EP3978665A1

EP3978665A1 - Method for producing recycled pet woven fabric and woven fabric made from recycled pet

Info

Publication number: EP3978665A1
Application number: EP21461521.3A
Authority: EP
Inventors: Dariusz Michta
Original assignee: Softex Dariusz Michta Firma
Current assignee: Softex Dariusz Michta Firma
Priority date: 2021-03-08
Filing date: 2021-03-08
Publication date: 2022-04-06
Anticipated expiration: 2041-03-08
Also published as: EP3978665C0; EP3978665B1; PL3978665T3

Abstract

The subject-matter of the invention is a method of 100% recycled PET technical fabric production, characterized in that it comprises steps where a warp of yarn obtained from 100% recycled PET filaments is warped with a thickness ranging from 40 to 334, preferably 84 to 334 dtex, and more preferably 84 to 167 dtex; the warp is tied on the loom, preferably using an automatic warp-tying machine; a weft of yarn obtained from 100% recycled PET filaments with a thickness ranging from 58 to 668 dtex, preferably 78 to 501 dtex, and preferably 167 to 334 dtex is threaded on a loom; after loom activation, the fabric pattern is established and weaving is carried out; the finished fabric is wound on a roller; initial quality control and preparation for the washing and dyeing process are carried out; the fabric is washed with heated water at 70°C to 100°C and a pressure of 0-1 bar and dyed at 110°C to 140°C and a pressure of 2.5-3 bar; the washed fabric is subjected to thermal stabilization in order to maintain its physicochemical parameters, and drying; the dried fabric is rolled on rollers and subjected to a final quality control, then the fabric is cut into smaller batches and labeled; wherein the stabilization of the fabric is carried out by annealing the fabric strip at 160°C to 220°C, with a fabric web feed rate from 10 m/min to 30 m/min. The subject-matter of the invention is also a fabric produced by this method.

Description

Subject-matter of the present invention is a method of 100% recycled PET fabric production, in particular technical fabrics such as fabrics for the production of roller blinds, tablecloths, upholstery, specialist clothing, and 100% recycled PET fabric obtained by this method.

