fabric have a longest axial length in the range of about 1 μm to about 1 mm, for example in the range of about 1 μm to about 800 μm.

[0061] In embodiments, the binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least about 90% by weight of the binder particles attached to the surface of the textile fabric have a longest axial length in the range of about 1 μm to about 1 mm, e.g., about 1 μm to about 800 μm, about 10 μm to about 600 μm, or about 10 μm to about 500 μm.

[0062] In embodiments, the binder particles attached to the surface of the functionalized textile have a size distribution such that at least 90% of the binder particles (by particle number) attached to the surface of the fibrous fabric have a longest axial length of less than about 2 mm, e.g., less than about 1 mm, less than about 800 μm, less than about 700 μm, less than about 600 μm, or less than about 500 μm. In embodiments, the binder particles attached to the surface of the functionalized textile have a size distribution such that at least 90% of the binder particles (by particle number) attached to the surface of the fibrous fabric have a longest axial length of at least about 1 μm, at least about 10 μm, or at least about 20 μm. In embodiments, the binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the binder particles (by particle number) attached to the surface of the textile fabric have a longest axial length in the range of about 1 μm to about 1 mm, e.g., about 1 μm to about 800 μm, about 10 μm to about 600 μm, or about 10 μm to about 500 μm.

[0063] The longest axial length of the binder particles of the functionalized textile can be determined by measuring the largest dimension across the binder particles attached to the textile fabric. An optical microscope, such as a Keyence™ optical microscope, can be used to determine the longest axial length of the binder particles attached to the textile fabric. The binder particle size distribution can be determined using an optical microscope (e.g., a Keyence™ optical microscope, e.g., Keyence™ VHX-500) and associated image analysis software (e.g., ImageJ software). The binder particle size distribution is determined using an optical microscope and associated image analysis software (e.g., as described herein) to determine the maximum axial length of the binder particles attached to the textile fabric over a given area (e.g., about 5 mm 2 ~ approx. 50mm2 The area of ​​the functionalized textile in the range of, for example, about 5 mm 2 ~about 20mm 2 The area of ​​functionalized textile in the range of about 5 mm 2 ~about 10mm 2 The binder particle size distribution over a 5 mm area of ​​the functionalized textile can be calculated. In the examples, the binder particle size distribution is determined using an optical microscope and associated image analysis software (e.g., as described herein) to determine the binder particle size distribution over a 5 mm area of ​​the functionalized textile. 2 or 10mm 2 The binder particle size distribution over an area of ​​can be calculated.

[0064] In embodiments, the binder of the functionalized textile fabric can be described as binder particles having a volume average particle size (i.e., after application and attachment / fixation (e.g., by melting) to the textile fabric) that can be determined using a numerical aperture microscope (e.g., Keyence™ VHX-500) and associated image analysis software (e.g., the size of each particle can be determined as the largest dimension across the particle, i.e., the longest axial length of the particle attached to the surface of the textile fabric). In embodiments, the volume average particle size of the binder particles after application and attachment / fixation to the textile fabric ranges from about 10 μm to about 1 mm, e.g., from about 20 μm to about 600 μm, from about 30 μm to about 500 μm.

[0065] In embodiments, the binder of the functionalized textile can be described as binder particles, where the binder particles prior to application to the textile textile have a D90 particle size of less than about 1 mm (i.e., 90% by volume of the particles have a particle size of less than about 1 mm), for example, less than about 800 μm, less than about 600 μm, less than about 500 μm, less than about 400 μm, less than about 300 μm, or less than about 200 μm. The D90 particle size (by volume) can be determined by sieve analysis according to ISO 8130-1.

[0066] In an embodiment, the binder (e.g., binder particles) has a shear modulus G in the range of about 5 to about 50 MPa, e.g., about 5 to about 40 MPa, or about 7 to about 30 MPa at 30° C. The shear modulus G of the binder at 30° C. can be determined using a binder sample having a thickness of 400 μm and a diameter of 25 mm, employing a heat-cool-heat cycle of heating from 30° C. to 130° C. at a rate of 3° C. / min, cooling to 130° C. to 30° C., and heating to 30° C. to 130° C. at a rate of 3° C. / min using an oscillatory rheometer at a frequency of 1 Hz and 0.1% deformation in a planar-planar geometry.

[0067] In an embodiment, the binder (e.g., binder particles) has a dynamic viscosity η in the range of about 1 to about 400 Pa.s, e.g., about 10 to about 400 Pa.s, at 130° C. The dynamic viscosity η of the binder at 130° C. can be determined using a binder sample having a thickness of 400 μm and a diameter of 25 mm, employing a heat-cool-heat cycle of heating from 30° C. to 130° C. at a rate of 3° C. / min, cooling to 130° C. to 30° C., and heating to 30° C. to 130° C. at a rate of 3° C. / min, using an oscillatory rheometer at a frequency of 1 Hz, with 0.1% deformation in a planar-planar geometry.

[0068] In an embodiment, the binder (e.g., binder particles) comprises or consists of a resin containing epoxy functional groups, for example, the binder may be an epoxy resin. In an embodiment, the binder comprises or consists of an epoxy resin having a molecular weight Mw in the range of about 2000 to about 6000, e.g., about 3000 to about 6000, about 4000 to about 6000, or about 4500 to about 5500. In an embodiment, the binder comprises or consists of an epoxy resin having a molecular weight Mw in the range of about 2000 to about 6000 and a polydispersity (wherein the polydispersity is calculated as Mw / Mn) in the range of 1 to 5, e.g., 2 to 4, 2 to 3, or 2.5 to 3. In an embodiment, the binder comprises or consists of an epoxy resin, the epoxy resin being epoxidized BPA or an epoxy novolac. In an embodiment, the binder comprises or consists of an epoxy resin, the epoxy resin being epoxidized BPA.

[0069] In some embodiments, the binder (e.g., binder particles) comprises or consists of a resin containing ester functional groups, for example, the binder may be a polyester resin. In embodiments, the binder comprises or consists of a polyester resin having a molecular weight MW in the range of about 1000 to about 300000. In embodiments, the binder comprises or consists of an unsaturated polyester resin, for example, an aromatic unsaturated polyester resin or an aliphatic unsaturated polyester resin. Examples of suitable polyester-based resins include BPA polyesters, such as BPA fumarate polyesters, for example, alkoxylated (e.g., ethoxylated or propoxylated) BPA fumarate polyesters.

[0070] At least a portion of the binder (e.g., binder particles) of the functionalized textile is present on a surface of the functionalized textile, e.g., at least a portion of the binder of the functionalized textile is disposed on a surface of the fiber fabric or between fibers on a surface of the fiber fabric.

[0071] In embodiments, a majority of the binder (e.g., binder particles) of the functionalized fabric is disposed on a surface of the fiber fabric, for example, in embodiments, at least 50% by weight, such as at least about 60% by weight, at least about 75% by weight, at least about 85% by weight, or at least about 90% by weight, of the binder of the functionalized fabric is disposed on one surface of the fiber fabric.

[0072] In embodiments, the binder of the functionalized textile may be applied to the fiber textile in the form of binder particles (which may also be described as powdered binder particles), a dispersion containing the binder, or a solution containing the binder.

[0073] In embodiments, the binder of the functionalized fabric may infiltrate the fiber fabric. In embodiments, the functionalized fabric may include a binder, e.g., binder particles, within the fiber fabric.

[0074] Functionalized textiles The functionalized fabric of the present invention includes a woven fiber fabric as described herein and a binder (eg, binder particles) as described herein.

[0075] The binder (e.g., binder particles) comprises up to about 5% by weight of the functionalized textile. In embodiments, the binder comprises up to about 5.0% by weight of the functionalized textile, e.g., up to about 4.5% by weight, up to about 4.0% by weight, or up to about 3.5% by weight of the functionalized textile. In embodiments, the binder comprises at least about 0.1% by weight of the functionalized textile, e.g., at least about 0.2% by weight, or at least about 0.3% by weight of the functionalized textile. In embodiments, the binder comprises between about 0.1% and about 5.0% by weight of the functionalized textile, e.g., between about 0.1% and about 4.0% by weight, or between about 0.2% and about 3.5% by weight of the functionalized textile.

