Composite yarns, manufacturing processes and textile surfaces containing such yarns

Abstract

To provide a manufacturing process of a flame-retardant composite yarn, and a flame-retardant composite yarn.SOLUTION: A composite yarn comprising a continuous multifilament core yarn incorporated in a matrix, is characterized in that the matrix comprises at least one polymer material and at least one reinforcing filler, the reinforcing filler being formed from functionalized particles, the particles having a median size (dv50) of less than 40 μm. A process for manufacturing such a composite yarn, comprises at least one step of depositing, by coating or extrusion, a matrix comprising a polymer and a reinforcing filler, onto a core yarn. A textile surface comprises at least one such composite yarn.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The invention disclosed below relates to the general field of composite yarns, which are generally obtained by coating continuous multifilament yarns with a matrix comprising at least one polymer; to the general field of textiles made from these yarns, and to sunshades or other sunblocks, sunscreens or sunshields made from such textiles or yarns. [Background technology]

[0002] Composite yarns are well-known and commonly used technical yarns and generally include; · A core containing a continuous multifilament yarn (i.e., a yarn formed from several filaments), which is generally twisted; a matrix comprising a flame-retardant system consisting of at least one polymeric material, for example a chlorinated polymeric material such as polyvinyl chloride (PVC), a plasticizer, and usually one or more mineral flame-retardant fillers; and · Sheath or envelope.

[0003] Mineral fire-retardant fillers are insoluble mineral solid substances, usually intended to be dispersed in an organic matrix by mechanical means. Fire-retardant fillers are used to improve the fire resistance of materials. Fire-retardant fillers are usually halogenated, organophosphorous (phosphonates, phosphinates, phosphates, etc.), boron-based or molecular nitrogen, (M(OH) n) type metal hydroxides (M is a metal), for example aluminum or magnesium, or antimony oxides, such as antimony trioxide or antimony pentoxide. Many applications require flame-retardant materials (i.e. materials with fire resistance). For this purpose, at least one flame-retardant filler can be incorporated into the material. It is also necessary to adapt the formulation thus obtained to the application conditions. To achieve this, other materials can be present in the matrix, such as viscosity reducers, which make it possible to adjust the viscosity of the chemical preparation made for the production of the matrix of the composite yarn.

[0004] Composite yarns are generally obtained by depositing a polymer onto a continuous multifilament yarn or "core yarn" (also known as a "fiber"), usually with a twist. Two main techniques are used for this purpose: the "plastisol" technique, which involves coating the core yarn with at least one layer of plastisol, which contains a polymer, a plasticizer, and optionally other components such as fillers. This is followed by gelation of the plastisol around the core yarn. The other technique is the "extrusion coating" technique, which involves heating the polymer from a solid to a liquid form in an extruder, followed by deposition onto the core yarn and subsequent calibration in a die. The term "plastisol" refers to a product obtained by dispersing a polymer in a plasticizer, typically in the form of an oil. This dispersion is heated; starting at a certain temperature, the plasticizer becomes a solvent for the polymer. Thus, a two-phase medium is transformed into a one-phase medium. This transformation, a type of gelation, is irreversible. The "extrusion coating" technique is exclusively used for extrudable thermoplastic polymers.

[0005] Typically, the center of a composite yarn is formed by a region where all filaments are concentrated. This region typically contains very little polymer. Therefore, the filaments are generally in direct contact with each other. The lack of separation between the filaments and the lack of cohesion due to the lack of polymer can lead to tension during the cutting process of textiles made with these composite yarns. Once the sheath is cut, the filaments are no longer held in place and can easily pull. This can cause problems over time, as the pulled filaments form weak areas that can reduce the mechanical properties of the composite yarn. This is especially true for composite yarns made with textile glass yarns, as they are very sensitive to water. Water that can penetrate the composite yarn via capillary action can significantly reduce its mechanical properties after a certain period of time.

[0006] To overcome this problem, various technical solutions have been implemented, including the solution described in patent application WO 03 / 056082. This document describes a composite yarn obtained by coating each filament. Thus, it is possible to produce a flame-retardant composite yarn by depositing a flame-retardant coating on the composite yarn obtained after the first coating, which does not contain fillers. However, coating the filaments individually hardens the composite yarn, which makes the textile obtained from this composite yarn difficult to handle and may even render it unsuitable for use as a blind fabric in accordance with the provisions of standard EN 13561 by giving it a "memory" after rolling. This "memory" significantly affects the appearance after several cycles of use. Standard EN 13561 is concerned with exterior blinds and includes performance requirements, including those related to safety.

[0007] Patent application WO 2011 / 033130 itself describes an improvement over patent application WO 03 / 056082 in that the process for producing the composite yarn includes a preliminary step of mechanical opening of the individual filaments that make up the core yarn (to allow matrix access to each filament); preferably fanning. However, the process described in WO 2011 / 033130 is very complicated to implement. Furthermore, the core yarn must be able to withstand the considerable mechanical stresses generated by the mechanical opening of the individual filaments that make it up. This limits the choice of core yarn.

[0008] Textiles, generally obtained by weaving composite yarns and intended to make blind fabrics, are subject to fire performance regulations in various jurisdictions.

[0009] In Germany, under the standard DIN 4102-1, there are classes consisting of three categories (codes B1 to B3) that define the reaction of materials to fire. Code B1 indicates the strictest classification for organic materials. It is generally required for sun protection textiles, especially in German enthusiast regions and, by extension, in Northern Europe.

[0010] In France, standard NF P92-507 has five categories (or classes) that define the fire response of materials (codes M0 to M4). For non-fusible materials, such as inorganic fiber-based fabrics, this classification is based on the duration of the flame after the burner is removed, the length of the specimen broken, and the likelihood of ignited drips during testing under standard NF P92-503. Standard NF P92-507 describes classes that utilize tests performed under standard NF P92-503. For fusible materials, additional tests are required according to standards NF P92-504 and NF P92-505. Flammability is the heat released by the total combustion of the material, and ignition is the amount of flammable gas produced by the material. Code M1 indicates non-flammable combustible materials and applies specifically to sun protection textiles for the French market, and by implication to Southern European markets.

[0011] Currently, the French and German classifications are still widely used but are in the process of being superseded by the European standard EN13-501-1, which defines "Euroclasses".

[0012] Euroclasses define fire resistance performance. They are used, among other things, to characterize products for construction and building accessories. They are more complete than the French and German classes, which are considered individually, because they take into account the fire resistance of materials, designated A1, A2, B, C, D, or F depending on the level of energy released; the opacity (quantity and velocity) of the emitted smoke, designated by the letter "s" for "smoke" (codes s1 to s3); and the emitted ignited droplets and debris, designated by the letter "d" for "droplets" (codes d0 to d2). Common commercial composite yarns, obtained by coating mineral core yarns such as textile glass yarns (or glass fibers) with highly flame-retardant plastisols, allow for the preparation of textiles that best meet the fire resistance criteria of Euroclass Cs3d0 of standard EN 13-501-1. Ideally, they should meet the fire resistance performance criteria of Euroclass Bs2d0 of standard EN 13-501-1.However, at present, commercially available composite yarns obtained by coating mineral core yarns, such as glass textile yarns, with flame-retardant PVC plastisols do not allow the preparation of sun protection textiles that meet the fire resistance performance criteria of Euroclass Bs2d0 or Bs3d0 of standard EN 13-501-1.

