I + D / Nuevos materiales y sostenibilidad. Revalorización de residuos, no tejidos y composites

ECO&TECNO CARPET II  – The use of new techniques for functionalisation and reducing the environmental impact of the carpet sector 

Year: 2019

 

MOTIVATION

The carpets and rug industry is highly traditional and its innovations are more concerned with design and textures rather than the incorporation of new materials or processes, which are only used to satisfy the requirements of certain sectors such as transportation and construction. 

In the textile sector, the functionalisation of fabrics has become a useful way for companies to remain at the forefront of innovation since it enables them to enhance fabrics with new properties using a range of technologies. Functionalisation enables a manufacturer to produce a product with added value within its own market sector and stand out from the competition. 

Functionalising textiles has enabled manufacturers to enhance their products with technical and innovative applications, such as sanitary or cosmetic functions where price is not usually a determining factor and where it is easier to identify the requirements of almost and segment, one of which could be the carpet industry. 

Our society is increasingly aware of the need to protect the environment and principles such as sustainability, biodegradability or recyclability are factors taken into account by consumers when choosing a product. 

The concept of sustainability has evolved from the linear to the circular economy and now to “cradle to cradle”, which aims not only for zero waste, but that the product serves as raw material for new products for other sectors, including carpets and rugs.

 

OBJECTIVES

The main objective of the ECO & TECNO CARPET II project is the development of functional rugs and carpets incorporating materials and processes improve the recyclability of the final product and to undertake research into the revaluation of the waste generated at all the manufacturing stages to increase a product’s life cycle and provide added value. 

The project was planned for two years and during 2019 it is intended to consolidate and optimise the results of the first year, while exploring new lines of work such as printed finishings. To achieve the overall objective of the project the following specific objectives will be addressed: 

1. Technological surveillanceto understand the current situation in the carpet sector. 

• Identifying functionalities of interest thatcan be used.
• Identifying sustainable solutions applied in the industry.
• Identifying equipment and / or processes likely tobe usedin the sector. 

2. Endowment of functionality tocarpets. 

• Identify fibres with functional properties forusein carpet spinning and weaving. 
• Development of prototypes spun with the selected functional fibres
• Development of functionalfabricprototypes with the yarns selected by tufting. 
• Identification of functional finishing products thatcan be usedin the printing process for carpet functionalisation. 
• Development of functional prototypes by printing carpets.
• Identify functional materials with different functional properties foruse in carpetbacking. 
• Development of functional carpets through the lamination of functional substrates in thecarpetbacking. 

3. Making carpets sustainable.

• Identify fibres from renewable and recycledsourcesfor use in carpet spinning and weaving. 
• Development of prototypes spun with sustainable fibres
• Use of natural dyes in biofibre dyeing.
• Development of sustainable prototypes through tufting.
• Identify adhesives from renewable, biodegradable or recyclable sources.
• Development of sustainable carpets through lamination with ecological films.
• Development of prototypes that revaluecarpetresidues using certain technologies: Wet-laid, glue, kinetic mixer and / or thermoformed. 

4. Strengthen the business fabric of the Valencian Community from the perspective of the incorporation of innovation and sustainability in a very traditional and conservative sector.

 

EXPECTED RESULTS

The ECO & TECNO CARPET project, despite being research intense, is also highly focused on product development, and the expected results include: 

1. Development of functional carpetsusing biofibres and functional fibres: 

• Carpet prototype withenhancedfreshness. 
• Carpet prototype with the ability to improve the biomechanical balanceby usingfibres additivated with bioceramic compounds. 
• Prototype of intrinsically antibacterial and antifungal carpetusing fibres with these properties.

2. Development of functional carpetsusing lamination: 

• Carpet prototype with the ability to attenuate and / or shield EMI radiation, by using a screening fabric in the backing of the carpet.
• Prototype carpet with heating capacity. Incorporation of heated textronic elements in the backing of the carpet.
• Anti-slip carpet prototype. Continuous lamination of non-slip film in the backing of the carpet.

3. Development of functional carpets through the application of finishes by printing:
   

• Carpet prototype with the ability to generate a sensation of freshness.
• Prototype of carpet with ability to decontaminate interiorenvironments.
• Antibacterial and antifungal carpet prototype.

4. Development of sustainable carpetsusing biofibres or recycled fibres: 

• Sustainable carpet prototypecontaininga high percentage of sustainable product. 
• Sustainable carpet prototypeusingnatural dyes. 

5. Development of sustainable carpets using continuous lamination:

• Sustainable carpet prototype, easily recyclableby usinghot melt adhesives as an alternative to the usual systems. 

6. Development of cradle-to-cradle economy in the carpet sector:

• Prototype construction material (panels) from recycledcarpet andrugs by any of the technological approaches detailed in this report. 

 

This project is funded by the Conselleria d’Economia Sostenible, Sectors Productius, Comerç i Treball de la Generalitat Valenciana, through IVACE, and is co funded by ERDF from the European Commission within the framework of the Operational Programme FEDER for the Comunitat Valenciana 2014-2020.

GRANT NUMBER: IMDEEA/2019/47
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Additional Information

• Year: 2019

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• Status: Finished

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• Entity: IVACE

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