[0076] In embodiments, the glass fibers constitute at least about 50% by weight of the functionalized fabric, e.g., at least about 60% by weight of the functionalized fabric, at least about 70% by weight of the functionalized fabric, at least about 80% by weight of the functionalized fabric, or at least about 90% by weight of the functionalized fabric.

[0077] In an embodiment, the functionalized textile has a thickness of up to about 30 g / m 2 of binder (e.g., binder particles), e.g., up to about 25 g / m 2 , maximum about 20g / m 2 , maximum about 18g / m 2 , maximum about 16g / m 2 , maximum about 15g / m 2 , or up to about 13 g / m 2 In an embodiment, the functionalized textile comprises at least about 2 g / m 2 of binder, e.g. at least about 4 g / m 2 , at least about 5 g / m 2 , at least about 7 g / m 2 , at least about 8 g / m 2 , or at least about 10 g / m 2 In an embodiment, the functionalized textile comprises about 2 g / m2 ~about 30g / m 2 of binder, e.g., about 4 g / m 2 ~about 25g / m 2 , about 4g / m 2 ~Approx. 15g / m 2 , about 7g / m 2 ~Approx. 13g / m 2 , or about 10 g / m 2 ~Approx. 13g / m 2 The binder is

[0078] In embodiments, the functionalized textile includes a binder (e.g., binder particles) disposed on a surface of the textile fabric. The textile fabric can be described as a generally two-dimensional fabric having an upper surface and a lower surface. In embodiments, the functionalized textile has one surface having binder particles disposed thereon and another surface that is substantially free of binder particles (e.g., about 0.1 g / m 2 The fabric may include a woven fiber having a surface containing less than about 1000 μm of binder particles.

[0079] In embodiments, the functionalized fabric may include binder particles within the fiber fabric.

[0080] The functionalized textile comprises a fiber fabric and a binder (e.g., binder particles), the binder being attached to the fiber fabric. In an embodiment, the binder is attached to the fiber fabric, e.g., the surface of the fiber fabric. In an embodiment, the binder may be attached to the fiber fabric by a suitable treatment, e.g., heating, curing, or exposure to UV radiation. In an embodiment, the binder is attached to the fiber fabric, e.g., the surface of the fiber fabric, by heating such that the binder melts or at least partially melts, e.g., at least partially melts on the surface of the fiber fabric. For example, the functionalized textile may comprise a solid binder, e.g., solid binder particles, attached to the fiber fabric, the binder, e.g., binder particles, applied to the fiber fabric being previously softened or at least partially melted. The inventors have found that because the amount of binder (e.g., binder particles) applied to the fiber fabric is small, even after the binder is melted, discrete areas of the binder (which may be referred to as binder particles or separate binder particles) are provided in the functionalized textile, e.g., on the surface of the functionalized textile. 2 is a 3D microscope image of an example of a functionalized textile as described herein, showing that the binder particles applied to the surface of the textile fabric and then melted and solidified do not solidify to form a layer on the textile surface, but can instead be seen as separate binder particles. The term "separate binder particles" or "discrete binder particles" may be used herein to describe binder particles attached to the textile fabric having a size distribution as described herein. As explained above, the terms "separate binder particles" and "discrete binder particles" refer to binder particles attached to the surface of the textile fabric spaced apart from one another, i.e., there is a surface area of ​​the textile fabric free of binder particles around each binder particle.

[0081] The inventors have found that the functionalized textile described herein, which includes a textile fabric having about 5% by weight or less of a binder (e.g., binder particles) attached to the textile fabric (relative to the total weight of the functionalized textile fabric), can be described as including a textile fabric having a surface to which the binder (e.g., binder particles) is permanently attached. The term "permanently attached" is used herein to refer to a binder (e.g., binder particles) that cannot be removed from the textile fabric by abrasion (e.g., after the abrasion test described in the Examples section below). The binder (e.g., binder particles) can be permanently attached to the surface of the textile fabric by softening or at least partially melting the binder on the surface of the textile fabric, as described herein. For example, following a scrub test carried out according to ISO 11998-2006 (using an Elcometer 1720 Abrasion Tester) without liquid and using a microfibre fabric or a Scotch-Brite™ 7446 type pad as abrasive pad (the abrasive pad with holder weighs 455 g, the scrubbed surface is 300 mm long and 200 runs (back and forth) are carried out), if no effect on the binder adhesion is observed and no weight loss occurs, the binder is considered to be permanently attached to the surface of the fibre fabric.

[0082] In an embodiment, the functionalized textile comprises binder particles attached to a surface of the woven fiber fabric. For example, the functionalized textile may comprise solid binder particles attached to the woven fiber fabric, the binder particles being pre-softened or at least partially melted on the surface of the woven fiber fabric.

[0083] In embodiments, the functionalized fabrics described herein may be impregnated with a resin, and the resin may be cured to form a composite article.

[0084] In an embodiment, the functionalized textile comprises: Fiber fabrics, and binder particles having a glass transition temperature of up to about 75° C.; Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; The binder particles comprise from about 0.1% to about 3.5% by weight of the functionalized fabric, and the functionalized fabric has a mass of from about 2 to about 30 g / m 2 the binder particles being attached to a surface of the fiber fabric; The binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the total number of binder particles attached to the surface of the textile fabric have a longest axial length in the range of about 1 μm to about 1 mm.

[0085] In an embodiment, the functionalized textile comprises: Fiber fabrics, and binder particles having a glass transition temperature of up to about 75° C.; Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; The binder particles may comprise from about 0.1% to about 3.5% by weight of the functionalized fabric, and the functionalized fabric may have a mass of from about 2 to about 20 g / m 2 the binder particles being attached to a surface of the fiber fabric; The binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the total number of binder particles attached to the surface of the textile fabric have a longest axial length in the range of about 1 μm to about 1 mm.

[0086] In an embodiment, the functionalized textile comprises: Fiber fabrics, and binder particles having a glass transition temperature in the range of about 40°C to about 70°C; Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; The binder particles comprise from about 0.1% to about 3.5% by weight of the functionalized fabric, and the functionalized fabric has a mass of from about 2 to about 20 g / m 2 the binder particles being attached to a surface of the fiber fabric; The binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the total number of binder particles attached to the surface of the textile fabric have a longest axial length in the range of about 10 μm to about 1 mm.

[0087] In an embodiment, the functionalized textile comprises: Fiber fabrics, and binder particles having a glass transition temperature in the range of about 40°C to about 70°C; Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; The binder particles comprise from about 0.1% to about 3.5% by weight of the functionalized fabric, and the functionalized fabric has a mass of from about 2 to about 20 g / m 2 the binder particles being attached to a surface of the fiber fabric; The binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the total number of binder particles attached to the surface of the textile fabric have a longest axial length in the range of about 10 μm to about 800 μm.

[0088] In an embodiment, the functionalized textile comprises: Fiber fabrics, and binder particles having a glass transition temperature in the range of about 40°C to about 70°C; Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; The binder particles comprise from about 0.1% to about 3.5% by weight of the functionalized fabric, and the functionalized fabric has a mass of from about 2 to about 20 g / m 2 the binder particles being attached to a surface of the fiber fabric; The binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the total number of binder particles attached to the surface of the textile fabric have a longest axial length in the range of about 10 μm to about 600 μm.

[0089] In an embodiment, the functionalized textile comprises: Fiber fabrics, and binder particles having a glass transition temperature in the range of about 40°C to about 70°C; Fiber fabrics are first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers include glass fibers and / or carbon fibers, the second fibers include glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; The binder particles comprise from about 0.1% to about 3.5% by weight of the functionalized fabric, and the functionalized fabric has a mass of from about 2 to about 20 g / m 2 the binder particles being attached to a surface of the fiber fabric; The binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the total number of binder particles attached to the surface of the textile fabric have a longest axial length in the range of about 20 μm to about 500 μm.