Background of the Invention

Many currently produced technical fabrics are enriched with admixtures meant to ensure their durability, resistance to using conditions, while maintaining an appropriate quality-price ratio. The admixtures introduced into the material structure, especially of the roller blind, are usually in the form of synthetic threads woven together with natural fibers or cheaper synthetic fibers woven with other, more expensive threads with higher technological parameters.
The working conditions of technical fabrics, especially those used in roller blinds, require protection against a series of consequences of performing a sequence of the same and repetitive movements, such as unrolling of the central strip of the roller blind material, ripping and fraying of the edge of the roller blind material or abrasions in contact with, for example, the window frame or roller blind guide rail.
Most often, the technical fabrics are woven by admixing significant amounts of synthetic yarns or are woven completely of such yarns, as these can be stabilized in the course of the production process by annealing, during which the extreme, frayed fibers melt and stick together.
For this purpose, polyester fibers are usually used, but in their case, their production process, which is related to the petroleum refining processes, is perceived as significantly harmful to the natural environment, and energy-consuming. During laboratory work it was found that polyester fibers obtained in a conventional way (hereinafter referred to as virgin polyester fibers) by polycondensation from dimethyl terephthalate (DMT) and ethylene glycol could be replaced with polyester fibers produced by recycling secondary raw materials, sometimes used in the production of nonwovens, for example, such as PET, but due to the high heterogeneity of such fibers (yarn), they require additional technological operations to homogenize structure of the obtained fabric, especially in terms of mechanical strength. At the same time, the yarn with a heterogeneous structure and non-uniform tear resistance requires a significant reduction in the speed of weaving on mechanical looms, which practically makes it necessary to use air-jet looms in the production process.
The patent specification PL 227700 B1 discloses a fabric production method, especially for the production of covers, in particular roller blinds, in which the proportion of admixture fibers obtained from secondary PET raw materials is from 20 to 90%, preferably 80%, and the fibers obtained from secondary PET raw materials are incorporated into structure of the fabric as its weft and have dtex of preferably 500. The warp fibers are preferably synthetic fibers with dtex not higher than 90. According to that invention, the maximum proportion of recycled PET fibers was 90%. This was due to the fact that at that time, cotton twill fibers were used, which did not have the sufficient strength to be used as warp fibers. Therefore, it was necessary to use standard polyester fibers, i.e. virgin polyester fibers, as the warp fibers.
Also, Taiwanese patent application TW201348540 A discloses an environmentally friendly curtain fabric, the structure of which is formed by co-weaving a polypropylene (PP) filament yarn and a polyethylene terephthalate (PET) filament yarn and then hot pressing, which allowed mass recovery of recycled polypropylene (PP) and polyethylene terephthalate (PET).
Another Taiwanese patent application TW201209239 A discloses a 100% recycled green polyester fabric and a method its production which comprises six steps. In the first step, PET bottles are first recycled, green ones selected and baled into green PET bottle bales. In the second step, green PET bottles are crushed into 100% recycled green flakes and granulated into 100% recycled green PET chips. The chips are then melted and spun into 100% recycled green partially oriented yarn (POY) and 100% recycled green textured yarn (DTY). 100% recycled green polyester fabric is woven from the obtained yarns, which is characterized by a durable and elegant color and does not require finishing treatment including dyeing.
European patent application EP2415373 A1 discloses the use of a synthetic material for the production of carpets or drapes which have features similar to carpets or drapes made of natural materials. In particular, it was surprisingly found that a yarn made of recycled polyethylene terephthalate, when woven, makes it possible to obtain a drape having an appearance completely similar to a drape made of natural material. Indeed, the carpet of that invention made of recovered polyethylene terephthalate (RPET) is completely similar to a carpet woven from mercerized cotton or silk, and is also difficult to distinguish from it.