[0013] To prepare flame retardant composite yarns, flame retardant fillers are typically used that are dispersed in a matrix polymer and come in a wide variety of sizes and shapes.

[0014] Patent EP 0900294 describes a composite yarn whose matrix polymeric material is chlorinated and contains a flame-retardant filler of a ternary composition combining an oxygenated antimony compound (generally antimony trioxide), a hydrated metal oxide, and zinc borate, with a total inorganic content of 4-65%. The plasticizer generally contains at least one organic phthalate ester and does not contain phosphates. However, certain phthalates are said to be toxic, and antimony salts are suspected of being toxic.

[0015] Patent application WO 2010 / 001240 describes an improvement over patent EP 0900294 in that the flame-retardant plastisol contains a lead-free chlorinated polymer, the plasticizer does not contain orthophthalate, and the flame-retardant filler does not contain antimony but contains a metal hydrate and a zinc salt. However, the flame-retardant content is high while the plasticizer content is relatively low in order to comply with the fire resistance class, which leads to stiffness in the composite yarn and therefore makes it difficult to obtain from such composite yarn a blind fabric that also complies with the performance requirements specified by standard EN 13561. Summary of the Invention

[0016] There is therefore a need for a composite yarn that has improved fire resistance compared to the prior art, is easy to manufacture and allows for the production of blind fabrics that meet the requirements of standard EN 13561.

[0017] One aspect of the present disclosure is to provide an improved fire resistance performance of composite yarns. Another aspect of the present disclosure is to provide a process for manufacturing composite yarns that is easy to perform.

[0018] Another aspect of the present disclosure is to enable the use of glass textile yarns with low twist and standard sizing as core yarns, especially with the aim of reducing the manufacturing costs of composite yarns. Another aspect of the present disclosure is to provide a process that complies with environmental standards, in particular using ingredients that are not suspected to be toxic and that limit the emission of volatile organic compounds (VOCs).

[0019] Thus, according to a first aspect, a composite yarn comprising a continuous multifilament core yarn embedded in a matrix, the matrix comprising at least one polymeric material and at least one reinforcing filler, the reinforcing filler being made of functionalized particles, said particles having a median diameter (d v50 ) is characterized by having.

[0020] Advantageously, the composite yarn has a lower titre (or density) than that of prior art composite yarns. Thus, typically, a composite yarn has a titre of 135-140 tex for a core yarn with a titre of 68 tex, whereas prior art composite yarns have a titre of about 165 tex for the same core yarn. This advantageously allows for a reduction in the mass per unit area and thickness of textiles made from the composite yarn by about 10 to 20% and about 10 to 15%, respectively.

[0021] The continuous multifilament core yarn preferably has a twist in the range of 20 to 40 rounds per meter.

[0022] According to a preferred embodiment, the twist of the core yarn is between 28 and 40 turns per meter.

[0023] According to an even more preferred embodiment, the twist of the core yarn is 28 turns per meter.

[0024] Preferably, the functionalized particles of reinforcing filler (or reinforcing particles) are dispersed throughout the matrix of the composite yarn, the matrix being in contact with the core yarn filaments.

[0025] Particularly preferably, part of the reinforcing filler is present in the interstices between the filaments of the core yarn. Advantageously, the smallest particles of the reinforcing filler are present in the interstices between the filaments of the core yarn.

[0026] In any case, the matrix generally forms a continuous medium in which the functionalized particles are dispersed.

[0027] Preferably, the dispersion of the functionalized particles in the matrix is ​​homogeneous, where "homogeneous" is understood to mean that the concentration of the functionalized particles in the matrix is ​​of the same order of magnitude at any point in said matrix.

[0028] According to a preferred embodiment disclosed herein, the composite yarn is made of a core yarn, a matrix, and a sheath.

[0029] The term "between X and Y" (where X and Y are any numbers) means between X and Y, excluding the limits. The term "in the range Z to T" (where Z and T are any numbers) means between Z and T, including the limits.

[0030] The term "A and / or B" (where A and B are optional properties) means "A" or "B" or "A and B."

[0031] The term "tex", as is common to those skilled in the art, means the mass in grams of one kilometer of yarn.

[0032] The term "matrix" means an element comprising at least one polymeric material in contact with the core yarn.

[0033] Preferably, the particles have a hardness (Mohs) equal to or less than the hardness of the material that makes up the core yarn.

[0034] The Mohs scale is a measure of the hardness of a mineral. The Mohs scale is based on 10 readily available minerals. The hardness scale ranges from 1 (for talc) to 10 (for diamond). It can be measured by comparing a mineral with two other minerals of known hardness (the ability of one to scratch the other). This value is typically provided by the product supplier. Thus, a textile glass yarn formed from multifilaments has a hardness of 5.5. Textile glass yarns are commonly called silions. Textile glass yarns are assemblies of various sized silions twisted together. The term "sized" is explained below. According to a preferred embodiment, the Mohs hardness of the particles constituting the reinforcing filler is at least 1 and not more than 5.5, including, for example, increments of 0.5 between these values. In other words, this hardness ranges from 1 to 5.5.

[0035] If the hardness of the reinforcing particles is less than 1, the reinforcing filler is generally brittle and therefore cannot withstand the shear forces during the composite yarn manufacturing process, resulting in its destruction. If the hardness of the reinforcing particles is greater than 5.5, the reinforcing filler may locally damage the filaments that make up the core yarn.

[0036] The term "size" (or "average size"), as usual, means the diameter that a theoretical sphere that behaves identically to the particle under consideration during the selected particle size analysis procedure would have. The terms "diameter" or "equivalent diameter" are also used.

[0037] In the technical field under consideration, measurements are generally made by screening on a series of vibrating screens or by laser particle size analysis (using a diffraction laser). The particle size is preferably measured by laser particle size analysis. Machines that can be used for laser particle size measurement are usually machines of the Malvern Instruments brand, for example the Malvern Masterizer 2000 Instrument machine. This machine determines, among other things, the volume distribution of the particles, in particular the size d as explained below. v50 , d v10 and d v90 As known to those skilled in the art, it is common to combine the use of powder dryers of the Scirocco 2000 type, for example, which make it possible to dry the powder to be fed into a laser particle size analyzer.

[0038] Median diameter (d v50 ), or diameter (d v50 ) indicates the median value: 50% of the particles (by volume) have the smaller size and 50% of the particles (by volume) have the larger size. Particles have a median diameter (d ) of less than 40 μm, preferably less than 30 μm, generally greater than 5 μm, preferably greater than 15 μm. v50 ) Preferably, the median diameter (d v50 ) is between 5 μm and 40 μm, and even more preferably between 15 μm and 30 μm, or within the range of 15 μm to 30 μm, including, for example, 1 μm increments therebetween.