[0090] In an embodiment, at least about 80% by weight of the binder (e.g., binder particles) is disposed on one surface of the functionalized woven fiber fabric, e.g., at least about 85%, at least about 90%, or at least about 95% by weight of the binder (e.g., binder particles) is disposed on one surface of the functionalized woven fiber fabric. For example, the functionalized woven fiber fabric may include a woven fiber fabric having a first surface on which at least about 80% by weight (e.g., at least about 90% by weight or at least about 95% by weight) of the binder (e.g., binder particles) is disposed and a second surface that is substantially free of binder (e.g., less than 5% by weight of the binder (e.g., binder particles) is disposed on the second surface of the woven fiber fabric, e.g., less than 3%, less than 2%, less than 1%, or less than 0.5% by weight of the binder (e.g., binder particles) is disposed on the second surface of the woven fiber fabric).

[0091] In an embodiment, the functionalized textile has a surface having at least some binder (e.g., binder particles) present, and the surface has an average gloss value of about 65 G.U. or less, such as about 60 G.U. or less. In an embodiment, the functionalized textile has a surface having at least some binder present, and the surface has an average gloss value in the range of about 20 G.U. to about 65 G.U., such as 25 G.U. to about 65 G.U., or about 25 G.U. to about 60 G.U.

[0092] In embodiments, a functionalized textile comprising a binder (e.g., binder particles) has a surface with an average gloss value that is at least about 10 G.U. lower than the textile fabric prior to application of the binder, e.g., at least about 15 G.U. lower, at least about 20 G.U. lower, or at least about 25 G.U. lower than the textile fabric prior to application of the binder. When comparing the average gloss value of a surface of a functionalized textile fabric with the average gloss value of a surface of a textile fabric, the same surface of the textile fabric should be considered alone or as part of a functionalized textile fabric comprising a binder.

[0093] In an embodiment, the functionalized textile comprises a unidirectional fiber fabric and a binder, the functionalized textile having a surface on which at least a portion of the binder (e.g., binder particles) is present having an average gloss value of about 65 G.U. or less, e.g., about 60 G.U. or less, about 50 G.U. or less. In an embodiment, the functionalized textile comprises a unidirectional fiber fabric and a binder, the functionalized textile having a surface on which at least a portion of the binder is present having an average gloss value in the range of about 25 to about 65 G.U., e.g., about 25 G.U. to about 60 G.U. or less, or about 25 G.U. to about 50 G.U.

[0094] In an embodiment, the functionalized fabric has a thickness of 1200 g / m 2 Larger area weight (e.g., about 1300 g / m 2 ~about 2500g / m 2 The functionalized textile includes a fiber fabric having an average gloss value in the range of about 25 G.U. to about 60 G.U. (area weight in the range of about 25 G.U. to about 60 G.U.), and a binder, the functionalized textile having a surface on which at least a portion of the binder (e.g., binder particles) is present having an average gloss value in the range of about 25 G.U. to about 60 G.U.

[0095] In an embodiment, the functionalized fabric includes a biaxial fiber fabric and a binder, and the functionalized fabric has a surface having an average gloss value in the range of about 25 G.U. to about 65 G.U., where at least a portion of the binder (e.g., binder particles) is present.

[0096] In an embodiment, the functionalized fabric has a thickness of 1200 g / m 2 Larger area weight (e.g., about 1300 g / m 2 ~about 2500g / m 2 The functionalized textile includes a fiber fabric having an average gloss value in the range of about 25 G.U. to about 60 G.U., where at least a portion of the binder (e.g., binder particles) is present.

[0097] In an embodiment, the functionalized fabric has a mass of about 1300 g / m 2 Area weight of less than (e.g., about 500 g / m 2 ~Approx. 1300g / m 2The functionalized fabric includes a biaxial fiber fabric having an areal weight in the range of about 25 G.U. to about 65 G.U., where at least a portion of the binder (e.g., binder particles) is present.

[0098] In an embodiment, the functionalized fabric has a mass of about 1300 g / m 2 Area weight of less than (e.g., about 500 g / m 2 ~Approx. 1300g / m 2 The functionalized fabric includes a biaxial fiber fabric having an areal weight in the range of about 25 G.U. to about 65 G.U., where at least a portion of the binder (e.g., binder particles) is present.

[0099] The average gloss value of the textile may be determined for the surface of the textile, for example, the surface including at least a portion of the binder (e.g., binder particles) of the functionalized textile. The gloss value may be determined using a spectrophotometer (e.g., X-Rite Ci7600 spectrophotometer), for example, a spectrophotometer that allows for simultaneous measurement of the specular component excluded (SCE) and specular component included (SCI) components to provide a correlated gloss value. The average gloss value may be obtained by placing the textile on a neutral support and obtaining gloss values ​​for several, for example, 10 spots across the textile to provide an average gloss value. In an embodiment, the spectrophotometer (e.g., X-Rite Ci7600 Spectrophotometer) may be set up with the following settings: Geometry D\8°-Tribeam Simultaneous SCE / SCI (SPEX / SPIN), Irradiation-Pulsed Xenon, D65 Calibration, and Aperture Diameter 25 mm. The average gloss value may be provided for a 25 mm diameter sample of the functionalized textile.

[0100] Woven Stack The textile stack includes at least two layers of the functionalized textile described herein.

[0101] In an embodiment, the textile stack comprises at least two layers of functionalized textile as described herein, where one layer of functionalized textile is disposed directly on another layer of functionalized textile. In an embodiment, the textile stack comprises at least three layers of functionalized textile as described herein, e.g., at least four layers, at least six layers, or at least eight layers of functionalized textile as described herein. In an embodiment, the textile stack comprises up to 50 layers of functionalized textile as described herein, e.g., up to 30 layers, up to 25 layers, up to 20 layers, up to 15 layers, up to 10 layers of functionalized textile as described herein. In an embodiment, the textile stack comprises 2-50 layers of functionalized textile as described herein, e.g., 4-30 layers, or 6-25 layers of functionalized textile as described herein. In an embodiment, the textile stack comprises multiple layers of functionalized textile as described herein, where each of the multiple layers of functionalized textile is disposed directly on another of the multiple layers of functionalized textile.

[0102] In an embodiment, the textile stack includes multiple layers of functionalized textile as described herein, each of the multiple layers of functionalized textile being disposed directly on another layer of the multiple layers of functionalized textile, each of the multiple layers of functionalized textile having one surface on which a binder (e.g., binder particles) is disposed and another surface that is substantially free of binder, and each of the multiple functionalized textiles are stacked such that the surface of each of the multiple functionalized textiles on which a binder is disposed is disposed directly on the surface of another layer of the multiple layers of functionalized textile that is substantially free of binder.

[0103] In an embodiment, the layers of the woven stack are attached to one another. A woven stack in which the layers of the woven stack are attached to one another may be referred to herein as a "consolidated woven stack."

[0104] In embodiments, the layers of the textile stack may be attached to each other by a suitable treatment, such as, for example, heating, curing, or exposure to UV radiation. In embodiments, the layers of the textile stack may be attached to each other by heating the textile stack such that the binder particles of the first layer of functionalized textile adhere the first layer of functionalized textile to the second layer of functionalized textile. In embodiments, the layers of the textile stack may be attached to each other by heating the textile stack to a temperature above the glass transition temperature of the binder, for example, at least about 5° C. above the glass transition temperature of the binder, at least about 10° C. above the glass transition temperature of the binder, or at least about 15° C. above the glass transition temperature of the binder. In embodiments, the layers of the textile stack may be attached to each other by heating the textile stack to a temperature above the softening temperature of the binder, for example, at least about 5° C. above the softening temperature, at least about 10° C. above the softening temperature, or at least about 15° C. above the softening temperature. In embodiments, the layers of the textile stack may be attached to one another by heating the textile stack to a temperature above the melting temperature of the binder. In embodiments, the layers of the textile stack may be attached to one another by heating the textile stack to a temperature of at least about 50° C., e.g., at least about 60° C., at least about 70° C., at least about 80° C., at least about 90° C., or at least about 100° C. In embodiments, the layers of the textile stack may be attached to one another by heating the textile stack to a temperature of up to about 150° C., e.g., up to about 130° C., or up to about 120° C. In embodiments, the layers of the textile stack may be attached to one another by heating the textile stack to a temperature in the range of about 50° C. to about 150° C., e.g., from about 70° C. to about 130° C., or from about 80° C. to about 120° C. In embodiments, the layers of the textile stack may be attached to one another by heating the textile stack as described above for about 1 minute or more, e.g., up to about 1 hour, e.g., from about 1 to about 10 minutes.

