EP2415373A1

EP2415373A1 - Carpet or drapery of recycled PET

Info

Publication number: EP2415373A1
Application number: EP10425267A
Authority: EP
Inventors: Lucia Bozino
Original assignee: ABC Italia Srl
Current assignee: ABC Italia Srl
Priority date: 2010-08-03
Filing date: 2010-08-03
Publication date: 2012-02-08

Abstract

The present invention describes the use of a synthetic material for the production of carpets or drapery that have characteristics that are similar to the carpets or drapery made from natural materials.

Description

The present invention concerns the new use of a synthetic material, in particular for making carpets, as well as the carpets thus obtained.

TECHNICAL FIELD OF THE INVENTION

Furnishing fabrics made from synthetic material, for example, Nylon, Polypropylene, Polyethylene, etc.... have been known for a long time and have become common in daily life use.
There are many uses ranging from covering furniture like tables, cupboards or sideboards with the purpose of protecting their valuable surfaces, to covering both indoors and outdoors flooring.
With respect to the natural traditionally used materials, like cotton, linen and canvas, to mention the most common ones, the fabrics obtained with artificial fibres have the great advantage of being more resistant to mechanical wearing, typically represented by treading, to weather: rain, snow but also intense sunlight, as well as to chemical substances of various nature, or oily substances or dirt typically comprising mud or grass.
Being more resistant from different points of view, such carpets can be washed at high temperatures even in washing machines and can be treated so that they can regain to their initial characteristics.
The management of carpets in artificial material, by this meaning the cleaning and maintenance thereof, is thus overall very simple and meets the requirements of practicality of daily life.
It should not be underestimated, moreover, that normally the yarns often have a more affordable cost, thanks to the less valuable material they are made with; therefore, the carpets thus produced are a lot more cost-effective.
These and other reasons, therefore, have resulted in the commercial success of carpets produced from artificial materials.
In view of these advantages, however, it cannot be denied that the fabrics produced with artificial fibres have some drawbacks. For example, such fabrics are characterised by a translucency, which enhances their artificial appearance, which is not well accepted.
On the other hand, they are also less pleasant to touch, since they are rougher and often give the user the sensation of touching a plastic product.
Consequently, carpets thus produced are generally considered of low value and of inferior quality; therefore, they are usually used to cover surfaces like terraces, balconies or, in any case, they are often placed in rooms like cellars or storage rooms, where they are less visible.
There is thus the need to provide carpets made from synthetic material that nevertheless have the advantages of carpets made with natural materials, that consumers appreciate so much.
The present invention, therefore, has the purpose of proposing a carpet that on one hand has the advantages of carpets made from artificial materials, but does not have the aforementioned drawbacks.
In particular, the present invention concerns a carpet made from synthetic material that has the touch characteristics and visual appearance like a carpet made from common natural fibres.
This and other purposes are obtained by carpets in accordance with claim 1 and the dependent claims.
In the following description, with the term "carpet" we mean drapery obtained by plaiting through weaving of warp and weft threads, as well as carpets meant in the usual sense and obtained with knotting work.
More in particular, we mean knotted carpets, possibly hand-knotted or rolled, hand-tufted, hand-woven "Kelim" (or "Kilim"), "Schumacks" (or "Soumak"), "Karamanie" and similar hand-woven fabrics.
In the following description, the terms carpet and drapery are used without distinction.
In particular, it has surprisingly been found that a yarn made from recycled polyethylene terephthalate, once woven, makes it possible to obtain a drapery characterised by an appearance that is completely similar to that of a drapery made from natural material.
Indeed, the carpet according to the present invention made from recycled polyethylene terephthalate (RPET) is completely similar to and it is also difficult to tell apart from a carpet woven in mercerised cotton or in silk.
These properties are completely unexpected and surprising in view of the similarities between recycled polyethylene terephthalate and the other synthetic materials known in the state of the art, like for example polypropylene, polyamide, polyethylene.
Completely surprisingly, moreover, rPET has proven to be particularly suitable for the purposes of the present invention even with respect to non recycled (virgin) polyethylene terephthalate.
The carpet of the present invention, therefore, is obtained by plaiting threads of warp and threads of weft both made from recycled PET, with no other material being used for the manufacture thereof.
If necessary, however, for making handloom or tufted carpets that require a fabric on the back arranged so as to support the carpet itself, a PET based glue can advantageously be used.
As far as polyethylene terephthalate and, therefore, recycled polyethylene terephthalate is concerned, this is represented by the molecule shown below.
From the chemical point of view, as can clearly be seen from the repetitive unit structure, PET and recycled PET are esters of terephthalic acid with ethylene glycol.
Thanks to the compatibility with food products, polyethylene terephthalate is the material of choice for the production of containers intended for preserving food and, particularly, beverages. Common plastic bottles used for mineral water, typically produced in PET, represent the main source of material for obtaining recycled PET.
In particular, as mentioned above, the material used for the production of carpets according to the present invention, consists of post consumption recycled polyethylene terephthalate.
Through the so called waste sorting, which represents an approach that is widespread and strongly encouraged by institutions, indeed, bottles and containers made from polyethylene terephthalate, are separated from other types of waste, like organic waste, metal, paper or plastics of different nature, are triturated and the material thus obtained in powder or granules are washed so as to eliminate possible foreign residue like paper or possible metallic parts.
The powder or the granules are then melted and then the mass is extruded obtaining the yarn made from rPET.
In particular, the yarn of recycled polyethylene terephthalate used for the purposes of the present invention has the characteristics shown in the Table 1.