[0039] The median diameter of the reinforcing particles (d v50 If the median diameter (d) of these reinforcing particles is less than 5 μm, there are too many reinforcing filler particles present in the interstices between the filaments of the core yarn. From a processing point of view, this generally results in too large a surface area for these particles, leading to an increase in the viscosity of the polymer material that constitutes the matrix when it is deposited. v50If the average particle size (μm) is greater than 40 μm, there are too few reinforcing particles in the gaps between the filaments of the core yarn. From a processing standpoint, this generally results in the difficult and therefore insufficient dispersion of the reinforcing filler particles in the gaps between the filaments of the core yarn. In this case, the breaking strength of the composite yarn is generally considered to be insufficient.

[0040] Diameter (d v10 ) indicates the size below which 10% of the particles (by volume) have a smaller size and 90% of the particles (by volume) have a larger size. Particles generally have a diameter (d ) of less than 15 μm, preferably in the range of 1 μm to 15 μm. v10 )

[0041] The diameter of the reinforcing particles (d v10 If the diameter (d) of the reinforcing particles is less than 1 μm, there will be too many particles of reinforcing filler in the gaps between the filaments of the core yarn. From a processing point of view, this generally results in the surface area of ​​these particles being too large, which leads to an increase in the viscosity of the polymer material that constitutes the matrix when it is deposited. v10 If the diameter (d) is greater than 15 μm, there are too few reinforcing particles in the gaps between the filaments of the core yarn. From a process point of view, this generally results in the difficult and therefore insufficient dispersion of the reinforcing filler particles in the gaps between the filaments of the core yarn. In that case, the breaking strength of the composite yarn is generally judged to be insufficient. v90 ) indicates the size below which 90% of the particles (by volume) have a smaller size and 10% of the particles (by volume) have a larger size. Particles generally have a diameter (d) of less than 90 μm, preferably in the range of 30 μm to 90 μm, and even more preferably in the range of 30 μm to 80 μm. v90 )

[0042] The diameter of the reinforcing particles (d v90If the diameter (d) of the reinforcing particles is less than 30 μm, there will be too many particles of reinforcing filler in the spaces between the filaments of the core yarn. From a processing point of view, this generally results in the surface area of ​​these particles being too large, leading to an increase in the viscosity of the polymer material that constitutes the matrix when it is deposited. v10 If the average diameter (average diameter) of the core yarn is greater than 90 μm, there are too few reinforcing particles in the interstices between the filaments of the core yarn. From a processing standpoint, this generally results in the difficult and therefore insufficient dispersion of the reinforcing filler particles in the interstices between the filaments of the core yarn. In such cases, the breaking strength of the composite yarn is generally deemed to be insufficient. In the textile field where composite yarns are used, the nominal value of the average diameter of each filament of the core yarn is generally within the range of 3.5 μm to 13 μm, typically within the range of 3.5 μm to 9 μm, and more preferably within the range of 6 μm to 9 μm, e.g., 6 μm or 9 μm. This nominal value is usually provided by the core yarn supplier. For other applications of composite yarns, other nominal values ​​may be assumed.

[0043] According to a preferred embodiment, the median diameter (d v50 The ratio between the diameter of each filament of the core yarn and the length of the core yarn is generally in the range of 0.15:1 to 12:1, preferably in the range of 1.5:1 to 5:1.

[0044] According to a preferred embodiment, the weight percent of reinforcing filler present in the composite yarn is in the range of 0.5 to 30%. According to a more preferred embodiment, the weight percent of reinforcing filler present in the composite yarn is in the range of 0.5 to 20%. According to an even more preferred embodiment, the weight percent of reinforcing filler present in the composite yarn is in the range of 1 to 10%.

[0045] According to a preferred embodiment, the reinforcing filler is selected from the group formed by functionalized fillers, preferably from the group formed by functionalized glass beads, functionalized calcium carbonate, and functionalized talc.

[0046] The hardness of the functionalized glass beads is 5.5. The hardness of the functionalized calcium carbonate is 3.0. The hardness of the functionalized talc is 1.0.

[0047] The term "functionalized" means "surface-treated," i.e., functionality has been added to the particle surface via at least one organic group. This functionalization is carried out using at least one compound known as a functionalizing agent. Functionalization allows for the formation of "chemical crosslinks" between the filler and its environment (in this case, the matrix). Thus, the filler, core yarn, and matrix can be chemically bonded (e.g., via covalent bonds) or physicochemically bonded (e.g., via hydrogen bonds). Advantageously, this makes it possible to obtain a substantially homogeneous medium in which all components are bonded together via organic-type chemical bonds. This advantageously confers substantial cohesion and uniformity of mechanical properties to the material. This is consistent with the use of the term "reinforcing filler." In other words, the reinforcing filler is completely attached to the polymer and core yarn that make up the matrix.

[0048] Furthermore, the reinforcing fillers have a particle size small enough that some of them reside in the interstices between the filaments of the core yarn, which advantageously allows for filling of the interstices between the filaments, preferably all of the interstices between the filaments.

[0049] For talc consisting of phyllosilicate particles, the functionalizing agent is generally selected from the group formed by oxysilane (or siloxane) and oxygermane with at least one organic group, as described, for example, in WO 2014 / 207397.

[0050] Functionalized glass beads are generally prepared by chemically grafting reagents onto the surface of glass, either covalently or directly. This is described, for example, in WO 2014 / 083162. Functionalized glass beads are sold by Sovitec under the names Microperl® or Omicron®.

[0051] Calcium carbonate is generally functionalized by chemical grafting of reagents onto the surface, a process similar to that used for glass beads.

[0052] Preferably, the reinforcing filler is functionalized with at least one compound selected from silanes, for example silanizing agents such as alkylalkoxysilanes; epoxies (including, inter alia, epoxysilanes and DGEBA (bisphenol A diglycidyl ether)); polyisocyanates such as MDI derivatives (or 4,4'-MDI in the case of 4,4'-diphenylmethane diisocyanate) or HDI (in the case of hexamethylene diisocyanate).

[0053] Preferably, the reinforcing filler is functionalized with at least one compound selected from silanating agents, epoxies, and polyisocyanates, even more preferably silanating agents.

[0054] The silanizing agent is a compound containing at least one silyl group, such as alkylalkoxysilanes, alkylsilyl halides, such as trimethylsilyl chloride or dimethylsilyl dichloride, tetramethylsilane, tetraethoxysilane, dimethylsiloxane, 1,1,1,3,3,3-hexamethyldisilazane, and the like.

[0055] "Silyl" means a radical derived from silane.

[0056] "Alkyl" means a radical derived from an alkane and contains 1 to 20 carbon atoms, preferably 1 to 10 carbon atoms, and more preferably 1 to 5 carbon atoms.

[0057] "Alkoxysilane" refers to a compound containing the divalent group --Si--O and an alkyl group containing from 1 to 20, preferably 1 to 10, more preferably 1 to 5 carbon atoms.