[0105] In an embodiment, providing a consolidated textile stack may include adhering layers of the textile stack to one another. In an embodiment, the layers of the textile stack may be adhered to one another by exposing the textile stack to a temperature of up to about 150° C. and a pressure less than atmospheric, for example, a pressure in the range of about 500 mbar to about 1000 mbar, or about 600 mbar to about 1000 mbar, about 700 mbar to about 1000 mbar, about 750 mbar to about 1000 mbar, about 800 mbar to about 1000 mbar, or about 900 mbar. In an embodiment, the textile stack is exposed to elevated temperature (i.e., heated) and / or reduced pressure for a period of up to about 5 hours, for example, up to about 3 hours, up to about 2 hours, or up to about 1 hour, to form the consolidated textile stack. In an embodiment, the textile stack is exposed to elevated temperature (i.e., heated) and / or reduced pressure for at least about 10 minutes, for example, at least about 30 minutes, to form the consolidated textile stack. In embodiments, the woven stack is exposed to elevated temperature (i.e., heat) and / or reduced pressure for a period of from about 10 minutes to about 5 hours, such as from about 30 minutes to about 2 hours, or from about 30 minutes to about 1 hour, to form a consolidated woven stack.

[0106] In embodiments, the woven stack or consolidated woven stack described herein may be impregnated with a resin and the resin cured to form a composite article.

[0107] Process for fabricating functionalized textiles The process for producing functionalized textiles includes: Providing a fiber fabric as described herein; The method can include applying binder particles having a glass transition temperature of up to about 75° C. to a fibrous fabric, and adhering the binder particles to the fibrous fabric to provide a functionalized fabric, wherein the binder is applied to the fibrous fabric in an amount such that the binder comprises up to about 5% by weight of the functionalized fabric.

[0108] The process for producing functionalized textiles includes: Providing a fiber fabric as described herein; applying a binder (e.g., binder particles) described herein to a fiber fabric to provide a functionalized fabric; and applying a binder to the fiber web, A binder is applied to the fiber fabric in an amount such that the binder comprises up to about 5% by weight of the functionalized fabric; The functionalized textile has a surface on which at least a portion of the binder is present that has an average gloss value of about 65 G.U. or less.

[0109] In an embodiment, the process involves applying a binder (e.g., binder particles) to a woven fiber fabric to provide a binder of up to about 30 g / m 2 , for example, up to about 20 g / m 2 , maximum about 25g / m 2 , maximum about 18g / m 2 , maximum about 16g / m 2 , maximum about 15g / m 2 , or up to about 13 g / m 2 In an embodiment, the process includes applying a binder to the fiber fabric to provide a functionalized fabric having a binder distribution of at least about 2 g / m 2 , e.g., at least about 4 g / m 2 , at least about 5 g / m 2 , at least about 7 g / m 2 , at least about 8 g / m 2 , or at least about 10 g / m 2 In an embodiment, the process includes applying a binder to the fiber fabric to provide a functionalized textile having a binder distribution of about 2 g / m 2 ~about 30g / m 2 , for example, about 4 g / m 2 ~about 20g / m 2 , about 4g / m 2 ~Approx. 15g / m 2 , about 7g / m 2 ~Approx. 13g / m 2 , or about 10 g / m 2 ~Approx. 13g / m 2 The present invention relates to a method for producing a functionalized textile having a binder distribution in the range of 0.1 to 1.0 μm.

[0110] In an embodiment, the binder (e.g., binder particles) is applied to the fiber fabric in an amount such that the binder comprises up to about 5% by weight of the functionalized fabric. In an embodiment, the binder comprises up to about 5.0% by weight of the functionalized fabric, e.g., up to about 4.5% by weight, up to about 4.0% by weight, or up to about 3.5% by weight of the functionalized fabric. In an embodiment, the binder comprises at least about 0.1% by weight of the functionalized fabric, e.g., at least about 0.2% by weight, or at least about 0.3% by weight of the functionalized fabric. In an embodiment, the binder comprises between about 0.1% and about 5.0% by weight of the functionalized fabric, e.g., between about 0.1% and about 4.0% by weight, or between about 0.2% and about 3.5% by weight of the functionalized fabric.

[0111] In embodiments, the binder is applied to the surface of the fiber fabric, for example, by scattering binder particles across the surface of the fiber fabric.

[0112] In an embodiment, the binder is applied to the surface of the fiber fabric as binder particles. The binder particles applied to the fiber fabric may have a volume average particle size of up to about 1 mm, for example up to about 800 μm, up to about 600 μm, up to about 500 μm, up to about 400 μm, up to about 300 μm, or up to about 200 μm. In an embodiment, the binder particles applied to the fiber fabric have a volume average particle size of more than about 10 μm, for example more than about 20 μm or more, more than about 30 μm, more than about 40 μm, or more than about 50 μm. In an embodiment, the binder particles applied to the fiber fabric have a volume average particle size in the range of about 10 μm to about 1 mm, for example, about 20 μm to about 600 μm, about 30 μm to about 500 μm, about 40 μm to about 400 μm, or about 50 μm to about 300 μm. The volume average particle size of the binder particles applied to the fiber fabric can be determined using dynamic light scattering techniques on a dispersion of the binder particles before application to the fiber fabric. A particle size analyzer such as the Beckman™ LS13320 Particle Size Analyzer can be employed to determine the volume average particle size by laser diffraction according to the ISO 13320 2009 standard (i.e., using dynamic light scattering techniques on a dispersion of the binder particles before application to the fiber fabric). Samples can be analyzed twice as received and after dispersion in air, and the amount of sample is typically about 20 g per test.

[0113] In an embodiment, the binder (e.g., binder particles) may be attached to the fiber weave by a suitable treatment, such as, for example, heating, curing, or exposure to UV radiation. In an embodiment, the process includes heating the functionalized fabric to attach the binder to the fiber weave. In an embodiment, the method includes heating the binder to attach the binder to the fiber weave. In an embodiment, heating the binder / functionalized fabric to attach the binder to the fiber weave includes heating the functionalized fabric to a temperature above the glass transition temperature of the binder, such as at least about 5° C. above the glass transition temperature of the binder, at least about 10° C. above the glass transition temperature of the binder, or at least about 15° C. above the glass transition temperature of the binder. In an embodiment, heating the binder / functionalized fabric to attach the binder to the fiber weave includes heating the functionalized fabric to a temperature above the softening temperature of the binder, such as at least about 5° C. above the softening temperature, at least about 10° C. above the softening temperature, or at least about 15° C. above the softening temperature. In an embodiment, heating the binder / functionalized fabric to attach the binder to the fiber fabric comprises heating the functionalized fabric to a temperature above the melting temperature of the binder. In an embodiment, heating the binder / functionalized fabric to attach the binder to the fiber fabric comprises heating the functionalized fabric to a temperature of at least about 50° C., such as at least about 60° C., at least about 70° C., at least about 80° C., at least about 90° C., or at least about 100° C. In an embodiment, heating the binder / functionalized fabric to attach the binder to the fiber fabric comprises heating the functionalized fabric to a temperature of up to about 150° C., such as up to about 130° C., or up to about 120° C. In an embodiment, heating the binder / functionalized fabric to attach the binder to the fiber fabric comprises heating the functionalized fabric to a temperature in the range of about 50° C. to about 150° C., such as from about 70° C. to about 130° C., or from about 80° C. to about 120° C. In embodiments, heating the binder / functionalized fabric to adhere the binder to the fiber fabric includes heating the functionalized fabric described above for about 1 minute or more, such as up to about 1 hour, for example, from about 1 to about 10 minutes.

[0114] In embodiments, the binder particles attached to the surface of the functionalized textile have a size distribution such that at least 90% of the binder particles (by particle number) attached to the surface of the fibrous fabric have a longest axial length of less than about 2 mm, e.g., less than about 1 mm, less than about 800 μm, less than about 700 μm, less than about 600 μm, or less than about 500 μm. In embodiments, the binder particles attached to the surface of the functionalized textile have a size distribution such that at least 90% of the binder particles (by particle number) attached to the surface of the fibrous fabric have a longest axial length of at least about 1 μm, at least about 10 μm, or at least about 20 μm. In embodiments, the binder particles attached to the surface of the functionalized textile have a size distribution such that at least 90% of the binder particles (by particle number) attached to the surface of the textile fabric have a longest axial length in the range of about 1 μm to about 1 mm, such as about 1 μm to about 800 μm, about 10 μm to about 600 μm, or about 10 μm to about 500 μm. The binder particle size distribution can be determined as described herein.

