Functionalized textiles

Abstract

Described herein is a functionalized textile that includes a fiber textile and a binder that includes, consists of, or consists essentially of a fluorescent material.

Description

[Technical field]

[0001] The present invention relates to functionalized fabrics comprising glass and / or carbon fibers and the production thereof, in particular 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 receiving increasing attention as the search for alternative energy sources continues. As interest in generating more energy from 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, potentially creating problems related to compliance and quality control.

[0005] It is desirable to provide improvements in the efficiency and suitability of the production of reinforced structural components, such as wind turbine blades. Summary of the Invention

[0006] Most generally, the invention provides functionalized textiles and the production thereof, comprising a fiber fabric and a binder, the binder comprising, consisting of, or consisting essentially of a fluorescent material (e.g., a UV fluorescent material). Binders comprising, consisting of, or consisting essentially of a fluorescent material may be referred to herein as fluorescent binders.

[0007] In a first aspect, the present invention provides a functionalized textile comprising: Fiber fabrics, a binder that comprises, consists of, or consists essentially of a fluorescent material; A functionalized woven fabric is provided, the woven 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 0-90 degrees of the first direction.

[0008] In a second aspect, the present invention provides a textile stack comprising at least two layers of the functionalized textile described herein.

[0009] In a third aspect, the present invention provides a molded part comprising a woven stack as described herein.

[0010] In a fourth aspect, the present invention provides a process for making 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 second direction being within 0-90 degrees of the first direction, the first fibers comprising glass fibers and / or carbon fibers, and the second fibers comprising glass fibers and / or carbon fibers; applying a binder that comprises, consists of, or consists essentially of a fluorescent material to a fiber fabric to provide a functionalized fabric.

[0011] In a fifth aspect, the present invention provides a process for making a molded part, comprising: stacking multiple layers of a functionalized fabric as described herein; forming a shaped stack of a plurality of stacked fabric layers; heating the mold stack at a temperature up to about 150° C. to provide a molded part.

[0012] In a sixth aspect, the present invention provides a composite article comprising a molded part as described herein.

[0013] In a seventh aspect, there is provided a method of making a composite article, comprising impregnating a molded part as described herein with a resin and curing the resin to form the composite article.

[0014] In an eighth aspect, there is provided a method for assessing the distribution of a fluorescent binder on a functionalized textile as described herein by exposing the binder to light to cause fluorescence.

[0015] The light may be UV light.

[0016] The fluorescent binding agent may be observed, detected, or analyzed. For example, the fluorescent binding agent may be observed, detected, or analyzed, either with or without assistance.

[0017] In any of the embodiments of the present invention, the fluorescent material may be a UV fluorescent material or the fluorescent binder may be a UV fluorescent binder.

[0018] The method for assessing the distribution of the fluorescent binder may be part of the production process, for example an in-line process.

[0019] The inventors have found that the present invention provides functionalized fabrics that provide improved production efficiencies for reinforced structural components such as wind turbine blades and related components. The inventors have also found that the present invention provides a means by which improved analysis and characterization can be provided and reflected in associated functionalized fabrics, molded parts, and composite articles.

[0020] Further, the inventors have surprisingly found that it is possible to use the binders described herein in small amounts (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 textile, and / or in amounts of 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 woven fibers, including 100% polyester, ...

[0021] The inventors have also found that the use of binders in the production of functionalized textiles that fluoresce when exposed to electromagnetic radiation, such as UV light, provides a means by which the quality of the functionalized textiles (and associated components) can be assessed in a simple manner.

[0022] The present invention includes combinations of the aspects and preferred features described herein, except where such combinations are expressly not permitted or explicitly avoided. [Brief description of the drawings]

[0023] BRIEF DESCRIPTION OF THE DRAWINGS Embodiments and experiments illustrating the principles of the present invention will now be 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]1 is an image of a fluorescent binder on the surface of a fiber fabric. [Figure 3b] 1 is an image of a fluorescent binder on the surface of a fiber fabric. [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. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] 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.