Table 1

Characteristic
Resistance to dirt and stains	Good
Resistance to light	Good
Abrasion/wear resistance	Good
Resistance to fire	Good
Specific weight	1.38
Dyeing speed	Good
Softness	Good
Static control	Very high
Humidity absorption	0.4-0.5
Hypoallergenic and bacteriostatic capacities	Good
Resistance to alkaline substance	Good
Water absorption (%)	poor
Breaking tenacity (g/d)	2.0-6.0

As far as the weight of the fibre used is concerned, this is for example selected in the range of 1,2 and 3 denier.
By denier we mean the unit of measurement of the linear mass of the fibres and it is defined in grams of material per 9,000 metres.
The fibre used, moreover, preferably has a length comprised between 50-150 mm.
For making the carpet according to the present invention, a single or double fibre can be used, whereas the double fibre is obtained by intertwining single fibres. The man skilled in the art shall be able to select the type of fibre based upon the requirements.
The carpet produced with the yarn made from recycled polyethylene terephthalate according to the present invention can be made in different sizes and thicknesses. For example, carpets with fleece will be characterised by having an overall thickness of about 10-11 mm, in which the fleece has a height of about 6-7 mm. In the case, however, of carpets made with a flat weave, these will normally be characterised by having a smaller thickness, that is variable, for example, between 2 and 5 mm.
Of course, variations to the aforementioned characteristics will equally be made and are within the capabilities of the man skilled in the art. A thicker carpet, thanks to its particular strength, can be used to cover or protect outdoor surfaces or, more in general, should it need to, stand greater friction and wearing, like in places characterised by frequent treading; a thinner thickness will be preferred, on the other hand, for carpets or drapery for covering and protecting furniture like shelves, consoles, chests of drawers, etc.
Advantageously, the yarn made from recycled polyethylene terephthalate of the present invention can undergo dyeing processes before it is weaved, by using natural or artificial dyes known in the field and according to the techniques known by the man skilled in the art.
Thanks to the possibility of dyeing the fibres, the carpet made by weaving the yarn described according to the present invention can thus be characterised by geometrical, flower, tartan or striped patterns, according to the appropriate arrangement of the threads of warp and weft, according to methods known in the art.
The dyeing of the yarn made from recycled polyethylene terephthalate surprisingly makes it possible to obtain the same chromatic effects that can be obtained with non recycled (virgin) polyethylene terephthalate.
Moreover, it has surprisingly been noted that the colourfastness, i.e. the capability of the yarn of rPET of not losing its colour when washed, even at a temperature of 60°C, and of not fading over time due to light exposure, contrarily to many other synthetic fibres that, on the other hand, have low colourfastness.
The carpet made according to the present invention, therefore, advantageously has all the desired characteristics of a carpet obtained with the commonly used natural yarn.
In addition to this, the yarn made from polyethylene terephthalate surprisingly makes it possible to make drapery that is particularly soft to touch.
Consequently, a carpet can be obtained that is characterised by having the same softness and same pleasant feel of those made from natural materials.
From the appearance point of view, the carpet of the present invention can surprisingly and advantageously be mistaken for a carpet made from a much more valuable natural yarn.
Wear and stain resistance, the possibility of being able to undergo washing even at high temperatures, the possibility of being dyed, as well as finally the substantially pleasant feel, make the carpet according to the present invention very appreciated by consumers.

