Carpet recycling enabled by VAE polymers

VAE polymers are thermoplastic polymers that are soluble in water and other chemicals. Therefore carpets that are made with VAE binders are recycleable via chemicaal separation processes. By this process, the backing, which is mainly filler, is cleanly seperated from the fibers, which can be mechanical recycled. The carpet fibers are the most valueable. While the backing with it’s binder, can be reused as a backing.

How is Carpet made?

Carpets are woven or tufted fibers in a backing. In order to fixate the fibers a binder is needed. Often used polymers are:

• Styrene Butadien (SB, SBL, SBR).
• Vinyl Acetate Ethylene (VAE, Vinyl-Rubber, PVAC)
• Polyethylene dispersions (PE, PP)
• Hot melt (powder, thermoplastic)
• Polyurethante (PU, PUR)

Furthermore a heavy backing is often applied for stabilisation purposes. This is often a filled backing for economic reasons, but the reason can also be thermical or because of fire resistant properties.

What is VAE polymer?

VAE polymer is made by copolymerization of Vinyl Acetate Monomer (VAM) and Ethylene. By variating the ratio, a polymer can have different properties, especially the glass temperature (Tg) can be made in a range from -20°C to +30°C. In general the properties for VAE as a binder are:

• Dispersion (water) or Solid (powder) form
• Thermoplastic (standard) or crosslinkable
• Water solluble (standard) or water resistant (crosslinked)
• Low VOC, because of low VOC monomers
• Low flammability, due to low oxygen index.
• Good recycleability

Special compounds

Intercol can develop special carpet compounds on request, with the required properties like dimension stability, drying, FR, handfeel and adhesion properties. Just contact us with your request.