[0058] Due to the wide variety of these products, silanes are used primarily. Silanes are molecules of the formula SiH4. By extension, the term "silane" here refers, as usual, to compounds in which the central atom is silicon, such as SiHCl3 (trichlorosilane), tetramethylsilane Si(CH3)4, or tetraethoxysilane Si(OC2H5)4. Functionalized reinforcing fillers are called silanates when they are functionalized with silanes, i.e., when a covalent bond is formed between at least one silyl group of the silane and the particle of the reinforcing filler. For example, silanization with trimethylsilyl chloride forms a trimethylsilyl group covalently bonded to the particle, or silanization with dimethylsilyl dichloride forms a dimethylsilyl group covalently bonded to the particle. Those skilled in the art can easily identify the grade that is perfectly suited to the situation, depending on the filler, core yarn, and matrix. Epoxies and polyisocyanates are most preferred, especially when the core yarn is of organic origin (polyester, polyamide, polyvinyl alcohol, etc.).

[0059] According to a preferred embodiment, the matrix further comprises at least one flame-retardant filler.

[0060] Flame-retardant fillers are well known to those skilled in the art and are generally selected from oxygenated antimony compounds, such as antimony trioxide, certain zinc salts, including zinc hydroxystannate or zinc borate, hydrated metal oxides selected from the group in which the metals are formed by aluminum, magnesium, tin and zinc, for example alumina hydrates, such as alumina trihydrate, or magnesium hydrates, such as magnesium hydroxide, and phosphorus-based ceramics that function as intumescent systems.

[0061] The core yarn is preferably made of a material selected from the group consisting of silion, basalt, aramid, polyester, polyamide, carbon, and polyvinyl alcohol. In a particularly preferred method, the core yarn is made of silion. As indicated above, the Mohs hardness of silion is 5.5.

[0062] When the constituent material of the core yarn is silion, it is known that the core yarn can be formed from "standard" textile glass yarn or "specialty" glass yarn.

[0063] The twist of standard textile glass yarns is generally in the range of 20 to 40 turns per meter. The twist is usually 28 turns per meter for 33-tex or 68-tex core yarns, or 40 turns per meter for 22-tex core yarns. Standard textile glass yarns also generally contain a starch-based sizing, the purpose of which is to protect the siloxane filaments and ensure their cohesion. This is called sized textile glass yarn. The composition of such sizing is generally developed by the companies that commercialize these core yarns, but they are not disclosed.

[0064] Sizing is deposited on the individual filaments that make up textile glass yarns during what is known in the industry as the "forming" operation, which involves spinning molten glass filaments through holes in a die at high speed. This sizing is generally deposited on the surface of the filaments in the form of an aqueous emulsion during the manufacture of the core yarn. It generally represents 0.5% to 1.5% of the weight composition of the core yarn. In textile yarns, the role of the sizing is to protect the filaments, making them easier to handle, and to reduce the occurrence of static electricity during weaving. Textile sizing usually consists of an adhesive (usually starch) and, optionally, at least one wetting agent (aimed at improving yarn impregnation) and / or at least one lubricant. In contrast to specialty textile glass yarns, standard textile glass yarns do not contain coupling agents in their sizing.

[0065] Thus, a standard textile glass yarn is generally a textile glass yarn having a twist in the range of 20 to 40 turns per meter and comprising a sizing comprising, preferably formed from, at least one adhesive and optionally at least one wetting agent and / or at least one lubricant.

[0066] Specialized textile glass yarns typically used in coating textile glass yarns with PVC plastisol generally have a twist in the range of 40 to 80 turns per meter and / or what is called special sizing, which, in addition to the standard textile glass yarn sizing, also contains at least one adhesion promoter and / or at least one coupling agent for the sizing. The twist value is usually related to the relevant end use. The adhesion promoter and / or coupling agent are intended to enable adhesion (primarily by creating at least one chemical bond) between the constituent filaments of the textile glass yarn and the adhesion promoter and / or coupling agent, and also between the adhesion promoter and / or coupling agent and the polymer that constitutes the matrix. Thus, the constituent filaments of the textile glass yarn and the polymer are chemically bonded. Preferably, the special sizing also contains at least one organic binder and / or at least one lubricant. The adhesion promoter / coupling agent is typically a silane. Each textile glass yarn manufacturer has its own proprietary sizing, the exact chemical composition of which is a trade secret. Thus, there are sizings specifically developed to promote silion / PVC adhesion, such as VETROTEX sizings TD52 and TD53, and sizings specifically developed to promote adhesion of silion to various types of polymers, such as VETROTEX sizings TD22 and TD37.

[0067] Thus, specialty textile glass yarns are generally textile glass yarns having a twist in the range of 40 to 80 turns per meter and / or comprising a sizing comprising, preferably formed from, at least one adhesive and at least one adhesion promoter and / or at least one coupling agent.

[0068] Therefore, the special textile glass yarns are much more expensive than the standard textile glass yarns.

[0069] In a particularly advantageous way, the composite yarn may comprise a core yarn which is a standard textile glass yarn rather than a strictly special textile glass yarn.

[0070] Without wishing to be bound by any theory, the applicant believes that this advantage is obtained by controlling the specific amount of bonding between the polymer that constitutes the matrix and the core yarn, and thanks to the presence in the matrix of functionalized particles that play an intermediate role and act as "joints" between the constituent filaments of the textile glass yarn and the constituent polymer of the matrix. These functionalized particles create chemical bonds between the standard sizing of the core yarn and the polymer that constitutes the matrix, which is not possible in the prior art.

[0071] In the case of textile applications, this therefore advantageously allows special textile glass yarns to be replaced by standard textile glass yarns, thereby significantly reducing the manufacturing costs of the composite yarns by an amount of the order of 25%, which opens up a panel of potential suppliers of core yarns for composite yarn manufacturers, especially those with the largest global production capacities, for example Asian suppliers producing textile glass yarns intended for the manufacture of printed circuit boards. In particular, not only is the raw material for the core yarn cheaper, in particular by avoiding the use of special and expensive organic products for sizing (i.e. at least one adhesion promoter and / or at least one coupling agent), but also, due to the lower twist of the core yarns, which are textile glass yarns, it is possible to limit the transit time of these yarns on twisting machines commonly used in textile production.

[0072] As shown in the examples, the quality of the composite yarn obtained by using a standard textile glass yarn core yarn is not compromised and is in fact superior to the quality of prior art composite yarns using special textile glass yarn core yarns. Without wishing to be bound by any theory, the applicant believes that this is due to easier access to the interstices between the filaments made possible by the functionalized particles present in the matrix.

[0073] Thus, the core yarn of the composite yarn can be a standard textile glass yarn.

[0074] The core yarn of the composite yarn can also be a special textile glass yarn.