Concerning this, the carpet of the present invention has been subjected to numerous tests with the purpose of verifying its composition and evaluating its performances. The list of such tests is shown below.

TEST	EXAMINED CHARACTERISTIC
ASTM D276	Chemical recognition of the fibres
AATCC-16E or AATCC 16E-1976	Colourfastness following light exposure
AATCC 165	Dye staining other items
AATCC 129-175	Colourfastness in the presence of ozone
AATCC 23-1975	Colourfastness in the presence of gas from the combustion of natural gases like nitrogen oxides
AATCC 107	Colourfastness to humidity
AATCC 134	Inclination to generate electrostatic charges after being trodden upon
ASTM D-257	Ability to inhibit the transmission of electric charges
DIN-STD-54318	Dimensional stability
OHM Test	Electric resistance
AATCC 138	Resistance to dimensional modification and durability of the antimicrobial properties following washing
AATCC 174	Defining the quality and the quantity of microbial and mould activity
ASTM D5116	Emissions of volatile organic compounds
ASTM D3511	Pilling resistance and resistance to other surface changes
ASTM D4158	Abrasion resistance
ATCC 175-2008	Resistance to staining from acid food colouring
AATCC TM 16 Option E	Colourfastness to Xenon light in particular conditions
AATCC TM 129	Colourfastness to ozone in conditions of high temperature and humidity greater than 85%
AATCC TM 164	Colourfastness to nitrogen oxides in conditions of high temperature and humidity greater than 85%