[0115] For example, in embodiments in which the binder is applied to the fiber fabric in the form of a binder-containing dispersion or binder-containing solution, applying and / or depositing the binder on the fiber fabric may include evaporating a liquid component of the binder or binder-containing solution.

[0116] Molded parts The molded part includes a woven stack (eg, a consolidated woven stack) as described herein.

[0117] The molded parts are a) providing a textile stack as described herein; b) forming a woven stack; and c) heating the fabric stack at a temperature up to about 150°C.

[0118] In an embodiment, shaping the woven stack involves placing the woven stack (e.g., a consolidated woven stack) over or into a mold. In an embodiment, shaping the woven stack involves placing the woven stack (e.g., a consolidated woven stack) over or into a mold and applying increased heat and / or reduced pressure to the woven stack.

[0119] In an embodiment, providing the molded part includes molding the woven stack (e.g., the consolidated woven stack) and heating the woven stack (e.g., the consolidated woven stack) at a temperature of at least about 50° C., e.g., at least about 60° C., at least about 70° C., at least about 80° C., at least about 90° C., or at least about 100° C. In an embodiment, providing the molded part includes molding the woven stack (e.g., the consolidated woven stack) and heating the woven stack (e.g., the consolidated woven stack) at a temperature of up to about 150° C., e.g., up to about 130° C., or up to about 120° C. In an embodiment, providing the molded part includes molding the woven stack (e.g., the consolidated woven stack) and heating the woven stack (e.g., the consolidated woven stack) at a temperature in a range of about 50° C. to about 150° C., e.g., about 70° C. to about 130° C., or about 80° C. to about 120° C.

[0120] In an embodiment, fabricating the molded part may include molding the woven stack and heating the woven stack at a temperature of up to about 150° C. and a pressure less than atmospheric pressure, for example, at a pressure in the range of about 500 mbar to about 1000 mbar, or about 600 mbar to about 1000 mbar, about 700 mbar to about 1000 mbar, about 750 mbar to about 1000 mbar, about 800 mbar to about 1000 mbar, or about 900 mbar.

[0121] In an embodiment, the textile stack is exposed to elevated temperature (i.e., heating) and / or reduced pressure for a period of up to about 5 hours, e.g., up to about 3 hours, up to about 2 hours, or up to about 1 hour, to form a molded article. In an embodiment, the textile stack is exposed to elevated temperature (i.e., heating) and / or reduced pressure for at least about 10 minutes, e.g., at least about 30 minutes, to form a molded article. In an embodiment, the textile stack is exposed to elevated temperature (i.e., heating) and / or reduced pressure for a period of from about 10 minutes to about 5 hours, e.g., from about 30 minutes to about 2 hours, or from about 30 minutes to about 1 hour.

[0122] In embodiments, the molded parts described herein may be impregnated with a resin and the resin cured to form a composite article.

[0123] In embodiments, the binder is selected to be compatible with the resin used to form the composite article. For example, an epoxy-compatible (e.g., epoxy-based binder) binder can be selected if the functionalized textile is to be incorporated into a composite article that includes an epoxy resin. For example, a polyester-compatible (e.g., polyester-based binder) binder can be selected if the functionalized textile is to be incorporated into a composite article that includes a polyester resin. The binder may be selected such that the binder is soluble in the resin used to form the composite article.

[0124] The functionalized textiles described herein may be stacked in a manner that allows multiple textile stacks to be connected / joined to each other. The manner in which the functionalized textile layers are stacked can provide different joint types by which the multiple textile stacks can be connected / joined to each other. In an example, the functionalized textile layers may be stacked directly on top of each other (i.e., with the edges of the functionalized textile of each layer directly on top of each other), and two or more textile stacks (e.g., consolidated textile stacks) are joined to each other such that the edges of one textile stack abut the edges of the second textile stack (butt joint). In another example, the functionalized textile layers may be stacked such that at least one (in some examples, at least two or at least three layers of functionalized textile) overlaps the or each underlying layer of functionalized textile, and the two textile stacks thus formed may then be joined by a lap joint. In another example, multiple functionalized textile layers may be stacked to form a hole (tenon) at the joined edge of the textile stack, and the joined textile stack may include multiple layers of functionalized textile stacked such that a protrusion of one textile stack fits into a hole of the other textile stack (tenon joint) to form a protrusion (tenon) at the joined edge of the textile stack.

[0125] The tongue-and-groove connections described herein can be considered similar to tongue-and-groove type joints commonly used in woodworking and construction. The concept involves creating a protruding tongue on one textile stack (e.g., a consolidated textile stack) and forming a corresponding groove or slot on another textile stack (e.g., a consolidated textile stack). When the two (or more) textile stacks are assembled (i.e., connected / joined), the tongue fits snugly into the groove, creating a strong and secure joint that resists torsional and tensile forces. The use of such tongue-and-groove connections between textile stacks has been found to provide improvements in the assembly of composite articles formed from textile stacks (including consolidated textile stacks and molded parts) by reducing slippage of the textile stacks during assembly, which also reduces wrinkling in the resulting composite article.

[0126] In an embodiment, a woven stack (which may be a consolidated woven stack or may be formed into a molded part) includes a plurality of functionalized woven layers as described herein, where the plurality of functionalized woven layers are stacked such that at least one edge of the woven stack forms a groove configuration (female) or a tongue configuration (male).

[0127] In an embodiment, a woven stack (which may be a consolidated woven stack or formed into a molded part) includes a plurality of functionalized woven layers as described herein, stacked such that one edge of the woven stack forms a groove configuration (female) and an opposing edge of the woven stack forms a tongue configuration (male). Figures 3a and 3b show a cross-section of a woven stack in which a plurality of functionalized woven layers are stacked such that one edge of the woven stack forms a groove "G" configuration (female) and an opposing edge of the woven stack forms a tongue "T" configuration (male).

[0128] In an embodiment, A textile stack (the textile stack may be a consolidated textile stack or may be formed into a molded part) comprising a plurality of functionalized textile layers as described herein, wherein the plurality of functionalized textile layers are stacked such that at least one edge of the textile stack forms a groove configuration (female); A textile stack (the textile stack may be a consolidated textile stack or may be formed into a molded part) comprising a plurality of functionalized textile layers as described herein, wherein the plurality of functionalized textile layers are stacked such that at least one edge of the textile stack forms a tongue configuration (male); a fabric stack, the tongue arrangement configured to mate with the groove arrangement.

[0129] The woven stack (which may be a consolidated woven stack or may be formed into a molded part as described herein) includes multiple layers of functionalized woven fabric as described herein. The woven stack (which may be a consolidated woven stack or may be formed into a molded part as described herein) includes layers stacked such that at least one edge of the woven stack forms a groove configuration (female) or a tongue-and-groove configuration (male) is formed from at least three layers of functionalized woven fabric. The woven stack (which may be a consolidated woven stack or may be formed into a molded part as described herein) includes layers stacked such that at least one edge of the woven stack forms a groove configuration (female) or a tongue-and-groove configuration (male) can be considered to be formed from at least one top layer of functionalized woven fabric, at least one middle layer of functionalized woven fabric, and at least one bottom layer of functionalized woven fabric. In an embodiment, a woven stack (which may be a consolidated woven stack or may be formed into a molded part as described herein) including layers stacked such that at least one edge of the woven stack forms a groove configuration (female) or a tongue-in-cheek configuration (male) can be considered to be formed from at least one top layer of functionalized woven fabric, multiple middle layers of functionalized woven fabric, and at least one bottom layer of functionalized woven fabric. In an embodiment, a woven stack (which may be a consolidated woven stack or may be formed into a molded part as described herein) including layers stacked such that at least one edge of the woven stack forms a groove configuration (female) or a tongue-in-cheek configuration (male) can be considered to be formed from multiple top layers of functionalized woven fabric, multiple middle layers of functionalized woven fabric, and multiple bottom layers of functionalized woven fabric. A "groove configuration" includes a recess formed along one edge of the woven stack, the recess or depression being formed by the location of at least one middle layer of functionalized woven fabric, or multiple middle layers of functionalized woven fabric. Examples of groove configurations can be seen in Figures 3a and 3b, where the groove configuration is marked with a "G".In an embodiment, the "groove configuration" may be a stepped groove configuration formed by multiple intermediate layers of the textile stack. An example of a stepped groove configuration can be seen in FIG. 3b, where the stepped groove configuration is marked with "G". The "tongue configuration" includes a protrusion formed along one edge of the textile stack, where the protrusion is formed by the location of at least one intermediate layer of functionalized textile, or multiple intermediate layers of functionalized textile. An example of a tongue configuration can be seen in FIG. 3a and FIG. 3b, where the tongue configuration is marked with "T". In an embodiment, the "tongue configuration" may be a stepped tongue configuration formed by multiple intermediate layers of the textile stack. An example of a stepped tongue configuration can be seen in FIG. 3b, where the stepped groove configuration is marked with "T".

