Backing Development – Development of innovative backing systems with a high pile fixation in the greige good in order to manufacture recyclable carpets

In collaboration with the Object Carpet GmbH we are developing a recyclable carpet design made of environmental friendly and harmless to health materials with a high value in use. Moreover, optimal production runs as well as energy consumption for coating will be taken into consideration.

Recyclability means that the different materials in a carpet are separable. Therefore, instead of a conventional coating process the Object Carpet GmbH uses the innovative method by Covestro-Niaga. The greige good is thermobonded fusing pile yarn and backing to oneantoher. In a second step this material unit is glued to a secondary backing via hotmelt. Due to the hotmelt’s technical properties (so-called “click-unclick system”) secondary backing and hotmelt can be removed from the top side of the carpet with almost no residues. Therefore, the secondary backing is fully recyclable. In order to use this method we are pursuing the new approach to achieve a high pile fixation already in the backing material (see illustration). The pile fixation is measured via the pile withdrawal force. The higher the pile fixation is, the lesser the effort for the energy consuming solidification process.

Based on the existing test method “Endless Loop Test” TFI designs a new test method. In the existing test method, an “endless” pile yarn is pulled parallel through a backing material and the force is recorded. The higher the measured force is, the higher is the sliding friction between pile yarn and backing material.

Funding program and project number

ZIM KK5494501KT2

Duration

01.04.2023 – 31.03.2025