In Germany, around 400 million m² of textile floor coverings are installed in the contract sector and around 45 million m² are added every year. However, cleaning often leads to long drying times and can damage the textile floor coverings.

Due to these disadvantages, resilient floor coverings are preferred, although textile floor coverings offer advantages such as thermal insulation, acoustics, slip resistance and high binding capacity for fine dust and allergens.

In order to remain competitive, manufacturers of textile floor coverings need innovative products with a longer service life and more efficient cleaning options. The aim of this research project was therefore to develop these floor coverings.

The innovative floor coverings are based on yarns with a core-sheath structure (helix) and a new latex-free process for pile nap fixation and back coating. The yarns consist of a metal core that is wrapped in voluminous, fluffy carpet yarns to achieve the typical characteristics.

Helix yarns were developed in a two-stage, counter-rotating winding direction as well as a pile nap fixation and back coating based on the thermobonding principle. With certain limitations, the stress tests showed results that were suitable for the project, and the health and safety requirements were met.

In order to develop a generally suitable process for the acoustomechanical cleaning of textile floor coverings, textile, specifically soiled floor covering monitors were produced. These were used to characterize the cleaning effect using shock wave treatment.

The development of the acoustomechanical process for cleaning textile floor coverings was carried out in a laboratory cleaning system. Optimum conditions for the shock wave and process parameters for dirt removal were developed. The limitations found in the stress tests were confirmed here.

Nevertheless, the positive effect of the helix yarn structure with metallic yarn on the removal of film-forming soiling during shock wave treatment compared to conventional looped fabric was demonstrated.

The findings were scaled up to a functional sample with three shock wave applicators. It was not possible to achieve the cleaning intensity of conventional spray extraction. Improvement approaches could be formulated with regard to travel speed and application time.

Compared to conventional spray extraction, the shock wave method with liquor and cleaning agent can be expected to reduce the use of cleaning agents by 90 % and water consumption by 50 % while doubling the area coverage. Corresponding process recommendations were developed.

The cost analysis of the processes showed a fundamental usability of the result against the background of industrial upscaling and the increased useful life from 10 to 15 years.

The research report is available on request from FRT.