[0130] In an embodiment, the groove (the recess formed by the location of at least one intermediate layer of the functionalized textile in the textile stack or molded part) is composed of at least two layers of the functionalized textile as defined herein, e.g., at least three layers of the functionalized textile as defined herein, at least four layers of the functionalized textile, or five or more layers of the functionalized textile.

[0131] In an embodiment, the tongue (the protrusion formed by the location of at least one intermediate layer of functionalized textile in the textile stack or molded part) is composed of at least two layers of functionalized textile as defined herein, e.g., at least three layers of functionalized textile as defined herein, at least four layers of functionalized textile, or five or more layers of functionalized textile.

[0132] In an embodiment, the functionalized textile intermediate layer of the textile stack (the layer of functionalized textile of the textile stack positioned to form a tongue and / or groove configuration of the textile stack) is formed from at least two layers of functionalized textile, e.g., at least three layers of functionalized textile, at least four layers of functionalized textile as defined herein, or five or more layers of functionalized textile as defined herein. In an embodiment, the functionalized textile intermediate layer of the textile stack is formed from 2 to 10 layers of functionalized textile.

[0133] In an embodiment, the top layer of the functionalized textile of the textile stack is formed from at least two layers of functionalized textile, for example at least three layers of functionalized textile, at least four layers of functionalized textile as defined herein, or five or more layers of functionalized textile as defined herein, in an embodiment, the top layer of the functionalized textile of the textile stack is formed from 2 to 5 layers of functionalized textile.

[0134] In an embodiment, the functionalized textile bottom layer of the textile stack is formed from at least two layers of functionalized textile, for example at least three layers of functionalized textile, at least four layers of functionalized textile as defined herein, or five or more layers of functionalized textile as defined herein, in an embodiment, the functionalized textile bottom layer of the textile stack is formed from 2 to 5 layers of functionalized textile.

[0135] Also provided herein is a process for forming a subcomponent article, e.g., a subcomponent for a wind turbine blade, comprising a woven stack or a molded part, the process comprising: Providing a plurality of functionalized textile layers as described herein; The method includes stacking a plurality of functionalized textile layers to form a first textile stack edge having a groove configuration and a second textile stack edge having a tongue configuration, the second textile stack edge facing the first textile stack edge.

[0136] Also described herein is a process for joining at least two woven stacks or molded parts as described herein, the process comprising: providing a first woven stack as described herein having a stack edge with a groove configuration and a second woven stack as described herein having a stack edge with a tongue configuration; Positioning the first and second woven stacks adjacent to one another within the mold such that a tongue of the second woven stack is inserted into a groove of the first woven stack. EXAMPLES

[0137] The following illustrate examples of the textiles and related aspects described herein, and therefore should not be construed as limiting the disclosure, but are merely intended to teach how to carry out the methods and obtain the products of the disclosure.

[0138] Functionalized textiles were fabricated by applying various amounts of binder to one surface of different fiber textiles. The materials used are described below, and Table 1 summarizes each of the example functionalized textiles.

[0139] Fiber fabrics used in the examples All of the fiber fabrics used in the examples were non-crimped fabrics and contained first fibers of glass and second fibers of glass, the first and second fibers being held in their respective orientations by sutures. The glass fibers making up the fiber fabrics contained an epoxy compatible sizing agent.

[0140] The unidirectional fiber fabrics used in these examples (referred to as "UD" in the tables below) contain second fibers (glass fibers) that make up to about 5% by weight of the fiber fabric, with first fibers (glass fibers) that make up at least 95% by weight of the fiber fabric, and the second direction is substantially perpendicular to the first direction. The unidirectional fabrics are referred to as "UD0" and "UD90", with the UD0 fabric containing first fibers oriented in the 0 direction (i.e. aligned to the length of the fabric) and the UD90 fabric containing first fibers oriented in the 90 direction (i.e. perpendicular to the length of the fabric).

[0141] The biaxial fiber fabrics used in these examples contain second fibers (glass fibers) that constitute at least about 15% by weight of the fiber fabric, with the second direction being either substantially perpendicular to the first direction (these fabrics are designated "BX90" in the tables below) or at about 45 degrees to the first direction (these fabrics are designated "BX45" in the tables below).

[0142] The inventors anticipate that other fiber weaves described herein will provide functionalized fabrics that offer similar benefits as the fiber weaves employed in these examples.

[0143] Measurement method The glass transition temperature of the binder was determined using differential scanning calorimetry (DSC) according to EN ISO 11357-2 (Determination of glass transition temperature) by heating the binder under an air flow of 80 mL / min at a heating rate of 10 K / min from -60°C to 120°C, then holding at 120°C for 5 min, followed by cooling at a cooling rate of 10 K / min from 120°C to -60°C, then holding at -60°C for 5 min, followed by heating again at a heating rate of 10 K / min from -60°C to 120°C. The glass transition temperature was determined as the value obtained in the second heating cycle.

[0144] The volume average particle size of the binder applied to the fiber fabrics described in the examples below to provide functionalized fabrics was determined using dynamic light scattering techniques on the binder dispersion using a particle size analyzer (Beckman™ LS13320 Particle Size Analyzer) and on the binder dispersion according to the ISO 13320 2009 standard.

[0145] The shear modulus G at 30°C of the binders employed in the following examples was determined using an oscillatory rheometer at 0.1% deformation in planar-planar geometry, at a frequency of 1 Hz, using binder samples of 400 μm thickness and 25 mm diameter employing a heat-cool-heat cycle of heating from 30°C to 130°C at a heating rate of 3°C / min, cooling from 130°C to 30°C, and heating again at a heating rate of 3°C / min from 30°C to 130°C.

[0146] The dynamic viscosity η at 130°C of the binders employed in the following examples was determined using an oscillatory rheometer with 0.1% deformation in planar-planar geometry, at a frequency of 1 Hz, using binder samples with a thickness of 400 μm and a diameter of 25 mm, employing a heating-cooling-heating cycle of heating from 30°C to 130°C at a heating rate of 3°C / min, cooling from 130°C to 30°C, and heating again from 30°C to 130°C at a heating rate of 3°C / min.

[0147] Binder EP1 - an epoxy resin obtained from Hexion™ and having a glass transition temperature of 58°C (determined using DSC as described above), a softening point of 72°C determined using an oscillatory rheometer according to the method described above, a volume average particle size of about 80 μm (determined using dynamic light scattering techniques employing a Particle Size Analyzer (LS13320 from Beckman™), see also line A in Figure 1), a shear modulus G at 30°C of 11.5 MPa (determined using an oscillatory rheometer as described above), a dynamic viscosity η at 130°C of 32.5 Pa.s (determined using an oscillatory rheometer as described above), a molecular weight Mw, 5245, and a polydispersity index, 2.83 (determined as Mw / Mn).

[0148] An epoxy based binder obtained from EP2-CTP™ and having a glass transition temperature of 54° C. (measured using DSC as described above) and a softening point of 69° C., measured using an oscillatory rheometer according to the method described above, a volume average particle size of about 169 μm using DSC as described above (see also FIG. 1 , line B), a shear modulus G of 18.4 MPa at 30° C. (measured using oscillatory rheometer as described above), a dynamic viscosity η of 16.8 Pa.s at 130° C. (measured using oscillatory rheometer as described above), a molecular weight Mw of 4771 and a polydispersity (measured as Mw / Mn) of 2.83.