[0025] Described herein is a functionalized textile comprising a fiber textile and a binder, where the binder comprises, consists of, or consists essentially of a fluorescent material.

[0026] Textiles The fiber fabric is first fibers oriented in a first direction; 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 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 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 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 of the first direction, e.g., about 45 degrees of the first direction. In an embodiment, the fiber fabric is a biaxial fabric, and the second direction is at least 45 degrees of 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 may 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 embodiments, the glass fibers constitute 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.

[0034] The term "glass fiber" is used herein 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 fiber and / or the second fiber include a polyester-compatible sizing or an epoxy-compatible sizing.

[0035] 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.

[0036] In an embodiment, the fiberglass strands or fiberglass tows are provided from fiberglass direct rovings, which are made from a bundle of continuous, untwisted (i.e., substantially parallel, or parallel) glass filaments that are combined into a single strand (as the glass filaments are formed) and wound on a bobbin.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] In an embodiment, the carbon fibers may have a fiber density 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, about It has a linear mass density of 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.

[0041] 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.

[0042] 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 stitching thread (the first and second fibers are not woven together, i.e., the non-crimp fabric is a non-woven fabric). Any suitable stitching thread can be employed. In an embodiment, the stitching thread is a polyester thread. In an embodiment, the stitching thread has a linear mass density in the range of about 50 decitex to about 300 decitex. In an embodiment, the stitching thread forms 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 stitching thread forms a stitching pattern through the fabric, and the stitching pattern is a tricot stitching pattern. In an embodiment, the suture defines a suture length, the suture length being within the range of about 2 mm to about 7 mm, for example about 3 mm.

[0043] In an embodiment, the textile fabric is a woven fabric, for example a plain weave fabric, a warp knit fabric, or a twill weave fabric.

[0044] 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.

[0045] 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.

[0046] 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 The area weight of the textile fabric may be determined according to ISO 3374.

[0047] In an embodiment, the fiber fabric comprises: first fibers oriented in a first direction; 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 to 90 degrees of the first direction, and the first fibers and the second fibers are maintained in their respective orientations by a suture.

[0048] In an embodiment, the fiber fabric comprises: first fibers oriented in a first direction; second fibers oriented in a second direction; The first fibers include glass fibers and the second fibers include glass fibers, the second direction is within 45-90 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.

[0049] In an embodiment, the fiber fabric comprises: first fibers oriented in a first direction; 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 45-90 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.

[0050] Binder The functionalized textile includes a binder. The binder may be in the form of 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.

[0051] The binder (e.g., binder particles) comprises, consists of, or consists essentially of a fluorescent material. Both the binder and the fluorescent material may comprise one or more types of material. The fluorescent material may be one or more fluorescent materials. The binder fluoresces in response to incident electromagnetic radiation, i.e., light. The fluorescent material or materials may be UV fluorescent materials, which is taken to mean that the material fluoresces when exposed to UV light.

[0052] UV light emits at shorter wavelengths than visible light. When UV light is absorbed by a fluorescent material, it is reflected back to the viewer as longer wavelength visible light. The color of the fluorescence observed depends on the material and the wavelength of light being used. For example, a UV source with the appropriate wavelength can be used in combination with a given UV fluorescent material.

[0053] Fluorescence and fluorescent material generally refer to any material, pigment, compound or agent that absorbs electromagnetic radiation, i.e. light, at a particular frequency and re-emits it at a lower frequency, such that the fabric in which the fluorescent material is present appears to glow when exposed to the lower frequency electromagnetic radiation, i.e. light. References to fluorescent materials are to be construed as including references to phosphorescent materials. The incident radiation may be referred to as having an excitation wavelength. The excitation wavelength is understood to be electromagnetic radiation that includes wavelengths that cause the fluorescent material to emit light. Typically, the excitation wavelength corresponds to a wavelength of UV light or visible light.