[0075] The softening point or melting point of the constituent material of the core yarn must be higher than the mounting temperature of the polymeric material of the matrix of the composite yarn. For example, if the constituent material of the core yarn is a textile glass yarn, the softening point of the constituent material of the core yarn is at least 20°C higher, preferably at least 30°C higher, and even more preferably at least 50°C higher than the mounting temperature of the polymeric material of the matrix of the composite yarn. By way of example, the mounting temperature of the polymeric material of the matrix of the composite yarn is typically in the range of 50 to 180°C. The softening point of the constituent material of the core yarn is typically about 600°C when said yarn is a textile glass yarn.

[0076] According to a preferred embodiment, the composite yarn further comprises at least one layer, also called a "sheath" or "envelope", which envelops the matrix and comprises at least one polymeric material and at least one reinforcing filler. This layer is usually deposited in the same way as the matrix, preferably by coating. According to a preferred embodiment, the composite yarn is formed from a core yarn, a matrix, and a sheath.

[0077] Preferably, the polymeric material of this layer is of the same chemical nature as the polymeric material of the matrix, the term "same chemical nature" meaning compatible chemical composition, as known to those skilled in the art.

[0078] According to a preferred embodiment, the reinforcing fillers of the layers are of the same chemical nature as the reinforcing fillers of the matrix. Advantageously, this chemical identity makes it possible to obtain a composite yarn with better homogeneity, i.e. the core yarn, the matrix and the layers that constitute it interact in terms of sorption and adhesion.

[0079] Additionally, at least one other additive may be incorporated and dispersed in the matrix, the layer, or both (layer and matrix), such as one or more flame retardant fillers, pigmented fillers, and / or heat stabilizers and / or UV stabilizers.

[0080] Preferably, the sheath further comprises at least one flame-retardant filler, which is selected from the flame-retardant fillers known to those skilled in the art and described above.

[0081] The present disclosure advantageously makes it possible to limit the amount (by weight) of flame-retardant filler present in the composite yarn. Thus, typically, the amount (by weight) of flame-retardant filler in the composite yarn is generally greater than 1.5% and less than 7.5% by weight, e.g., about 3% by weight relative to the total weight of the composite yarn, in order to obtain a level of flame retardancy similar to that of state-of-the-art composite yarns, where the amount by weight of flame-retardant filler is in most cases 8 to 12% by weight relative to the total weight of the composite yarn.

[0082] The present disclosure advantageously allows for the production of composite yarns with improved fire resistance, particularly compared to that of prior art composite yarns, for the same amount (by weight) of flame-retardant filler. Thus, for the first time, it is permitted to produce composite yarns in which the core yarn is formed from silica and meets the Bs2d0 or Bs3d0 criteria of Euroclass standard EN 13501-1. Without wishing to be bound by any theory, the applicant believes that the inorganic nature of the reinforcing filler allows for localized dispersion of the heat provided by a fire. Furthermore, filling the inter-filament gaps with reinforcing particles makes it possible to eliminate the "chimney" effect associated with the lack of material in the center of the core yarn, which favors flame propagation.

[0083] According to one embodiment, the composite yarn comprises a continuous multifilament core yarn and a matrix, the matrix comprising: (i) at least one polymeric material, the polymer being selected from the group consisting of PVC, polyacrylate, polyolefin, polyester, polyvinyl, polystyrene, polyurethane, EVA polymer, and polyamide; (ii) at least one reinforcing filler, which is constituted by particles dispersed in the matrix polymer material and present in the interstices between the filaments of the core yarn, said particles being functionalized and having a median diameter (d v50 ) The composite yarn further comprises a flame-retardant filler in an amount of about 0.5 to 5% by weight, such that the textile surface obtained from said yarn meets the performance requirements defined by standard EN 13561 (over 10,000 cycles).

[0084] "Textile surface" means a mechanical assembly of yarns such as a fabric, nonwoven, knit, textile grid, etc. "Textile surface obtained from said yarns" means that the yarn assembly is a composite yarn.

[0085] According to one embodiment, the composite yarn comprises a continuous multifilament core yarn and a matrix, the matrix comprising: (i) at least one polymeric material, the polymer being selected from the group consisting of PVC, polyacrylate, polyolefin, polyester, polyvinyl, polystyrene, polyurethane, EVA polymer, and polyamide; (ii) at least one reinforcing filler, which is constituted by particles dispersed in the matrix polymer material and present in the interstices between the filaments of the core yarn, said particles being functionalized and having a median diameter (d v50 ) The composite yarn further comprises a flame retardant filler in an amount of about 0.5 to 5% by weight, such that the textile surface obtained from said yarn meets the fire performance requirements of Class M1 of standard NF P-92-507.

[0086] According to one embodiment, the composite yarn comprises a continuous multifilament core yarn and a matrix, the matrix comprising: (iii) at least one polymeric material, the polymer being selected from the group consisting of PVC, polyacrylate, polyolefin, polyester, polyvinyl, polystyrene, polyurethane, EVA polymer, and polyamide. (iv) at least one reinforcing filler, which is constituted by particles dispersed in the matrix polymer material and present in the interstices between the filaments of the core yarn, said particles being functionalized and having a median diameter (d v50 ) The composite yarn further comprises a flame-retardant filler in an amount of about 5 to 15% by weight, such that the textile surface obtained from said yarn meets the fire performance requirements of Euroclass Bs2d0 or Bs3d0 of standard NF P13501-1.

[0087] According to a second aspect, the present disclosure also covers a process for manufacturing a composite yarn according to the first aspect, said process comprising at least one step of depositing, by coating or extrusion, a matrix comprising at least one polymeric material and at least one reinforcing filler onto a core yarn.

[0088] In addition to the polymeric material, the matrix incorporates at least one reinforcing filler and, optionally, at least one other additive, such as a flame retardant filler.

[0089] The polymers used for deposition are conventional polymers such as PVC, polyacrylates, polyolefins, polyesters, polyvinyls, polystyrenes, polyurethanes, ethylene-vinyl acetate (or EVA) polymers, or polyamides. PVC and polyacrylates are generally used by coating deposition, typically using plastisol technology. Polyolefins, polyesters, polyvinyls, polystyrenes, polyurethanes, EVA polymers, and polyamides are generally used by extrusion deposition.

[0090] Preferably, the reinforcing filler is dispersed throughout the polymer prior to deposition. In other words, the reinforcing filler is mixed with the polymer when it is heated for deposition, especially if the polymer is deposited in liquid form. If the polymer is in powder form, the reinforcing filler can be mixed as a powder mixture. The reinforcing filler can also be intimately mixed with the polymer by an extrusion operation ("compounding") if the polymer is in granular form.

[0091] Such deposition is particularly preferably carried out in such a way that part of the filler is located in the interstices between the filaments of the core yarn, which is generally achieved by adjusting the rheological properties of the matrix during deposition, as known to those skilled in the art.

[0092] Preferably, the depositing step is carried out by coating a plastisol onto the filaments of the core yarn, the plastisol being more preferably based on polyvinyl chloride (PVC) or based on acrylic resin (polyacrylic acid). "Based on" means "mainly comprising" according to the present invention.

