Method for an Alternative Pile Fixation of Tufted Fabrics for a Recyclable Textile Floor Covering (alNop)

Tufted textile floor coverings require a finishing step for filament and pile fixation before they can be used. A chalk-filled SBR latex is usually used for this purpose. After the use phase, this makes it difficult to separate the top and backing layers and thus to recycle them by type. The aim of this research project is therefore to develop an alternative process for the mechanical pile fixation to be able to avoid the latex layer component.

The approach investigated here is the controlled and specified shrinkage of the primary backing material after the production of the unfixated product. For this purpose, tufting primary backings are developed from industrially produced yarns and fibres with high shrinkage, tufted and then subjected to a hot treatment, i.e., a targeted shrinkage is triggered. The focus of the investigation is the influence of the yarn materials, the backing structures, the tufted yarns as well as the tufting construction on the pile integration. Furthermore, different methods for shrinkage initiation are evaluated about the design of the backing structure. The result of the research project is an evaluated demonstrator as well as a design guideline to produce textile floor coverings with alternative pile fixation.

SMEs from the areas of yarn and backing material producers can develop new products with the help of the research results. Manufacturers of textile floor coverings can create a unique selling point in the European competition by improving the recyclability of their products. In addition, the possibility of designing recycling-friendly tufting structures opens new technical applications, e.g., in the field of filter media, geotextiles and insulation materials.

Figure: Principle of mechanical fixation of pile yarn by controlled shrinkage

Funding program and project number

IGF 21336 N

Duration

01.09.2020 – 31.08.2022