Japanese patent application JP2003193349 A2 describes dust-free clothes in which at least 75 percent by weight of the fabric making up the dust-free clothes is made of polyester from recycled PET bottles or the like, and which content of recycled polyester fibers is significantly greater than or equal to 50 percent by weight, which is environmentally friendly and can be autoclaved. The polyester fabric of that invention comprised (A) polyester fibers obtained by melt-spinning recycled polyester and (B) polyester fibers obtained by melt-spinning of another polyester having an intrinsic viscosity [eta] greater than or equal to 0.70.
Chinese patent applications CN111011950 A and CN111005130 A disclose an environmentally friendly, recyclable, quick-drying bathrobe and towel which are made of a double-sided flannel formed by weaving regenerated polyester fiber yarn, wherein the thickness of monofilament fibers in regenerated polyester fiber yarn did not exceed 0.2 dtex and the regenerated polyester fiber yarn contained 100% regenerated polyester. Another Chinese patent application CN110644109 A discloses an environmentally friendly recycled fabric which comprises 20-35 parts of a first, physically regenerated PET fiber (polyethylene terephthalate) and 65-80 parts of a second, chemically regenerated PET fiber.
Korean patent specification KR101606846 B1 describes a composite textured yarn with recycled PET yarn and methods of curtain fabric weaving using the same, wherein the composite textured yarn comprises a low melting fiber and a recycled PET yarn.
Another Korean patent, KR101437236 B1 , discloses an environmentally friendly fabric for production of a flame retardant roller blind and blackout fabric with improved light-blocking efficiency using a flame retardant recycled composite yarn.
However, none of the prior art documents disclose the use of one type of 100% recycled PET yarn, which is used as both weft and warp, to produce technical fabrics for use as e.g. roller blind or curtain fabrics, or with a similar application.
Solutions using only 100% recycled PET yarns provided purely green fabrics, or yarns used to make carpets (with different physicochemical parameters than yarns used to produce fabrics for roller blinds), or yarns used to make towels or bathrobes (also characterized by different physicochemical parameters than yarns used for the production of technical fabrics) or for the production of filter cloth.
Thus, the object of the present invention was to develop a method of technical fabric production from 100% recycled PET, especially of technical fabrics such as fabrics for the production of roller blinds, tablecloths, upholstery, specialist clothing, providing fabrics with high performance parameters, and strength such as fabrics obtained from virgin polyester.
Out of concern for the natural environment, authors of the present invention have been conducting for many years research on the possibility of using yarns obtained from 100% recycled PET and, unexpectedly, found that due to the use of yarn obtained from 100% recycled PET filaments, it is not only possible to use the same yarn as weft and warp, but also a technical fabric is obtained with high performance parameters and strength, which are at least equal to that of fabrics obtained from virgin polyester (which was confirmed by research carried out at the Lodz University of Technology), as well as with improved absorption of various types of additives or modifiers, such as dyes, achieving a homogeneous distribution of additive/modifier in the final fabric.
It was also found that the use of yarn obtained from 100% recycled PET filaments results in a smoother, high absorbent fabric. As a result, the obtained fabric is free from the drawback of fabrics obtained from 100% recycled PET cotton-type staple fibers. Namely, cotton-type fibers were not suitable for use as a warp (a more durable element of the fabric), but only as wefts. Accordingly, it was not possible to obtain a technical fabric exclusively from 100% recycled PET since it was necessary to use fibers other than those of 100% recycled PET with better strength as the warp. For this purpose, for example, virgin polyester fibers with better mechanical/strength properties were used. In addition, fabrics containing 100% recycled PET cotton-type fibers dyed non-uniformly, resulting in fabrics with non-uniform dyeing, which limited their utility as decorative utility fabrics of suitable aesthetic appeal. However, due to the use of yarn obtained from 100% recycled PET filaments, durable technical fabrics were obtained with excellent absorbent properties, uniformly dyed, smoother, and most importantly, environmentally friendly. The use of 100% recycled PET is crucial in relation to the protection of the natural environment, as it ensures the effective and efficient use of used components made of PET, such as, for example, mass-produced bottles for the storage of water and other beverages.
Moreover, the use of yarn obtained from twisting cotton-type staple fibers obtained from 100% recycled PET was associated with increased dusting during production - a nuisance in the production halls, which significantly increased the risk of fire, as well as the amount of dirt and contamination. In addition, the resulting fabric was more prone to pilling and quickly lost its aesthetic appeal.

