The façade of the Texoversum is just one example of a brand new technology that could completely revolutionize the construction industry. The sophisticated structure was designed on the computer and is based on carbon fibers wound by robots. Similar to networks in nature, for example in spider webs, beetle wings or palm leaves, the fiber structures are also very lightweight, but at the same time highly resilient, and require very little material. This not only saves resources, but also facilitates transport and assembly of the components.

The co-inventor of the innovative technology is architect Prof. Moritz Dörstelmann, whose company FibR also realized the façade of the Texoversum: "In contrast to conventional steel and concrete structures, we are able to get by with a minimum of material, because the robots only process as many fibers as are needed for the strength of the respective structure. As a result, we also save large amounts of CO₂ emissions." Dörstelmann also sees advantageous applications for the technology in roof structures, supports and, not least, interior fittings.

The necessary strength and durability of the composite is provided by ����AV's aliphatic polyurethane resin system Desmocomp^®, in which the fibers are embedded as if in a matrix. "The resin is highly resistant to weathering and the sun's high-energy UV radiation, making it very suitable for outdoor applications," explains Pejman Norastehfar, architect and specialist for construction applications in ����AV's Coatings and Adhesives segment. “Other plus points in the construction sector are its excellent chemical and flame resistance.”

In the Texoversum, the spun façade performs several important functions at once: it gives the building a unique look and stabilizes the surrounding balconies. It also serves as a railing and provides the necessary shade for the glass front behind it.

The building provides approximately 3,000 square meters of space for workshops, laboratories, a textile collection, think tank space and classrooms. The costs for the construction of the Texoversum amounting to 18.5 million euros were borne by the employers' association Südwesttextil, whose members include FibR GmbH in Kernen, east of Stuttgart.

"This is good news for anyone who wants to maintain an athletically active, healthy lifestyle in the most environmentally friendly way possible," says Tony Wu, Global Marketing Manager, Textile Coatings, ����AV. He emphasizes that the increased sustainability achieved does not compromise the durability, appearance or comfort of the footwear upper. In combination with Huafeng HAPTIC® printing technology, 3D shapes can be applied to textile fabrics creating trendy designs and high performance in athletic footwear. 
 

Impranil® eco DLS, as a partially bio-based binder, is part of the INSQIN® range of waterborne textile coating resins. Its use contributes to reduced greenhouse gas emissions with around 60 grams of CO₂ equivalents per pair of shoes. The value comes from internal calculations verified by independent external experts. It is obvious that the difference in the CO₂ footprint becomes even greater when solvent-based PU textile coatings are used for comparison. The use of fabric based on recycled PET yarns mitigates greenhouse gas emissions by about 170 grams of CO₂ equivalent per pair of shoes.

To share the experience and findings with the industry, ����AV, Huafeng and Cyclone jointly hosted a webinar globally to introduce the three technologies and the synergy created from this co-development. The recorded webinar can be accessed .

"Sustainability is key to our market success at Huafeng. With the help of the partially bio-based PU dispersion of ����AV, we were able to introduce more renewable ingredients into our HAPTIC® coatings, further improving their sustainability," says Dr. Thomas Schmidt, Director of Innovation at Huafeng. Dr. Torsten Pohl, Head of Global Textile Coatings at ����AV, adds, "The combination of our partially bio-based INSQIN® PU coating binder with Huafeng HAPTIC® printing on recycled PET fabric shows how partners in the value chain can work together creating more sustainable products."

The elastic fibers are made with a chemical component that consists in part of CO₂ instead of oil. This precursor called cardyon^® is already used for foam in mattresses and sports floorings. And now it is being applied to the textile industry.

“That’s a further, highly promising approach to enable ever broader use of carbon dioxide as an alternative raw material in the chemical industry and expand the raw materials base,” says Dr. Markus Steilemann, CEO of ����AV. “Our goal is to use CO₂ in more and more applications in a circular economy process and save crude oil.”

Sustainable production process

The fibers are made from CO₂-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 a yarn of endless fibers. Unlike dry spinning, which is used to produce conventional elastic synthetic fibers such as Elastane or Spandex, melt spinning eliminates the need for environmentally harmful solvents. A new chemical method enables carbon dioxide to be incorporated in the base material, which also has a better CO₂ footprint than traditional elastic fibers.

“The CO₂-based material could be a sustainable alternative to conventional elastic fibers in the near future,” states Professor Thomas Gries, Director of the Institute of Textile Technology at RWTH Aachen University. “Thanks to our expertise in industrial development and processing, we can jointly drive establishment of a new raw materials base for the textile industry.”

Development of the method of producing fibers from CO₂-based thermoplastic polyurethane has been funded by the European Institute of Innovation and Technology (EIT). It will now be optimized as part of the “CO₂Tex” project, which is to be funded by the German Federal Ministry of Education and Research (BMBF) so as to enable industrial production in the future. “CO₂Tex” is part of “BioTex Future,” a project initiative of RWTH Aachen University. The initiative is devoted to developing production and processing technologies to facilitate the future market launch of textile systems from bio-based polymeric materials.

Development partners display interest

What makes the CO₂-based TPU fibers so special is their properties: They are elastic and tear-proof and so can be used in textile fabrics. Initial companies from the textile and medical engineering sectors have already tested the CO₂-based fibers and processed them into yarns, socks, compression tubes and tapes.

The aim of launching CO₂-based textiles on the market is to promote a material cycle in the textile and clothing industry based on sustainable resources.

About ����AV:

With 2018 sales of EUR 14.6 billion, ����AV is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health, and the chemical industry itself. ����AV has 30 production sites worldwide and employed approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

About Institute of Textile Technology (ITA) at RWTH Aachen University:

The Institute of Textile Technology (ITA) at RWTH Aachen University is involved in the project. The ITA is part of the faculty of Mechanical Engineering at the RWTH and conducts research in the fields of materials, production processes and products for technical applications of textile structures. It has a fully equipped technology center with about 250 textile machines and test benches across all textile process stages from spinning to joining. Furthermore, various laboratories (textile testing, polymer analysis) and workshops are staffed by experts (mechanics, electronic software and hardware).

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Forward-Looking Statements

This press release may contain certain forward-looking statements that are based on current assumptions and forecasts issued by the management of ����AV. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in ����AV’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.