[0149] Polyester binder - polyester binder particles obtained from Coim™ and having a glass transition temperature of 46°C (measured using DSC as described above) and a softening point of 57°C measured using an oscillatory rheometer according to the method described above, a volume average particle size of about 185 μm measured using the dynamic light scattering technique by employing a Particle Size Analyzer (LS13320 from Beckman™) (see also Figure 1, line C), a shear modulus G of 30.7 MPa at 30°C (measured using an oscillatory rheometer as described above), a dynamic viscosity η of 387 Pa.s at 130°C (measured using an oscillatory rheometer as described above), a molecular weight Mw of 185710 and a polydispersity (measured as Mw / Mn) of 28.87.

[0150] [Table 1]

[0151] The functionalized textiles of Examples 1-12 were provided by applying the amount of resin binder shown in Table 1 to the above textile fiber fabric, heating the textile fiber fabric to a temperature of 110° C. (a temperature higher than the melting temperature of each of the resin binders) for 1 minute after the resin binder was applied, and then cooling to room temperature to attach the binder particles to the surface of the textile fiber fabric. FIG. 2 shows an example of an image (taken using a 3D microscope) of the surface of a functionalized textile fabric as described herein, in which the binder is attached to the surface of the textile fiber fabric by melting and solidifying (upon cooling). From FIG. 2, it can be seen that the functionalized textile fabric comprises binder particles (discrete binder particles) attached to the surface of the textile fiber fabric and spaced apart from each other, i.e., there is an area of ​​the textile fiber fabric surface without binder particles around each binder particle.

[0152] Figure 4a shows an example of an image (taken using a 3D microscope) of the surface of a functionalized textile fabricated according to Example 1. Figure 4b is a graph showing the binder particle size distribution at the surface of the functionalized textile shown in Figure 4a. The binder particle size distribution, showing the range of the longest axial length of each of the attached binder particles, was measured using an optical microscope (Keyence™ Optical Microscope) and associated image analysis software (ImageJ software) on a 5 mm 2 surface of the functionalized textile. 2 The binder particle size distribution over an area of ​​was calculated.

[0153] FIG. 5a shows an example of an image (taken using a 3D microscope) of the surface of a functionalized textile fabricated according to Example 10. FIG. 5b is a graph showing the binder particle size distribution at the surface of the functionalized textile shown in FIG. 5a. The binder particle size distribution, showing the range of the longest axial length of each of the attached binder particles, was measured using an optical microscope (Keyence ( The thickness of the functionalized fabric was measured using a 10 mm optical microscope (ImageJ software) and associated image analysis software. 2 The binder particle size distribution over an area of ​​was calculated.

[0154] Abrasion Test The adhesion strength between the fiber fabric and the adhesive binder particles of the functionalized fabric of Example 11 was measured using a scrub test (Elcometer 1720 Abrasion Tester) according to ISO 11998-2006. The test was carried out without liquid and with three abrasive materials: a microfiber fabric, a Scotch-Brite™ 7446 type pad, and sandpaper 100 grade. The weight of the abrasive pad with holder is 455 g. The rubbed surface is 300 mm. 200 runs (before and after) were carried out. The following results were obtained for each of the functionalized fabrics tested:

[0155] Scrub test with microfiber fabric - no effect on binder adhesion and no weight loss. A slight visual change is observed where the fiber fabric is abraded.

[0156] Scrub test with Scotch-Brite™ 7446 type pad - no effect on binder adhesion, no weight loss, slight visual change in fiber fabric where abrasion occurs.

[0157] Scrub test with sandpaper P100 - the fabric was destroyed. After only 5-10 runs, fuzzing begins to appear. The binder was found to be retained within the fuzz glass, indicating that the adhesion between the deposited binder particles and the fiber fabric is greater than the fiber fabric resistance to abrasion.

[0158] Thus, following these tests, the inventors found that the binder particles attached to the fiber weave of these functionalized textiles are permanently attached to the surface of the fiber weave, as the binder particles cannot be removed from the fiber weave by abrasion as described above.

[0159] The inventors expect that the other functionalized fabrics described herein will exhibit similar abrasion resistance.

[0160] The functionalized fabric of each of the examples was found to handle extremely well with no binder peeling off.

[0161] The functionalized fabric was then formed into a fabric stack by stacking 5-20 layers, and a different fabric stack was formed for each of the functionalized fabrics of Examples 1-12.

[0162] Each type of woven stack was then molded using a mold and heated under a vacuum of about 900 mBar for about 30 minutes to 1 hour. It was found that each of the woven stacks was successfully consolidated to form a molded part (i.e., a part that takes the shape of the mold even after removal from the mold) in this relatively short period of time at temperatures ranging from 50 to 100°C, with a temperature of about 100°C providing the most clearly molded part.

[0163] Each of the molded parts formed from the different functionalized textiles was then infused with either epoxy or polyester resin. The molded parts containing the functionalized textile with an epoxy binder were infused with epoxy resin, and the molded parts containing the functionalized textile with a polyester binder were infused with polyester resin. For comparison, samples of each of the fiber textiles used in Examples 1-12 without a binder were also infused with epoxy / polyester resin (Reference Examples 1-12, respectively). The resin infused molded parts were cured to form composite articles.

[0164] Molded parts formed from the functionalized fabrics of Examples 1-12 were found to exhibit superior exudation rates, in fact exhibiting faster exudation rates than the corresponding fiber fabrics without the binder.

[0165] The mechanical performance (e.g., shear and strength properties in the 0° (first direction), 45° and 90° directions) of composite articles containing the functionalized fabrics of Examples 1-12 were found to be comparable to those of composite articles containing the corresponding fiber fabrics without a binder.

[0166] Gloss Measurement Gloss measurements were performed on a number of functionalized textiles produced according to the Examples and Reference Examples. Gloss measurements were performed using a spectrophotometer X-Rite Ci7600 instrument with the following settings: Shape: D\8°-Tribeam simultaneous SCE / SCI (SPEX / SPIN) Illumination: Pulsed Xenon, D65 calibrated Opening diameter: 25mm.

[0167] The spectrophotometer device contains two ports, a sample viewing port and a specular port. The viewing port contains a receiver and a light-sensing detector that quantifies the light reflecting from the surface of the sample. The specular port can be opened or closed to control the type of measurement. When the port is open, the device takes a Specular Excluded (SPEX) reading to provide a Specular Component Excluded (SCE) value to the gloss measurement. When the port is closed, the device takes a Specular Included (SPIN) reading to provide a Specular Component Included (SCI) component to the gloss measurement. The ability to simultaneously measure SCI / SCE allows for the calculation of correlated gloss values ​​related to product appearance.

[0168] The gloss measurements of each of the tested samples were provided by placing the functionalized or reference textile sample on a neutral support (e.g., cardboard with double-sided adhesive tape to avoid wrinkles and keep the glass rovings aligned) so that the surface on which the binder resin was applied faced away from the support (i.e., towards the aperture of the spectrophotometer). The sample was then fixed between the aperture and the sample holder. The samples were oriented such that the rovings constituting the warp of the textile were oriented vertically. Even for textiles in which the warp was oriented at 90° compared to the roll length, the samples were placed so that the warp was oriented vertically. For each sample, 10 random spots over an area of ​​25 mm in diameter were investigated, two measurements were made per spot, and the average of these values ​​was provided. The results are provided in Table 2 below.

[0169] [Table 2]

[0170] The results provided above demonstrate the lower average gloss values ​​exhibited by the functionalized textiles of the examples compared to the reference textiles. Without being bound by theory, it is believed that the lower average gloss values ​​are due to the lower amount of binder employed in these functionalized textiles, resulting in discrete areas of binder (e.g., discrete binder particles) on the surface of the functionalized textile (as opposed to, e.g., a continuous layer of binder on the surface of the textile).

[0171] The inventors have also fabricated and tested functionalized fabrics similar to those described above, except that a range of other fiber fabrics described herein were used to provide the functionalized fabrics. These additional functionalized fabrics were found to provide similar benefits as the fiber fabrics employed in these examples.