Summary of the invention

Thus, the subject-matter of the present invention is a method of 100% recycled PET technical fabric production, characterized in that it comprises the steps where

a warp of yarn obtained from 100% recycled PET filaments is warped with a thickness ranging from 40 to 334, preferably 84 to 334 dtex and more preferably 84 to 167 dtex;
the warp is tied on a loom, preferably using an automatic warp-tying machine;
a weft of yarn obtained from 100% recycled PET filaments, with a thickness ranging from 58 to 668 dtex, preferably 78 to 501 dtex, and preferably 167 to 334 dtex is threaded on the loom;
after loom activation, a fabric pattern is established and weaving is carried out;
the finished fabric is wound on a roller;
an initial quality control and preparation for washing and dyeing process are carried out;
the fabric is washed with heated water at 70°C to 100°C and pressure of 0-1 bar and dyed at 110°C to 140°C and pressure of 2.5-3 bar;
the washed fabric is subjected to thermal stabilization in order to maintain its physicochemical parameters, and drying;
the dried fabric is rolled up on rollers and subjected to a final quality control, then the fabric is cut into smaller batches and labeled;

Preferably, weaving is performed on a loom selected from an air-jet loom, a rapier loom, a water loom, a gripper loom or a hydraulic loom.
Preferably, after the stabilization step, the fabric is subjected to coating with a coating dispersion in an amount of 10 to 80 g/m², and the coated fabric is then annealed at 160°C to 200°C with a fabric feed of 10 to 30 m/min.
Preferably, the fabric is coated with dispersions selected from such as an acrylic dispersion, a styrene-acrylic dispersion, a polyurethane dispersion or an aqueous styrene-butadiene latex dispersion.
Preferably, the coating is carried out on one side, preferably with a spreading bar, or on both sides, preferably by dip padding.
Preferably, additives such as bioactive, antibacterial, antiviral substances, nanomodifiers, flame-retardants and/or anti-moisture substances, as well as water- and oil-repellent substances are applied to the fabric during its coating along with the coating.
Preferably the fabric obtained is then subjected to the pleating process at 90°C to 120°C with a fabric feed of 0.5 to 3 m/min.
The invention also relates to a technical fabric which is made only of yarn obtained from 100% recycled PET filaments, wherein the yarn used for the warp has a thickness of 40 to 334, preferably 84 to 334 dtex and more preferably 84 to 167 dtex and the yarn used for the weft has a thickness of 58 to 668 dtex, preferably 78 to 501 dtex, and more preferably 167 to 334 dtex.
Preferably, the technical fabric is coated at least on one side with a dispersion selected from such as an acrylic dispersion, a styrene-acrylic dispersion, a polyurethane dispersion or an aqueous styrene-butadiene latex dispersion, which after drying has a basis weight ranging from 5 to 40 g/m².
Preferably, the fabric coating is enriched with additives such as bioactive, antibacterial, antiviral substances, nanomodifiers, flame retardants and/or anti-moisture substances, as well as water- and oil-repellent substances.
Dtex means the weight in grams of 10000 m of yarn, therefore 334 dtex means that 10000 m of yarn with this thickness has a weight of 334 g.

EXAMPLES

The method of technical fabric production entirely from 100% recycled PET according to the present invention is shown in the drawing, in which Fig. 1 depicts a block diagram of the production process.

Example 1

A 100% recycled PET technical fabric according to the present invention was obtained as follows. The warp was warped from a yarn obtained from 100% recycled PET filaments with a thickness of 84 dtex, which was then tied on the loom using an automatic warp-tying machine. A weft of 100% recycled PET filaments with a thickness of 668 dtex is threaded on the loom. After loom activation, the weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to the process of washing at 70°C and dyeing at 130°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 190°C with a fabric web feed rate of 25 m/min in order to maintain its physicochemical parameters. After thermal stabilization, fabric coating was carried out by spreading an acrylic dispersion layer with a spreading bar of the coater. The amount of dispersion dispensed per 1 m² of fabric was 60 g/m², giving 30 g/m² of coating after drying.
The coated fabric was inserted into a stabilizer and annealed at 170°C with a fabric feed of 15 m/min. The dried fabric was wound on rollers, labeled, submitted to final quality control, and then cut into smaller batches.
A smooth fabric with uniform dyeing providing a high aesthetic appeal was obtained, with a weft density of 16 threads/cm and a warp density of 30 threads/cm.

Example 2

A 100% recycled PET technical fabric according to the present invention was obtained in an analogous manner to that of Example 1, except that for the warping a yarn obtained from twisting filaments of 100% recycled PET with a thickness of 167 dtex was used. The warp was tied on a loom using an automatic warp-tying machine. A weft of 100% recycled PET filament yarn with a thickness of 167 dtex was threaded on the loom. After loom activation, weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to the process of washing at 100°C and dyeing at 130°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 180°C with a fabric web feed rate of 20 m/min in order to maintain its physicochemical parameters. After thermal stabilization, the fabric was subjected to coating by spreading an polyurethane dispersion layer with spreading bar of the coater. The amount of suspension dispensed per 1 m² of fabric was 30 g/m², giving 15 g/m² of coating after drying.
The coated fabric was inserted into a stabilizer and annealed at 160°C with a fabric feed of 10 m/min. A fabric was obtained with a weft density of 23 threads/cm and a warp density of 42 threads/cm.
The dried fabric was then subjected to pleating to obtain an accordion shape of the window roller blind. The pleating process was carried out in a pleater at 110°C with the fabric feed of 1.5 m/min. After the pleating process, the fabric density increased by about 10%. The pleated fabric in the form of a rectangular block was packed into cardboard boxes.