[0054] The presence of a fluorescent material causes the binder to glow when a suitable wavelength of radiation is incident upon it. The wavelength of the incident radiation may correspond to that of visible light or UV light. Visible light is generally considered to be in the range of about 380 nm to about 750 nm. UV light is generally considered to be in the range of about 10 nm to about 400 nm. The use of UV fluorescent materials is preferred considering that the binder may not need to glow under all typical daytime lighting conditions. With respect to the use of UV light, the wavelength of the incident UV light or radiation may be from about 10 nm to about 400 nm, for example, from about 100 nm to about 400 nm, or from about 200 nm to about 400 nm, or from about 300 nm to about 400 nm, or from about 250 nm to about 380 nm. A typical example is about 254 nm or about 365 nm.

[0055] The source of electromagnetic radiation may be provided by any suitable radiation source known to those skilled in the art.

[0056] The fluorescent material may be selected from any known fluorescent material. The fluorescent material may be a polymer or a non-polymer material. In an embodiment, the binder comprises or consists of a fluorescent resin, for example a fluorescent polyester resin.

[0057] In the functionalized textile, the fluorescent material may be present in an amount of up to about 5% by weight, 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, based on the total weight of the functionalized textile. In embodiments, the fluorescent material may comprise at least about 0.05% by weight of the functionalized textile, e.g., at least about 0.1% by weight, at least about 0.2% by weight, or at least about 0.3% by weight of the functionalized textile. In embodiments, the fluorescent material comprises between about 0.05% and about 5.0% by weight of the functionalized textile, e.g., between about 0.1% and about 3.5% by weight of the functionalized textile.

[0058] In an embodiment, the functionalized textile has a thickness of up to about 30 g / m 2 of fluorescent material, e.g. up to about 25 g / m 2 , maximum about 20g / m 2 , maximum about 18g / m2 , 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 fluorescent material, 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 / m 2 ~About 30g / m 2 of fluorescent material, for example, about 4 g / m 2 ~about 25g / m 2 , about 4g / m 2 ~about 15g / m 2 , about 7g / m 2 ~Approx. 13g / m 2 , or about 10 g / m 2 ~Approx. 13g / m 2 The fluorescent material includes

[0059] 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 (e.g., binder particles) comprises or consists of a resin containing an epoxy, acrylate, or ester functional group, e.g., a resin containing 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 containing an epoxy, acrylate, or ester functional group. The resin or thermoplastic resin may itself provide the fluorescent property or may be a fluorescent material. The fluorescent property may be provided by a material other than the resin or thermoplastic resin. Thus, the fluorescent material may be any of the materials described herein as binder particles. For example, the fluorescent material may be selected from one or more of the fluorescent polymer resins including those mentioned herein, such as polyester resins, which may be saturated or unsaturated, or epoxy resins. Other suitable fluorescent polymer resins include polyacrylates or acrylate-functionalized polymers or polymers.

[0060] 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 (e.g., binder particles) 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.

[0061] 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 period of time, e.g., when exposed to a temperature of up to about 110° C. for at least a suitable period of time, when exposed to a temperature of up to about 100° C. for at least a suitable period of time, or when exposed to a temperature of up to about 90° C. for at least a suitable period of 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 period of 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.

[0062] 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.

[0063] 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 being applied 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 (i.e., using dynamic light scattering techniques on a dispersion of the binder particles) according to the ISO 13320 2009 standard. Samples are analyzed twice as received and after dispersion in air, and the amount of sample is typically about 20 g per test.

[0064] In embodiments, the binder of the functionalized fabric may be described as a binder particle.

[0065] In embodiments, the binder particles applied to the woven fiber fabric can be attached to a surface of the woven fiber fabric such that the functionalized fabric includes binder particles attached to the surface. In embodiments, the binder particles applied to the surface of the woven fiber fabric can be attached to the woven fiber fabric to form the functionalized fabric.