[0093] Plastisols are well known to those skilled in the art. They are generally paste-like at room temperature and are obtained by dispersing powdered synthetic resins (polymers) in liquid plasticizers. Various plastisols are described, for example, in patent application WO 2010 / 001240.

[0094] According to a preferred embodiment, the manufacturing process further comprises at least one step of coating on the composite yarn produced in the depositing step at least one layer of a polymeric material having at least one reinforcing filler dispersed therein, wherein the layer preferably further comprises at least one flame-retardant filler.

[0095] This coating step is typically carried out by coating a plastisol onto the composite yarn obtained in the deposition step or by extruding a compound onto the composite yarn obtained in the deposition step, preferably by coating a plastisol onto the composite yarn obtained in the deposition step.

[0096] This layer incorporates at least one reinforcing filler and, optionally, at least one other additive, such as a flame retardant filler.

[0097] The polymer used for coating is generally the same as the polymer used for deposition. The polymer used for coating is generally selected from the group consisting of PVC, polyacrylate, polyolefin, polyester, polyvinyl, polystyrene, polyurethane, EVA polymer, and polyamide.

[0098] The parameters of this coating step are generally similar to those of the deposition step described above, including the addition of one or more additives by mixing them into the polymer prior to coating.

[0099] Coating the composite yarn obtained in the deposition step with plastisol has been described above.

[0100] The term "compound" means a compound (generally in granular form) of a plasticized polymer (PVC, polyacrylate, etc.) or a compound (generally in granular form) of a polymer with a low glass transition temperature (polyolefin, polyester, polyvinyl, polystyrene, polyurethane, EVA, polyamide, etc.), said compound also optionally containing at least one additive, such as a stabilizer and / or a flame-retardant filler. The term "compound" is familiar to those skilled in the art. The term "plasticized polymer", as understood by those skilled in the art, means that there is an intimate mixture between the polymer and the plasticizer that has been used to plasticize it.

[0101] Preferably, when the coating step is carried out by extrusion of a compound, the coating step is carried out by extrusion coating of the composite yarn obtained in the depositing step with a compound having dispersed therein at least one reinforcing filler, the reinforcing fillers being as described above.

[0102] The present disclosure also relates in a third aspect to a textile surface comprising at least one composite yarn according to the first aspect or produced according to the second aspect.

[0103] Preferably, said textile surface is prepared by weaving.

[0104] The present disclosure will be more clearly understood in light of the following examples, which illustrate selected embodiments of the claimed invention without limiting its scope. [Example]

[0105] Example 1 Two composite yarns according to one embodiment were fabricated from PVC plastisol by coating a non-flame retardant matrix containing silanized glass microbeads as a reinforcing filler onto the core yarn, followed by a flame retardant layer itself, also containing silanized glass microbeads as a reinforcing filler. The core yarn was composed of textile glass yarns from two different sources. The silanized glass beads had a hardness of 5.5 Mohs. They were spherical, had an average diameter of 20 μm, and had a hardness of d v50 is 30 μm, d v10 is 15 μm, d v90 These were measured by laser particle size measurement using, for example, a Malvern Masterizer 2000 Instrument machine.

[0106] A control composite yarn was also made using two successive coatings of the same PVC plastisol on the same core yarn, based on the teachings of patent EP0900294.

[0107] 1. Composite yarn according to one embodiment of the present invention Core yarn: Textile glass yarn Textile glass yarns are characterized by their chemical composition in silions, their titre expressed in tex, the diameter and number of filaments that make up the yarn, their twist, and the type of sizing used.

[0108] Since the sizing is a protective coating that is deposited immediately after spinning the silion, the final use of the textile glass yarn will dictate the sizing chemistry.

[0109] Two types of core yarns were used in two composite yarns according to one embodiment, respectively: A special (and therefore more expensive) textile glass yarn developed specifically for "PVC-coated" applications. It had a special sizing compatible with PVC coatings (a silane-based sizing TD52M sold by Vetrotex, the proprietary composition of which is unknown) and a high twist (52 turns per meter, or "1.3Z"); it was also used in the control composite yarn. Standard textile glass yarn (28 turns per metre twist, i.e. "0.7Z") covered with a starch-based sizing.

[0110] PVC Plastisol according to one embodiment In each case, the core yarn was coated with a first, non-flame retardant coating containing silanized glass microbeads, and then coated with a second, slightly flame retardant coating also containing silanized glass microbeads. The compositions of the two plastisols used are shown in Tables 1 and 2 below.

[0111] [Table 1]

[0112] The RV Brookfield viscosity of this plastisol was 1200 mPa·s (measured with a No. 3 spindle at 23°C).

[0113] The temperature of the yarn exiting the coating line was 125°C.

[0114] [Table 2]

[0115] The RV Brookfield viscosity of this plastisol was 1350 mPa·s (measured with a No. 3 spindle at 23°C).

[0116] The temperature of the yarn exiting the coating line was 135°C.

[0117] No viscosity reducers were included in Plastisol 1 and 2. This absence of viscosity reducers is an advantage, which is very beneficial for the conservation of the plastisols and contributes to reducing VOC emissions during the manufacture of the composite yarns.

[0118] In this way, two composite yarns were obtained according to one embodiment, the properties of which are shown in Table 3 below.

[0119] [Table 3]

[0120] 2. Control yarn The reference 165 tex control yarn was produced according to the recommendations of patent EP 0 900 294, starting from a core yarn, a special textile glass yarn with a high twist (52 turns per meter) similar to that used in one of the two composite yarns according to one embodiment, specially developed for PVC coatings with a special sizing type TD52M sold by Vetrotex. Only two successive coatings with the same plastisol were carried out. The composition of the plastisol used is shown in Table 4 below.

[0121] [Table 4]

[0122] The Brookfield RV viscosity of this plastisol was 1300 mPa.s (measured with a No. 3 spindle at 23°C). This value was obtained with the addition of 5.4% of a volatile viscosity reducer, the presence of which produced VOCs during conversion of the plastisol.

[0123] The temperature of the yarn at the exit of the coating line was 135°C.

[0124] 3.Results The three composite yarns and the corresponding textiles obtained by the same operation to weave these composite yarns had the properties presented in Tables 5 and 6 below, respectively.

[0125] [Table 5]

[0126] [Table 6]

[0127] As can be seen in Tables 5 and 6, the properties of Yarns A and B were found to be superior to those of the control yarn, regardless of the core yarn (standard for Yarn A or specific for Yarn B). Tables 7 and 8 below reveal the compositional differences between Control Yarn C and Yarn B according to one embodiment, both made with the same core yarn. These results also apply to Yarn A, which uses the same plastisol as Yarn B and is made with a textile glass yarn having the same titer as the textile glass yarn used to make Yarns B and C.

[0128] [Table 7]

[0129] Thus, it was found that Yarn B, according to one embodiment, for the same fire resistance class, contains an amount of flame-retardant filler equal to about 25% by weight of the flame-retardant filler in Control Yarn C (i.e., a ratio of 1.9% to 7.5%). Thus, the amount of flame-retardant filler could be reduced by about 75% to obtain a similar level of flame retardancy as the Control composite yarn.