Example 3

A 100% recycled PET technical fabric according to the present invention was obtained in an analogous manner to that of Example 1, except that for the warping a yarn made of 100% recycled PET filaments with a thickness of 167 dtex was used. The warp was tied on a loom using an automatic warp-tying machine. A weft of 100% recycled PET filament yarn with a thickness of 334 dtex was threaded on the loom. After loom activation, weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to process of washing at 80°C and dyeing at 125°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 180°C with a fabric web feed rate of 20 m/min in order to maintain its physicochemical parameters. After thermal stabilization, fabric coating was carried out by spreading an styrene-acrylic dispersion layer with spreading bar of the coater. The amount of suspension dispensed per 1 m² of fabric was 60 g/m², giving 30 g/m² of coating after drying.
The coated fabric was inserted into a stabilizer and annealed at 160°C with a fabric feed of 10 m/min. A smooth fabric with uniform dyeing providing an high aesthetic appeal was obtained, with a weft density of 20 threads/cm and a warp density of 42 threads/cm.

Example 4

A 100% recycled PET technical fabric according to the present invention was obtained in an analogous manner to Example 1, except that for warping a yarn obtained from twisting 100% recycled PET filaments with a thickness of 84 dtex was used. The warp was tied on a loom using an automatic warp-tying machine. A weft of 100% recycled PET filament yarn with a thickness of 167 dtex was threaded on the loom. After loom activation, weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to the process of washing at 90°C and dyeing at 130°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 180°C with a fabric web feed rate of 30 m/min in order to maintain its physicochemical parameters. After thermal stabilization, fabric coating was carried out by padding in the foulard with a hydro and oleophobic finish in the form of a polyurethane suspension. The coating was carried out at 160°C with a fabric web feed rate of 15 m/min. The amount of suspension dispensed per 1 m² of fabric was 20 g/m², giving 10 g/m² of coating after drying.
The coated fabric was inserted into a stabilizer and annealed at 170°C with a fabric feed of 30 m/min. A fabric was obtained with a weft density of 25 threads/cm and a warp density of 30 threads/cm.
The dried fabric was then pleated to obtain an accordion shape of the window roller blind. The pleating process was carried out in a pleater at 100°C with a fabric feed of 2 m/min. The pleated fabric in the form of a rectangular block was packed into cardboard boxes.

Example 5

A 100% recycled PET technical fabric according to the present invention was obtained in an analogous manner to that of Example 1. A yarn made of 100% recycled PET filaments with a thickness of 167 dtex was used for warping. The warp was tied on a loom using an automatic warp-tying machine. A weft of 100% recycled PET filament yarn with a thickness of 167 dtex was threaded on the loom. After loom activation, weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to the process of washing at 100°C and dyeing at 130°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 190°C with a fabric web feed rate of 25 m/min in order to maintain its physicochemical parameters. After thermal stabilization, the fabric was first coated by spreading an polyurethane dispersion layer with spreader bar of the coater. The amount of suspension dispensed per 1 m² of fabric was 30 g/m², giving 15 g/m² of coating after drying.
The coated fabric was inserted into a stabilizer and annealed at 170°C with a fabric feed of 15 m/min. Next, a second coating of the fabric was carried out by spreading the layer of an acrylic dispersion with addition of aluminum with spreader bar of the coater. The amount of suspension dispensed per 1 m² of fabric was 20 g/m², giving 10 g/m² of coating after drying. The coated fabric was inserted into a stabilizer and annealed at 170°C with a fabric feed of 15 m/min. A fabric was obtained with a weft density of 21 threads/cm and a warp density of 40 threads/cm.
The dried fabric was then subjected to pleating process to give an accordion shape of the window roller blind. The pleating process was carried out in a pleater at 110°C with a fabric feed of 1.5 m/min. After the pleating process, the fabric density increased by about 10%. The pleated fabric in the form of a rectangular block was packed into cardboard boxes.