Surprisingly and unexpectedly, the carpet of the present invention has proven to pass the tests carried out with results that were more than satisfactory, thus making it ideal for the aforementioned purposes.
Indeed, as mentioned above, the main source of rPET is represented by mineral water bottles recovered thanks to the waste sorting.
On the other hand, the fact that the carpet is made completely from recycled material should not be underestimated, and it is actually a substantial advantage.
Over the last few years, the public opinion and consumer's awareness of environmental problems has grown. Every day, the industrial field but also the private sector produce an enormous quantity of every kind of waste, which must be managed, as far as their collection, separation based upon their nature, elimination and/or recycling is concerned. The recycling represents the beginning of a second life for "thrown away" material and makes it possible to save a substantial amount of energy resources.
Indeed, making new products from reused material requires lower energy contribution than that necessary starting from virgin material. Consequently, the consumption of precious energy resources is limited. Moreover, the greater the amount of recycled goods, the smaller the volume of waste that must be eliminated, through incineration, or deposited in landfills.
Moreover, different institutions have issued regulations and norms aimed at increasing or in any case promoting the waste sorting on one hand and on the other hand the preferential use of goods from recycling activities.
For example, the Ministry of the Environment and Territorial Protection has issued a decree according to which public offices and societies publicly owned by the most part, must cover their annual demands of products and goods with an amount of products obtained from recycled material of the order of not less than 30% of the demand itself.
At the same time, consumers have started to preferentially direct their purchases choices towards the so called eco-friendly products, i.e. obtained by recycling other materials and that, preferably, are themselves in turn able to be recycled.
Like other materials, also the production of PET from recycled material has a lower energy cost with respect to the production of ex novo (virgin) PET. For the production of a carpet in recycled PET according to the present invention, the material from which the yarn to be used is obtained, as above said, comes from the reuse of the common bottles and containers used for mineral water and for beverages in general.
The considerable growth in the consumption of bottled water and beverages over the last few years has led to the production of enormous amounts of waste.
The possibility of making a yarn from recycled bottles, therefore, represents an enormous advantage since it makes it possible to drastically reduce the volume of plastic that would otherwise be deposited in a landfill or incinerated.
A drapery made according to the present invention, not only comes from recycled material but there should be emphasised how it is also completely recyclable.
Indeed, in order to produce it there is no need to use other non-recycled material. If it is foreseen for there to be a label for commercial purposes, at the moment in which the carpet is thrown away because it is too old or ruined, the label itself can be easily and quickly removed allowing the carpet to be placed in the containers suitable for recycling plastic. Disposal, therefore, is made much easier.
Consequently, the drapery of the present invention is extremely advantageous also with respect to the common "carpets" of the "wall to wall carpet" type. Indeed, their structure comprises a lower layer (secondary backing), in contact with the surface they are resting on, generally made from polypropylene to which a layer called primary backing is joined through a glue made from a styrene based latex (styrene-butadiene, SBR) comprising calcium carbonate. On such primary backing, through the tufting technique the yarn that projects on the surface is applied.
The gluing layer used, in particular, is represented by material of the thermosetting type that, once used, cannot be melted or used again. Since this cannot be separated from the rest of the material, the fabrics of the wall to wall carpet type cannot be recycled and will necessarily end up in the landfill.
This is a problem of unlimited environmental impact, since in the United States alone, there has been estimated that about 2-3 millions of tons of waste are made up of carpets, that, according to other research studies about 70% are going to be replaced with new carpets, thus enhancing the aforementioned problems.
Consequently, it can easily be understood how the present invention is extremely important in providing a valid and optimal solution to the problem of reducing waste consisting of polyethylene terephthalate, whilst at the same time offering to the consumer a product that is practical, handy, easily manageable, cost-effective and attractive.
Beyond the aforementioned advantages, the carpet made according to the present invention, advantageously, has anti stain properties, since the material is sufficiently hydrophobic not to absorb or limitably absorb possible liquids like oil, sauces or ink stains with which it can become soiled. In any case, even if it is soiled it can be washed in the washing machine at 60°C, thus being easily cleaned.
In this regard, see what mentioned above about the surprising results obtained in the tests carried out on the carpet of the present invention.
The recycled polyethylene terephthalate with which the carpet of the invention is made is an anti-mould material, therefore even in high humidity conditions it has surprisingly demonstrated to not promote the development of mould with the consequent advantage of avoiding the formation of bad odours.
Alternative embodiments of the carpet described according to the invention can be applied by the man skilled in the art in order to satisfy contingent needs and specifications; adaptations and modifications are equally possible without however departing from the scope of the following claims.

Claims

Carpet or drapery to cover surfaces and/or furniture made through weaving or knotting of fibres made from recycled polyethylene terephthalate.
Carpet or drapery to cover surfaces and/or furniture according to claim 1, wherein said woven or knotted fibres are single or double.
Carpet or drapery to cover surfaces and/or furniture according to claim 1 or 2, wherein the fibres of polyethylene terephthalate have a breaking tenacity of about 2.0-6.0 g/d.
Carpet or drapery to cover surfaces and/or furniture according to one of claims 1 to 3, wherein the weight of the fibre is selected in the range of 1, 2 and 3 denier.
Carpet or drapery to cover surfaces and/or furniture according to one of claims 1 to 4, wherein the fibre has a length comprised between 50-150 mm.
Process for making a carpet or drapery comprising the weaving or the knotting of fibres made from recycled polyethylene terephthalate.
Use of fibres made from recycled polyethylene terephthalate for the production of a carpet or of drapery.
Use of fibres made from recycled polyethylene terephthalate for the production of a carpet or of drapery according to claim 8, wherein said fibres have a weight selected in the range of 1, 2 and 3 denier.
Use of fibres made from recycled polyethylene terephthalate for the production of a carpet or of drapery according to claim 7 or 8, wherein said fibres have a length of between 50-150 mm.
Use of fibres made from recycled polyethylene terephthalate for the production of a carpet or of drapery according to one of claims 7 to 9, wherein said fibres are single or double.