Covestro and its partners, most importantly the Aachen University of Technology Textile Technology and various textile manufacturers, are developing production processes on an industrial scale to prepare innovative fibers for the market. For example, they can be used in stockings and medical textiles, and can replace traditional crude oil-based elastic fibers.
Elastic fibers are made from a chemical composition that replaces petroleum with some carbon dioxide. This precursor, called CARDYON®, has been used for foam in mattresses and sports floors. Currently being used in the textile industry.
Covestro CEO Markus Steilemann said that this is a further and promising approach that will enable the wider use of carbon dioxide as an alternative raw material in the chemical industry and expand the raw material base. Our goal is to use carbon dioxide more and more in the process of circular economy and save crude oil.
Sustainable production process
These fibers are made of carbon dioxide-based thermoplastic polyurethane (TPU), using a technique called melt-spinning, in which the TPU is melted, pressed into very fine threads, and finally processed into yarns without border fibers. Unlike dry spinning, which is used to produce traditional elastic synthetic fibers, such as elastic fibers or elastic rayon, melt spinning does not require the use of solvents that are harmful to the environment. A new chemical method can add carbon dioxide to the matrix material, which also has better resistance to carbon dioxide than traditional elastic fibers.
Professor Thomas Gries, director of the Institute of Textile Technology at Aachen University of Technology, said that in the near future, carbon dioxide-based materials may become a sustainable alternative to traditional elastic fibers. Thanks to our expertise in industrial development and processing, we can jointly promote the establishment of a new raw material base for the textile industry.
The European Institute for Innovation and Technology (EIT) has funded the development of a method for producing fibers from carbon dioxide-based thermoplastic polyurethanes. It will now be optimized as part of the "co2tex" project, which will be funded by the German Federal Ministry of Education and Research (BMBF) for industrial production in the future. co2tex is part of the "Biotex Future" project of the Aachen University of Technology. The initiative is dedicated to the development of production and processing technologies to promote the market introduction of future bio-based polymer material textile systems.
Development partners show interest
Carbon dioxide-based TPU fibers are so special because of their properties: they have elasticity and tear resistance, so they can be used in textile fabrics. Startups in the textile and medical engineering sectors have tested carbon dioxide-based fibers and processed them into yarns, socks, compression tubes, and tape.
The purpose of launching carbon dioxide-based textiles on the market is to promote the material cycle of the textile and apparel industry on the basis of sustainable resources.