[0066] In an embodiment, the binder (including, consisting essentially of, or consisting of a fluorescent material) may be present in an amount of up to about 5% by weight based on the total weight of the functionalized textile. In such an embodiment, due to the low amount of binder particles applied to the textile as described herein, the functionalized textile includes a textile having binder particles attached thereto, the binder particles forming discrete binder particles on the surface of the textile (e.g., as opposed to the binder solidifying to form a large patch or layer on the surface of the textile). As used herein, the terms "discrete binder particles" and "discrete binder particles" refer to binder particles attached to the surface of the textile in a spaced relationship to one another, i.e., each binder particle is surrounded by a surface area of ​​the textile that is free of binder particles. In an embodiment, the binder particles attached to the surface of the textile have a longest axial length of less than about 2 mm, e.g., less than about 1 mm.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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 longest axial length of the binder particles across a given area (e.g., about 5 mm 2 ) of the functionalized textile. 2 ~ approx. 50mm 2The 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.

[0072] 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.

[0073] 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% of the particles by volume are less than about 1 mm), such as 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] In an embodiment, the binder of the functionalized textile is disposed on a surface of the woven fiber fabric. In an embodiment, the binder particles of the functionalized textile are disposed on a surface of the woven fiber fabric. In an embodiment, at least a portion of the binder of the functionalized textile is present on a surface of the functionalized textile. For example, at least a portion of the binder of the functionalized textile is disposed on a surface of the woven fiber fabric or between fibers on a surface of the woven fiber fabric.

[0079] 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.

[0080] 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.

[0081] In embodiments, the binder of the functionalized fabric may infiltrate the fiber fabric. In embodiments, the functionalized fabric may include a binder within the fiber fabric.

[0082] In embodiments, the binder particles, when present on the functionalized textile, do not cover, coat, or impregnate the entire surface of the textile. For any given surface on which binder particles are present, there may be one or more gaps in the coverage of the functionalized textile by the binder particles. For any given surface on which binder particles are present, there may be discrete areas or isolated portions of the binder particles.

[0083] Functionalized textiles The functionalized fabric of the present invention comprises a woven fiber fabric as described herein and a binder (eg, binder particles) as described herein.

[0084] The binder (e.g., binder particles) may comprise 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.

[0085] 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.

[0086] 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 / m2 , 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 / m 2 ~About 30g / m 2 of binder, e.g., about 4 g / m 2 ~about 25g / m 2 , about 4g / m 2 ~about 15g / m 2 , about 7g / m 2 ~Approx. 13g / m 2 , or about 10 g / m 2 ~Approx. 13g / m 2 The binder is

[0087] 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 a binder disposed thereon and another surface that is substantially free of binder (e.g., less than about 0.1 g / m2). 2 and a surface comprising less than about 100% binder.

[0088] In embodiments, the functionalized fabric may include a binder (eg, binder particles) within the fiber fabric.

[0089] The functionalized textile comprises a fiber weave and a binder, the binder being attached to the fiber weave. In an embodiment, the binder is attached to the fiber weave, e.g., the surface of the fiber weave. In an embodiment, the binder may be attached to the fiber weave by a suitable treatment, e.g., heating, curing, or exposure to UV radiation. In an embodiment, the binder is attached to the fiber weave, e.g., the surface of the fiber weave, by heating such that the binder melts or at least partially melts, e.g., at least partially melts on the surface of the fiber weave. For example, the functionalized textile may comprise a solid binder, e.g., solid binder particles, attached to the fiber weave, the binder, e.g., binder particles, applied to the fiber weave being previously softened or at least partially melted. The inventors have found that because the amount of binder applied to the fiber weave is small, even after the binder is melted, discrete areas of 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.

[0090] In embodiments, the functionalized textiles described herein may be described as including a textile fabric having a surface to which a 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) may 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.

[0091] 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).

[0092] 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.

[0093] In embodiments, the functionalized fabrics described herein may be impregnated with a resin, and the resin may be cured to form a composite article.

[0094] Woven Stack The textile stack includes at least two layers of the functionalized textile described herein.

[0095] In an embodiment, the textile stack comprises at least two layers of functionalized textile as described herein, one layer of functionalized textile 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, each of the multiple layers of functionalized textile disposed directly on another of the multiple layers of functionalized textile.

[0096] 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.