Example 6

A 100% recycled PET technical fabric according to the present invention was obtained in an analogous manner to that of Example 1, except that for warping a yarn made of 100% recycled PET filaments with a thickness of 40 dtex was used. The warp was tied on a loom using an automatic warp-tying machine. A weft of 100% recycled PET filament yarn with a thickness of 56 dtex was threaded on the loom. After loom activation, weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to the process of washing at 70°C and dyeing at 125°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 180°C with a fabric web feed rate of 30 m/min in order to maintain its physicochemical parameters. After thermal stabilization, fabric coating was carried out by spreading an polyurethane dispersion layer with spreader bar of the coater. The amount of suspension dispensed per 1 m² of fabric was 20 g/m², giving 10 g/m² of coating after drying.
The coated fabric was inserted into a stabilizer and annealed at 170°C with a fabric feed of 20 m/min. A fabric was obtained with a weft density of 40 threads/cm and a warp density of 80 threads/cm.
The dried fabric was then subjected to pleating to obtain an accordion shape of the window roller blind. The pleating process was carried out in a pleater at 100°C with a fabric feed of 2 m/min. After the pleating process, the fabric density increased by about 10%. The pleated fabric in the form of a rectangular block was packed into cardboard boxes.

Example 7

A 100% recycled PET technical fabric according to the present invention was obtained in an analogous manner to that of Example 1, except that for warping a yarn made of 100% recycled PET filaments with a thickness of 334 dtex was used. The warp was tied on a loom using an automatic warp-tying machine. A weft of 100% recycled PET filament yarn with a thickness of 334 dtex was threaded on the loom. After loom activation, weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to the process of washing at 90°C and dyeing at 130°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 190°C with a fabric web feed rate of 25 m/min in order to maintain its physicochemical parameters. After thermal stabilization, fabric coating was carried out by spreading an aqueous styrene-butadiene latex dispersion layer with spreading bar of the coater. The amount of suspension dispensed per 1 m² of fabric was 80 g/m², giving 40 g/m² of coating after drying.
The coated fabric was inserted into a stabilizer and annealed at 170°C with a fabric feed of 12 m/min. A fabric was obtained with a weft density of 14 threads/cm and a warp density of 16 threads/cm.

Example 8

A 100% recycled PET technical fabric according to the present invention was obtained in an analogous manner to that of Example 1, except that for warping a yarn made of 100% recycled PET filaments with a thickness of 334 dtex was used. The warp was tied on a loom using an automatic warp-tying machine. A weft of 100% recycled PET filaments with a thickness of 668 dtex was threaded on the loom. After loom activation, weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to the process of washing at 100°C and dyeing at 130°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 190°C with a fabric web feed rate of 30 m/min in order to maintain its physicochemical parameters. After thermal stabilization, the fabric coating was carried out by padding the fabric with foulard with the styrene-acrylic dispersion. The amount of suspension dispensed per 1 m² of fabric was 60 g/m², giving 30 g/m² of coating after drying. The coated fabric was inserted into a stabilizer and annealed at 170°C with a fabric feed of 18 m/min. A fabric was obtained with a weft density of 14 threads/cm and a warp density of 16 threads/cm.