[0172] Additionally, the inventors have discovered that the woven fabric stacks or molded parts described herein may be employed to significantly increase the lay-up speed of composite articles that include the molded parts described herein. For example, molded parts that include the functionalized woven fabrics described herein may be employed during wind turbine blade manufacturing by directly incorporating the molded parts into the wind turbine blade during the lay-up procedure.

[0173] ASSEMBLY OF FUNCTIONALIZED TEXTILE TO FORM SUBCOMPONENT ARTICLES, SUCH AS WIND TURBINE BLADE SUBCOMPONENTS - Patent application Two or more woven stacks or molded parts as described above can be assembled to form a subcomponent article, for example a subcomponent of a wind turbine blade.

[0174] The inventors have found that advantages can be provided by providing a woven stack (which may be a consolidated woven stack or formed into a molded part) including a plurality of functionalized woven layers as described herein, stacked such that one edge of the woven stack forms a groove configuration (female) and an opposite edge of the woven stack forms a tongue configuration (male). Figures 3a and 3b show a cross-section of a woven stack in which a plurality of functionalized woven layers are stacked such that one edge of the woven stack forms a groove "G" configuration (female) and an opposite edge of the woven stack forms a tongue "T" configuration (male). The inventors have found that by providing such a tongue-and-groove configuration to the woven stack so that adjacent woven stacks can be interdigitated with each other, improvements in both assembly and mechanical properties of the resulting subcomponent article are improved.

[0175] The inventors have found that the tack arrangement addresses problems encountered during layup, such as slippage of the woven stack and / or wrinkling of the woven stack (e.g., by assembling using a butt joint or lap joint as described above, as compared to, for example, laying up a woven stack in which the woven layers are aligned on top of each other or overlapping to form a stepped configuration at opposing edges).

[0176] The inventors have also discovered that the inlay arrangement described herein also improves the mechanical strength of composite articles, including subcomponent articles, by reducing the size of "resin voids" (i.e., voids between woven stacks that are filled with resin during formation of the composite article due to voids formed between adjacent woven stacks).

[0177] Thus, the inventors have surprisingly discovered that a woven stack having a berry configuration can be used to provide a subcomponent for a wind turbine blade having improved properties, such as improved mechanical uniformity.

[0178] The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, may be expressed in their specific form, or in terms of means for performing a disclosed function, or a method or process for obtaining a disclosed result, as appropriate, and may be utilized individually or in any combination of such features to realize the invention in its various forms.

[0179] While the present invention has been described in conjunction with the exemplary embodiments set forth above, many equivalent modifications and variations will become apparent to those skilled in the art upon receipt of this disclosure. Accordingly, the exemplary embodiments of the present invention set forth above are considered to be illustrative and not limiting. Various modifications to the described embodiments may be made without departing from the spirit and scope of the present invention.

[0180] For the avoidance of doubt, any theoretical explanations provided herein are provided for the purpose of enhancing the understanding of the reader, and the inventors do not wish to be bound by any of these theoretical explanations.

[0181] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0182] When a standard test is referred to herein, unless otherwise specified, the version of the test referenced is the most current at the time of filing this patent application.

[0183] Throughout this specification, including the claims which follow, unless the context indicates otherwise, the terms "comprise" and "include", as well as variations such as "comprises", "comprising" and "including", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0184] It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. The term "about" in reference to numerical values ​​is optional and may mean, for example, + / - 10%.

Claims

1. A functionalized textile, comprising: Fiber fabrics, and binder particles having a glass transition temperature of up to about 75° C.; The fiber fabric is first fibers oriented in a first direction; and second fibers oriented in a second direction, wherein the first fibers comprise glass fibers and / or carbon fibers, the second fibers comprise glass fibers and / or carbon fibers, and the second direction is within a range of 0 to 90 degrees of the first direction; A functionalized textile fabric, wherein the binder particles comprise up to about 5% by weight of the functionalized textile fabric, and the binder particles are attached to a surface of the textile fabric.

2. The functionalized textile of claim 1 , wherein the binder particles comprise from about 0.1% to about 3.5% by weight of the functionalized textile.

3. Approximately 2 to approximately 20g / m ２ The functionalized textile of claim 1 or 2, comprising said binder particles of

4. 4. The functionalized textile fabric of claim 1, wherein the binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the binder particles attached to the surface of the textile fabric, by total number of particles, have a longest axial length of less than about 1 mm.

5. 5. The functionalized textile fabric of claim 1, wherein the binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the binder particles attached to the surface of the textile fabric, by total number of particles, have a longest axial length in the range of about 1 μm to about 1 mm.

6. The functionalized textile of any one of claims 1 to 5, wherein the functionalized textile has a surface on which a binder is present that has an average gloss value of about 65 G.U or less.

7. 7. The functionalized textile of claim 6, wherein the functionalized textile has a surface on which a binder is present that has an average gloss value in the range of about 25 to about 60 G.U.

8. The functionalized textile according to any one of claims 1 to 7, wherein the textile fabric is a unidirectional textile fabric or a multiaxial textile fabric.

9. Approximately 500 to approximately 2500g / m ２ The functionalized textile of any one of claims 1 to 8, having an areal weight in the range of

10. The functionalized textile of any one of claims 1 to 9, wherein the binder particles comprise a thermoplastic binder.

11. 11. The functionalized textile of any one of claims 1 to 10, wherein the binder particles have a glass transition temperature in the range of about 40°C to about 70°C, or about 40°C to about 60°C.

12. The functionalized textile of any one of claims 1 to 11, wherein the binder comprises an epoxy, an acrylate, or an ester functional group.

13. 13. The functionalized textile of any one of claims 1 to 12, wherein at least the first fibers or the second fibers are glass fibers, and optionally both the first fibers and the second fibers are glass fibers.

14. 14. The functionalized textile fabric of claim 1, wherein the textile fabric is a non-crimped textile fabric, and the functionalized textile fabric comprises a suture, the suture maintaining the first and second fibers in their respective orientations.

15. 15. The functionalized textile of claim 1, wherein at least about 80% by weight of the binder particles are disposed on one surface of the fiber weave of the functionalized textile.

16. A textile stack comprising at least two layers of the functionalized textile according to any one of claims 1 to 15, wherein one layer of the functionalized textile according to any one of claims 1 to 15 is directly disposed on another layer of the functionalized textile according to any one of claims 1 to 15.

17. A molded part comprising the fabric stack of claim 16.

18. 1. A process for making a functionalized textile, said process comprising: providing a fiber fabric comprising first fibers oriented in a first direction and second fibers oriented in a second direction, the first fibers comprising glass fibers and / or carbon fibers, the second fibers comprising glass fibers and / or carbon fibers, and the second direction being within a range of 0-90 degrees of the first direction; applying binder particles having a glass transition temperature of up to about 75°C to the woven fiber fabric; and adhering the binder particles to the woven fiber fabric to provide the functionalized fabric, wherein the binder is applied to the woven fiber fabric in an amount such that the binder comprises up to about 5% by weight of the functionalized fabric.

19. 20. The process for making a functionalized textile as described in claim 18, wherein applying the binder to the textile web comprises heating the functionalized textile.

20. 20. The process for making a functionalized textile fabric according to claim 18 or 19, wherein the binder particles are applied to and attached to the textile fabric such that the binder particles attached to the surface of the functionalized textile fabric have a size distribution such that at least 90% of the binder particles attached to the surface of the textile fabric, by total number of particles, have a longest axial length in the range of about 1 μm to about 1 mm.

21. 21. The process for making a functionalized textile according to claim 20, wherein the binder particles applied to the textile fabric have a volume average particle size ranging from about 20 μm to about 600 μm.

22. 22. The process for making a functionalized textile according to any one of claims 18 to 21, wherein the functionalized textile has a surface on which at least a portion of the binder is present that has an average gloss value of about 65 G.U. or less.

23. 1. A process for making a molded part, comprising: - stacking a plurality of layers of the functionalized textile according to any one of claims 1 to 15 to provide a textile stack; forming the fabric stack; heating the fabric stack at a temperature up to about 150°C.

24. 24. The process of claim 23, comprising heating the fabric stack at a temperature up to about 150° C. and a pressure in the range of about 750 mBar to atmospheric pressure.

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