[0097] 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."

[0098] 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.

[0099] 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, e.g., a pressure in the range of about 500 mbar to about 1000 mbar, 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, e.g., 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, e.g., 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.

[0100] 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.

[0101] Process for fabricating functionalized textiles The process for producing functionalized textiles includes: Providing a fiber fabric as described herein; applying a binder (e.g., binder particles) described herein to the fiber fabric to provide a functionalized fabric.

[0102] The binder may be applied to the fiber web in an amount such that the binder comprises up to about 5% by weight of the functionalized web.

[0103] 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 particle 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 fabric having a binder particle 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 ~about 15g / m 2 , about 7g / m 2 ~Approx. 13g / m 2 , or about 10 g / m 2 ~Approx. 13g / m 2 The method includes providing a functionalized fabric having a binder particle distribution in the range of

[0104] In embodiments, the binder is applied to the surface of the fiber fabric, for example, by sprinkling binder particles onto the surface of the fiber fabric.

[0105] 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 before being 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.

[0106] 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, e.g., 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, e.g., 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., 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, 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., e.g., 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., e.g., 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, e.g., up to about 1 hour, e.g., about 1 to about 10 minutes.

[0107] 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.

[0108] Molded parts The molded part includes a woven stack (eg, a consolidated woven stack) as described herein.

[0109] The molded parts are a) providing a textile stack as described herein; b) forming a woven stack; and c) heating the molded stack at a temperature up to about 150°C.

[0110] In an embodiment, heating the textile stack comprises heating the textile 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, heating the textile stack comprises heating the textile 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, heating the textile stack comprises heating the textile stack at 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.

[0111] In embodiments, fabricating the molded part may include heating the woven stack at a temperature up to about 150° C. and a pressure less than atmospheric, 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.

[0112] 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.

[0113] In an embodiment, shaping the woven stack involves placing the woven stack on or in a mold. In an embodiment, shaping the woven stack involves placing the woven stack on or in a mold and applying increased heat and / or reduced pressure to the woven stack.

[0114] In embodiments, the molded parts described herein may be impregnated with a resin and the resin cured to form a composite article.

[0115] 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.

[0116] Conformity and quality control The use of fluorescent binders according to the present disclosure provides a method or methods for evaluating the distribution of binder on the textile, for example, to evaluate and characterize the dispersion of binder and the amount present on the textile surface. This may include evaluating that the binder (e.g., binder particles) is evenly distributed, monitoring for defects, counting the particles of binder present (e.g., using image analysis), or incorporating unique identifiers. The inventors have found that fluorescent binders provide better contrast during production compared to when non-fluorescent binders are employed.

[0117] According to an eighth aspect of the present invention, there is provided a method of assessing or detecting the presence or distribution of a binder (e.g., binder particles) on a functionalized textile as described herein by exposing the binder to light (e.g., UV light, e.g., light having a wavelength in the range of about 10 nm to about 400 nm, e.g., about 100 nm to about 400 nm, or about 200 nm to about 400 nm, or about 300 nm to about 400 nm, or about 250 nm to about 380 nm) to generate fluorescence. The fluorescent binder can be observed, detected or analyzed. For example, the fluorescent binder may be observed, detected or analyzed, either aided or unaided. The fluorescent binder can be observed by the human eye or by other means, such as a fluorescence detector.

[0118] Such methods may be used as part of a manual or automated process, for example as part of a production line, and for quality control purposes. Examples of quality control include in-line and offline quality control. In-line quality control processes incorporate inspection points throughout the production line. These points may inspect the quality of the product with respect to various standards or specifications. In-line quality control is generally faster than offline systems. This is primarily because the inspections are performed along the process without the additional time required for removal or replacement. Data obtained from these inspections may be used to correct and adjust the production process in real time, thereby reducing waste and saving time. The products and methods provided in accordance with the present invention are particularly useful in connection with in-line quality control.

[0119] The distribution of the binder can be verified using exposure to UV light without resorting to destructive testing and without interrupting the production line, thus improving the efficiency of mass production. EXAMPLES

[0120] 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.