Example 9

A 100% recycled PET technical fabric according to the present invention was obtained in an analogous manner to that of Example 1, except that for warping a yarn made of 100% recycled PET filaments with a thickness of 84 dtex was used. The warp was tied on a loom using an automatic warp-tying machine. A weft of 100% recycled PET filament yarn with a thickness of 167 dtex was threaded on the loom. After loom activation, weaving was carried out, with the weft shot between the individual edges of the fabric being effected by means of compressed air without mechanical participation of the rapier. The fabric produced was wound on a roller and quality control was performed. Then the fabric was subjected to the process of washing at 70°C and dyeing at 130°C in pressure dyeing machines.
The washed fabric was subjected to thermal stabilization at 180°C with a fabric web feed rate of 30 m/min in order to maintain its physicochemical parameters.
A fabric with a weft density of 24 threads/cm and a warp density of 56 threads/cm was obtained, suitable for the production of clothes or as a curtain fabric.

Claims

A method of 100% recycled PET technical fabric production, characterized in that it contains steps in which
- a warp of yarn obtained from 100% recycled PET filaments is warped with a thickness ranging from 40 to 334, preferably 84 to 334 dtex and more preferably 84 to 167 dtex;

- the warp is tied on the loom, preferably using an automatic warp-tying machine;

- a weft of yarn obtained from 100% recycled PET filaments, with a thickness ranging from 58 to 668 dtex, preferably 78 to 501 dtex and preferably 167 to 334 dtex is threaded on a loom;

- after loom activation, a fabric pattern is established and weaving is carried out;

- the finished fabric is wound on a roller;

- initial quality control and preparation for the washing and dyeing process are carried out;

- the fabric is washed with heated water at 70°C to 100°C and a pressure of 0-1 bar and dyed at 110°C to 140°C and a pressure of 2.5-3 bar;

- the washed fabric is subjected to thermal stabilization in order to maintain its physicochemical parameters, and drying;

- the dried fabric is rolled on rollers and subjected to a final quality control, then the fabric is cut into smaller batches and labeled;
wherein the stabilization of the fabric is carried out by annealing the fabric strip at 160°C to 220°C, with a fabric web feed rate from 10 m/min to 30 m/min.
The method according to claim 1, characterized in that the weaving is performed on a loom selected from such as an air-jet loom, a rapier loom, a water loom, a gripper loom or a hydraulic loom.
The method according claim 1 or 2, characterized in that, after the stabilization step, the fabric is subjected to coating with the coating dispersion in an amount of 10 to 80 g/m², and the coated fabric is then annealed at 160°C to 200°C with a fabric feed of 10 to 30 m/min.
The method according to claim 3, characterized in that, the fabric is coated with dispersions selected from such as an acrylic dispersion, a styrene-acrylic dispersion, a polyurethane dispersion or an aqueous styrene-butadiene latex dispersion.
The method according to claim 3 or 4, characterized in that the coating is carried out on one side, preferably with a spreading bar, or on both sides, preferably by dip padding.
The method according to any of the claims 3 to 5, characterized in that enriching additives such as bioactive, antibacterial, antiviral substances, nanomodifiers, flame-retardants and/or anti-moisture substances, as well as water- and oil-repellent substances are applied to the fabric during its coating along with the coating.
The method according to any of the claims 1 to 6, characterized in that the fabric obtained is then subjected to a pleating process at 90°C to 120°C with a fabric feed of 0.5 to 3 m/min.
A technical fabric, characterized in that it is made exclusively of yarn obtained from 100% recycled PET filaments, wherein the yarn used for the warp has a thickness of 40 to 334, preferably 84 to 334 dtex and more preferably 84 to 167 dtex and the yarn used for the weft has a thickness of 58 to 668 dtex, preferably 78 to 501 dtex, and more preferably 167 to 334 dtex.
The technical fabric according to claim 8, characterized in that it is coated at least on one side with a dispersion selected from such as an acrylic dispersion, a styrene-acrylic dispersion, a polyurethane dispersion or an aqueous dispersion of a styrene-butadiene latex, which after drying has a basis weight of 5 to 40 g/m².
The technical fabric according to claim 8 or claim 9, characterized in that the fabric coating is enriched with additives such as bioactive, antibacterial, antiviral substances, nanomodifiers, flame-retardants and/or anti-moisture substances, as well as water- and oil-repellent substances.