[0130] This significantly reduces the manufacturing costs. Thus, in the case of a composite yarn according to the embodiment comprising a textile glass yarn as core yarn and a PVC plastisol, this significantly reduces the cost of the PVC plastisol by the order of 25% to 35% to obtain the same fire compliance result as obtained according to the prior art, for example class M1 according to the present example.

[0131] [Table 8]

[0132] Thus, it was found that the yarn B according to the embodiment has a similar mineral material / organic material ratio (58.8% for the control yarn C; up to 50.5% for yarn B), but the flame retardant / organic material ratio is significantly reduced (15.2% for yarn C and 4.5% for yarn B). However, yarn B makes it possible to obtain the same level of fire resistance performance.

[0133] Furthermore, the use of reinforcing fillers allows for higher mechanical properties (an 18.5% increase in the breaking strength of the yarns: 54 N for Yarn B and 42 N for Yarn C, see Table 5), but the overall plasticization level of the two yarns is similar (14.7% for Yarn C and 14.3% for Yarn B, see Table 8), which ensures comparable flexibility for the two yarns.

[0134] In summary, composite yarns are disclosed in which the use of particles within the matrix allows for material to reside in the interstices between the filaments of the core yarn by virtue of the particles being incorporated therein, and the particles interact with both the core yarn filaments and the matrix polymer to provide one or more of the benefits described above, based on the disclosed parameters and desired application.

[0135] Example 2 1. Composite yarn One composite yarn (D) according to one embodiment was produced from PVC plastisol by two successive coatings of the same PVC plastisol coating containing flame-retardant particles and silanized glass microbeads as reinforcing fillers on the core yarn. The core yarn was a standard textile glass yarn of Example 1, constructed with low twist (28 rounds per meter) and a titer of 68 tex. Two types of silanized glass beads were used. The silanized glass beads, Microperl®, had a hardness of 5.5 Mohs. They were spherical, had an average diameter of 20 μm, and had a d v50 is 30 μm, d v10 is 15 μm, d v90 The average particle size was 80 μm. These were measured by laser particle size measurement using, for example, a Malvern Masterizer 2000 Instrument. The silanized glass beads Omicron® had a Mohs hardness of 5.5. They were spherical, had an average diameter of 5 μm, and v50 is 7 μm, d v10 is 2 μm, d v90 These were measured by laser particle size measurement using, for example, a Malvern Masterizer 2000 Instrument machine.

[0136] One control composite yarn (E), a commercial product of the applicant, was also used, which was made by applying two successive coats of the same PVC plastisol onto a core yarn. The core yarn was a special textile glass yarn with a high twist (52 rounds per meter) and a titer of 68 tex, as in Example 1. This commercial product has the highest fire resistance of any commercial product sold by the applicant, and therefore meets both the fire performance standard "M1" of standard NF92-503 and the fire performance standard "B1" of standard DIN 4102-1.

[0137] The compositions of the plastisols used are shown in Tables 9 and 10 below.

[0138] [Table 9]

[0139] The plastisol had a Brookfield RV viscosity of 900 mPa.s (measured with a No. 3 spindle at 23°C.) The temperature of the yarn at the exit of the coating line was 155°C.

[0140] The composite yarn D according to the embodiment thus obtained had a titer of 139 tex.

[0141] [Table 10]

[0142] The plastisol had a Brookfield RV viscosity of 1300 mPa.s (measured with a No. 3 spindle at 23° C.) The temperature of the yarn at the exit of the coating line was 135° C.

[0143] The control composite yarn E thus obtained had a titer of 165 tex.

[0144] 2.Results The two composite yarns and the corresponding textiles obtained by the same operation to weave these composite yarns had the properties shown in Tables 11, 12 and 13 below, respectively.

[0145] [Table 11]

[0146] The composite yarn D according to the embodiment provides a textile surface having substantially the same weight, thickness, and openness modulus as the textile surface obtained with the control composite yarn E, and the mechanical properties of the two composite yarns are very similar.

[0147] [Table 12]

[0148] As can be seen in Tables 11 and 12, compared to Control Yarn E, Composite Yarn D according to the embodiment has a slightly lower flame retardant / organic material ratio (15.4% for Control Yarn E, 14% for Composite Yarn D) and a slightly lower flame retardant / plasticizer ratio (50.5% for Control Yarn E, 47.6% for Composite Yarn D).

[0149] [Table 13]

[0150] The FIGRA parameter measures the rate of energy production during combustion. 0.2 The parameters provide the speed level to reach 0.2MJ. FIGRA for Euroclass "B" 0.2 The value is less than 120W / s.

[0151] The THP parameter measures the total energy production during combustion. 600 The parameters provide the energy production level reached in 600 seconds. THP for Euroclass "B" 600 The value is 7.5MJ or less, but the THP of Euro Class "C" 600 is less than 15.MJ.

[0152] FIGRA obtained from a textile made from composite yarn D according to the embodiment 0.2 The values ​​reflect a very sharp reduction in energy production during combustion compared to the textile made from control yarn E (90 W / s vs. 260 W / s), even though they have very similar physical properties. 0.2 <100 W / s) is typically not achievable with glass fiber-based textiles coated with plasticized PVC.

[0153] Therefore, only composite yarn D can meet the requirements of Euro class "B" of standard EN13-501-1, while the control yarn only meets the requirements of Euro class "C" of standard EN13-501-1. However, the textile surface obtained with composite yarn D according to the embodiment has significantly improved fire resistance performance, although it has a lower flame retardant content (5.6% compared to 7.8%) and a slightly lower flame retardant / plasticizer ratio (47.6% compared to 50.5%) than the textile surface obtained with control yarn E.

[0154] To the applicant's knowledge, this is the first time that a composite yarn obtained by coating a glass textile yarn with a flame-retardant plastisol is able to meet the requirements of Euro class "B" of standard EN 13-501-1.