[0121] 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.

[0122] 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 fibers 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.

[0123] The unidirectional fiber fabric used in these examples (referred to as "UD" in the tables below) contains a second fiber (glass fiber) that constitutes up to about 5% by weight of the fiber fabric, with a first fiber (glass fiber) that constitutes at least 95% by weight of the fiber fabric, and the second direction is substantially perpendicular to the first direction. The unidirectional fabric is referred to as "UD0", and the UD0 fabric contains a first fiber oriented in the 0 direction (i.e. aligned to the length of the fabric). Functionalized fabrics including UD90 fabrics (fabrics containing a first fiber oriented in the 90 direction (i.e. perpendicular to the length of the fabric)) can also be prepared.

[0124] Biaxial fiber fabrics can also be used to prepare the functionalized fabrics described herein. For example, functionalized fabrics including biaxial fiber fabrics can be prepared as described in the following examples. Examples of suitable biaxial fabrics include fabrics containing a second fiber (glass fiber) that constitutes at least about 15% by weight of the fiber fabric, and the second direction is substantially perpendicular to the first direction (these fabrics may be referred to as "BX90" fabrics) or at about 45 degrees to the first direction (these fabrics may be referred to as "BX45" fabrics).

[0125] 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.

[0126] 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.

[0127] The volume average particle size of the binder particles applied to the fiber fabrics described in the examples below to provide functionalized fabrics was determined using dynamic light scattering techniques on the dispersion of binder particles using a particle size analyzer (Beckman™ LS13320 Particle Size Analyzer) and using dynamic light scattering techniques on the dispersion of binder particles according to the ISO 13320 2009 standard.

[0128] 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.

[0129] 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.

[0130] Binder Resin Resin binder-Polyester-based binder particles obtained from Coim™, having a glass transition temperature of 46° C. (determined using DSC as described above) and a softening point of 57° C. determined using an oscillatory rheometer according to the method described above, a volume average particle size of about 185 μm (see also FIG. 1, line C) determined using dynamic light scattering techniques by employing a Particle Size Analyzer (LS13320 from Beckman™), a shear modulus G of 30.7 MPa at 30° C. (determined using an oscillatory rheometer as described above), a dynamic viscosity η of 387 Pa.s at 130° C. (determined using an oscillatory rheometer as described above), a molecular weight Mw of 185710 and a polydispersity (determined as Mw / Mn) of 28.87. The polyester binder employed contained a fluorescent material that emits fluorescence in response to UV light.

[0131] [Table 1]

[0132] The functionalized textiles of Examples 1-4 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 particles are attached to the surface of the textile fiber fabric by melting and solidifying (upon cooling) the binder particles. 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 free of binder particles around each binder particle.

[0133] Figures 3a and 3b show examples of images of fluorescent binder particles on the surface of a fiber fabric taken under UV light with a wavelength of 365 nm, in relation to Examples 1 and 2. The images show that a uniform distribution of binder particles is provided. Observed under UV light with a wavelength of 254 nm, images similar to those shown in Figures 3a and 3b are provided. The images provided under UV light with a wavelength of 365 nm are found to be brighter than the images provided when viewed under UV light with a wavelength of 254 nm, and the brighter images provide an improvement in image analysis.

[0134] Figure 4a shows an example of an image (taken using a 3D microscope) of the surface of a functionalized textile fabricated according to Example 2. 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 extent of the longest axial length of each of the attached binder particles, was determined using an optical microscope (Keyence™ Optical Microscope) and associated image analysis software (ImageJ software) to measure the binder particle size distribution over a 10 mm area of ​​the functionalized textile. 2 The binder particle size distribution over an area of ​​was calculated.

[0135] Abrasion Test The adhesion strength between the fiber fabric and the adhesive binder particles of the functionalized fabric of Example 3 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. For each of the functionalized fabrics tested, the following results were obtained:

[0136] 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.

[0137] 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.