[0155] This application may include the following inventions. (1) A composite yarn comprising a continuous multifilament core yarn embedded in a matrix, said matrix comprising at least one polymeric material and at least one reinforcing filler, said reinforcing filler being formed from functionalized particles, said particles having a median diameter (d v50 ) A composite yarn characterized by having. (2) The composite yarn according to (1), wherein the particles have a hardness (Mohs) equal to or less than the hardness of the constituent material of the filaments of the core yarn. (3) The particles have a median diameter (d v50 (1) or (2), wherein the composite yarn has a cross-sectional area of ​​100 mm. (4) The particles have a diameter (d v90 The composite yarn according to any one of (1) to (3), (5) The particles have a diameter (d v10The composite yarn according to any one of (1) to (4), (6) The composite yarn according to any one of (1) to (5), wherein the functionalized particles of the reinforcing filler are dispersed throughout the composite yarn matrix, and the matrix is ​​in contact with the core yarn filaments. (7) The composite yarn according to any one of (1) to (6), wherein a portion of the reinforcing filler is present in the gaps between the filaments of the core yarn. (8) The composite yarn according to any one of (1) to (7), wherein the reinforcing filler is selected from the group formed by functionalized fillers, preferably from the group formed by functionalized glass beads, functionalized calcium carbonate, and functionalized talc. (9) The composite yarn according to any one of (1) to (8), wherein the reinforcing filler is functionalized with at least one compound selected from a silanizing agent, an epoxy, and a polyisocyanate, preferably a silanizing agent. (10) The composite yarn according to any one of (1) to (9), wherein the matrix contains at least one flame-retardant filler. (11) The composite yarn according to any one of (1) to (10), wherein the constituent material of the core yarn is selected from the group consisting of silion, basalt, aramid, polyester, polyamide, carbon, and polyvinyl alcohol. (12) The composite yarn according to any one of (1) to (11), wherein the constituent material of the core yarn is silion, and the core yarn is a standard textile glass yarn. (13) The composite yarn according to any one of (1) to (11), wherein the constituent material of the core yarn is silion, and the core yarn is a special kite glass yarn. (14) The composite yarn according to any one of (1) to (13), further comprising at least one sheath layer covering the matrix, the layer comprising at least one polymer material and at least one reinforcing filler. (15) 15. The composite yarn of claim 14, wherein the reinforcing filler of the layer is of the same chemical nature as the reinforcing filler of the matrix. (16) The composite yarn according to (14) or (15), wherein the layer further comprises at least one flame-retardant filler. (17) A process for producing a composite yarn according to any one of (1) to (16), comprising at least one step of depositing a matrix containing a polymer material and a reinforcing filler onto a core yarn by coating or extrusion. (18) 18. The manufacturing process of claim 17, wherein the reinforcing filler is dispersed throughout the polymer prior to deposition. (19) The manufacturing process according to (17) or (18), wherein a portion of the filler is present in the gaps between the filaments of the core yarn. (20) The process according to any one of (17) to (19), wherein the depositing step is carried out by coating the filaments of the core yarn with a plastisol, the plastisol preferably being based on polyvinyl chloride (PVC) or acrylic resin. (twenty one) The process according to any one of (17) to (20), further comprising at least one step of coating the composite yarn produced in the depositing step by coating or extruding at least one layer of a polymer material having at least one reinforcing filler dispersed therein onto the composite yarn obtained in the depositing step. (twenty two) 22. The process according to (21), wherein the coating step is carried out by coating with a plastisol or by extrusion of a compound. (twenty three) 23. The process of claim 21 or 22, wherein the layer of polymeric material further comprises at least one flame-retardant filler. (twenty four) A textile surface comprising at least one composite yarn according to any one of (1) to (16) or produced according to any one of (17) to (23). (twenty five) 24. A textile surface according to claim 24, characterized in that it is produced by weaving.

Claims

1. 1. A process for manufacturing a composite yarn comprising a continuous multifilament core yarn embedded in a matrix, comprising at least one step of depositing, by coating or extrusion, onto the core yarn a matrix comprising a polymeric material and a reinforcing filler formed from functionalized particles, said particles having functionality added to their surface via at least one organic group for chemically or physicochemically bonding the filler, the core yarn and the matrix, said particles having a median diameter (d v50 ) comprised between 5 μm and 40 μm, and said process comprising a step of dispersing some particles of said reinforcing filler in the interstices between the filaments of said core yarn.

2. The process of claim 1 , wherein the reinforcing filler is dispersed throughout the polymeric material prior to deposition.

3. The process of claim 1 , wherein the depositing step is carried out by coating the filaments of the core yarn with a plastisol.

4. 10. The process of claim 1, further comprising at least one step of coating the composite yarn produced in the depositing step with at least one layer of a polymeric material having at least one reinforcing filler dispersed therein.

5. 5. The process of claim 4, wherein the coating step is carried out by coating with a plastisol or by extrusion of a compound.

6. 5. The process according to claim 4, wherein said coating step is carried out by extrusion coating of the composite yarn obtained in said depositing step with a compound having at least one reinforcing filler dispersed therein.

7. The process of claim 4 wherein the layer of polymeric material further comprises at least one flame retardant filler.

8. A composite yarn comprising a continuous multifilament core yarn embedded in a matrix, said matrix comprising at least one polymeric material and at least one reinforcing filler, said reinforcing filler being formed from functionalized particles, said particles having a median diameter (d ｖ５０ ) and when the core yarn has a titre of 68 tex, the composite yarn has a titre of 135-140 tex, the particles have functionality added to their surfaces via at least one organic group for chemically or physicochemically bonding the filler, the core yarn, and the matrix, and a portion of the reinforcing filler is present in the interstices between the filaments of the core yarn.

9. 9. The composite yarn of claim 8, wherein the continuous multifilament core yarn has a twist in the range of 20 to 40 rounds per meter.

10. 9. The composite yarn of claim 8, wherein the average diameter of each filament of the core yarn is in the range of 3.5 μm to 13 μm.

11. The median diameter of the reinforcing particles (d ｖ５０ 9. The composite yarn of claim 8, wherein the ratio between the diameter of each filament of the core yarn and the diameter of each filament of the core yarn is in the range of 0.15:1 to 12:

1.

12. 9. The composite yarn of claim 8, wherein the weight percent of reinforcing filler present in the composite yarn is in the range of 0.5 to 30%.

13. 9. The composite yarn of claim 8, wherein the amount of flame retardant filler in the composite yarn is greater than 1.5% by weight and less than 7.5% by weight.

14. The composite yarn comprises a continuous multifilament core yarn and a matrix, the matrix comprising: (i) at least one polymeric material selected from the group consisting of PVC, polyacrylate, polyolefin, polyester, polyvinyl, polystyrene, polyurethane, EVA polymer, and polyamide; (ii) at least one reinforcing filler, said reinforcing filler being constituted by particles dispersed in said polymeric material of said matrix and present in the interstices between the filaments of said core yarn; 9. The composite yarn of claim 8, wherein the particles are functionalized, and the composite yarn further comprises a flame retardant filler in an amount of 0.5 to 5 wt. %.

15. The composite yarn comprises a continuous multifilament core yarn and a matrix, the matrix comprising: (i) at least one polymeric material selected from the group consisting of PVC, polyacrylate, polyolefin, polyester, polyvinyl, polystyrene, polyurethane, EVA polymer, and polyamide; (ii) at least one reinforcing filler, said reinforcing filler being constituted by particles dispersed in said polymeric material of said matrix and present in the interstices between the filaments of said core yarn; 9. The composite yarn of claim 8, wherein the particles are functionalized, and the composite yarn further comprises a flame retardant filler in an amount of 5 to 15 wt. %.

16. 9. The composite yarn of claim 8, wherein the particles constituting the reinforcing filler have a Mohs hardness in the range of 1 to 5.

5.

17. A textile comprising at least one composite yarn according to claim 8.

18. 18. The textile of claim 17, selected from sunshades, sunblock textiles, sunscreen textiles, sunshield textiles, and combinations thereof.

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