[0138] 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 fuzzing glass. This indicates that the adhesion between the attached binder particles and the fiber fabric is greater than the resistance of the fiber fabric to abrasion.

[0139] The inventors expect that the other functionalized fabrics described herein will exhibit similar abrasion resistance.

[0140] The functionalized fabric of each of the examples was found to handle extremely well with no binder peeling off.

[0141] 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 1-4.

[0142] 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.

[0143] Each of the molded parts formed from the different functionalized fabrics was then infused with polyester resin. For comparison, a sample of each of the fiber fabrics used in Examples 1-4 without the application of the binder was also impregnated with polyester resin. The resin-infused molded parts were cured to form composite articles.

[0144] Molded parts formed from the functionalized fabrics of Examples 1-4 were found to exhibit superior exudation rates, in fact exhibiting faster exudation rates than the corresponding fiber fabrics without the binder.

[0145] 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 1-4 were found to be comparable to those of composite articles containing the corresponding fiber fabrics without a binder.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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.

[0150] 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.

[0151] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0152] 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.

[0153] 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. Functionalized textiles, Textile fabrics and, A binder containing a fluorescent material, The functionalized textile comprises a first fiber oriented in a first direction and a second fiber oriented in a second direction, wherein the first fiber includes glass fiber and / or carbon fiber, and the second fiber includes glass fiber and / or carbon fiber, and the second direction is within 0 to 90 degrees of the first direction.

2. The functionalized fabric according to claim 1, wherein the fluorescent material generates fluorescence in response to UV light.

3. The functionalized fabric according to claim 1, wherein the fluorescent material is present in an amount of up to about 5% by weight, based on the total weight of the functionalized fabric.

4. The functionalized fabric according to claim 1, wherein the binder has a glass transition temperature of approximately 75°C.

5. The functionalized fabric according to claim 1, wherein the binder constitutes about 0.1% to about 3.5% by weight of the functionalized fabric.

6. Approximately 2 to approximately 30g / m 2 The functionalized fabric according to claim 1, comprising the binder.

7. The functionalized fabric according to claim 1, wherein the binder comprises a polymer resin containing epoxy, acrylate, or ester functional groups.

8. The functionalized fabric according to claim 1, wherein the binder is made of a fluorescent material or is essentially made of a fluorescent material.

9. The functionalized fabric according to claim 1, wherein at least the first fiber or the second fiber is a glass fiber, or both the first fiber and the second fiber are glass fibers.

10. The functionalized fabric according to claim 1, wherein the textile fabric is a non-crimped fabric, and the functionalized fabric includes sutures, the sutures maintaining the first fiber and the second fiber within their respective orientations.

11. The functionalized fabric according to claim 1, wherein the binder containing the fluorescent material is in the form of binder particles.

12. A fabric stack comprising at least two layers of the functionalized fabric according to any one of claims 1 to 11, wherein one layer of the functionalized fabric according to any one of claims 1 to 11 is directly positioned on top of another layer of the functionalized fabric according to any one of claims 1 to 11.

13. A molded part comprising the fabric stack described in claim 12.

14. A process for producing functionalized textiles, wherein the process is To provide a textile fabric comprising a first fiber oriented in a first direction and a second fiber oriented in a second direction, wherein the second direction is within 0 to 90 degrees of the first direction, the first fiber includes glass fiber and / or carbon fiber, and the second fiber includes glass fiber and / or carbon fiber. A process comprising applying a binder containing a fluorescent material to the textile fabric to provide the functionalized fabric.

15. The process according to claim 14, further comprising exposing the binder to UV light.

16. The process according to claim 15, wherein the process is part of an inline quality control process.

17. A process for manufacturing molded parts, To provide a fabric stack by stacking multiple layers of functionalized fabric according to any one of claims 1 to 11, Forming the aforementioned fabric stack, A process comprising heating the aforementioned fabric stack to a maximum temperature of approximately 150°C.

18. A method for evaluating the distribution of a fluorescent binder on a functionalized fabric according to any one of claims 1 to 11, comprising exposing the binder to UV light to generate fluorescence in the binder.

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