Coated functional and technical textiles containing recycled silica powders

Abstract

The invention particularly relates to the development of high value-added, environmentally friendly functional and technical textiles by using amorphous "biobased silica" and "silica fume" obtained by recovery methods from wastes as fillers in textile coatings, taking into account the demands for "sustainable production". With these materials, which are used as an alternative to traditional fillers (especially TiO2, calcite, kaolin, synthetic silica and carbon black), the selected textile surfaces are provided with light-proofing (in blackout curtains, etc.), heat insulation and energy saving, limited flammability and sound insulation (acoustic) properties.

Description

[0001] COATED FUNCTIONAL AND TECHNICAL TEXTILES CONTAINING RECYCLED SILICA POWDERS

[0002] Technical Field

[0003] The invention relates to the development of coated functional and technical textiles used in various fields.

[0004] The invention particularly relates to the development of coated functional and technical textiles with high added value by using amorphous "silica fume" or “microsilica” and "biobased silica" obtained by recovery methods from wastes, taking into account the demands of "sustainable production". With these materials, which will be used as an alternative to traditional fillers (especially titanium dioxide (TiO2), synthetic silica, calcium carbonate and carbon black), light blocking (black-out, black-out curtains), heat insulation and a certain level of flame retardancy (in all coated technical textiles) and partially sound insulation (acoustic) properties are provided to the selected textile surfaces.

[0005] Known State of the Art

[0006] The importance of recycling products is rapidly increasing in response to the demands for sustainability and ecological approach in the textile sector. Renewable energy sources have also come to the fore due to the insufficiency of traditional energy sources and their harmful effects on the atmosphere. Thermal insulation is of great importance for energy saving.

[0007] Functional textiles are product groups with high added value having superior performance properties. Lamination and coating are widely applied techniques to provide functional properties to fabrics used in technical textile production and to increase their usage areas. With the coating process, various chemicals and fillers are transferred to the fabric in the form of paste or foam and a film layer is formed on the fabric. Coating formulations can contain a wide variety of chemicals according to the properties of the binder polymers used, end-use areas, types of coating machine used. Products such as carbon black, titanium dioxide, calcite, talc, kaolin, silica are generally used as fillers.

[0008] For example, in the patent application numbered TR 2020 / 17798, it is a double-sided foam coating, does not wrinkle, can return to its old flat form even if it wrinkles, provides 100% light-proof black-out or optionally, black-out percentages can be kept variable; wherein disclosed a fabric characterized in that it contains colourant and / or thickener and / or air freshener and / or pH regulator and / or polyacrylate; contains 10% to 20% of a polycarboxylic acid mixture and / or 5% to 10% of titanium paste and / or 2% to 5% of a chemical which provides flexibility and has silicone properties. As can be seen, the use of titanium dioxide with a colouring agent used for opacity in the coating composition is available.

[0009] In the present art, considering that the thermal insulation properties of conventional fillers used in the textile sector are poor and that the highest energy losses in buildings occur through windows and other glazed parts, textile products using conventional fillers cannot make a significant contribution to heat gains and losses. In addition, in conventional textile coatings, flame retardant chemicals, especially those containing antimony and halogen groups, are not only expensive, but also have serious ecological drawbacks.

[0010] In blackout curtains produced by traditional methods, "carbon black" is used in the middle layer coating. Carbon black has toxic effects. It also increases greenhouse gas emissions due to high carbon emission.

[0011] As a result, due to the negativities described above and the inadequacy of the existing solutions on the subject, it is necessary to make a development in the relevant technical field.

[0012] Purpose of Invention

[0013] The invention aims to solve the above-mentioned disadvantages inspired by existing situations.

[0014] The main purpose of the invention is to develop functional and technical textiles with low carbon footprint and high added value by using partially or completely recycled filling materials instead of traditional filling materials used in textile coating methods. Technical textiles developed by using amorphous "silica fume" and "biobased silica" obtained by recovery methods from wastes offer features such as ecological product feature with low carbon footprint, energy saving with improved thermal insulation feature, light-proofing (in blackout curtains, etc.), a certain level of structural flame retardancy (in all coated technical textiles), partial sound insulation (acoustic).

[0015] Another purpose of the invention is to develop ecological and value-added coating compositions to be used in the production of all home textiles, especially black-out and roller blinds, contract textiles, outdoor textiles, wall fabrics and all coated technical textiles.

[0016] Another purpose of the invention is the use of recycled silica powders for the first time in the art as a sustainable alternative to traditional filling materials which are considered ecologically objectionable, as well as providing additional properties to coated functional and technical textiles used in various fields. With the invention silica fume particle size <50 (preferably <25 p) and biobased silica particle size <25 p is sufficient for a smooth surface coating, by using dark grey silica fume in foam and paste coatings, 100% black-out effect can be achieved and in this way, the use of carbon black, which is used in blackout curtain fabric coatings and whose ecological drawbacks are discussed, can be completely eliminated or at least reduced by 70%, silica fume and biobased silica have a flame retardant (FR) effect, herewith it is possible to reduce the FR chemical used in conventional production by at least 20%, the use of silica fume and biobased silica contributes to energy saving by improving the thermal insulation properties of coated technical textiles at certain rates,

[0017] It has been demonstrated that white colored silica fume can be used instead of traditional filling materials such as titanium dioxide due to its adequate hiding power and in this way, titanium dioxide, whose health risks are discussed, can be partially or completely abandoned.

[0018] In order to fulfil the above-mentioned objects, the invention is a functional and technical textile surface which offers ecological product feature with low carbon footprint, energy saving with thermal insulation feature, light-proofing feature (in blackout curtains, etc.), a certain level of flame retardancy and partially sound insulation feature; at least one surface of the selected fabric includes at least one coating layer comprising recycled amorphous "silica fume" and / or " biobased silica".

[0019] According to an embodiment of the invention, the preferred silica powder "silica fumed", i.e. "micro silica", is a very fine pozzolanic material consisting of amorphous silica recovered from high temperature furnace stacks in industry. A particle size of <50 p (preferably <25 p) is sufficient for the products according to the invention.

[0020] According to one embodiment of the invention, the other preferred silica powder is biobased silica powder based on rice, wheat, etc. cereal husks. These husks in the form of biobased waste must first be reduced to ash by incineration and grinding processes under suitable conditions and sieved to a suitable particle size (preferably <25 p).

[0021] According to an embodiment of the invention, the weight of the preferred fabric is between 50-500 g / m2and is intended for functional and technical textile product groups.

[0022] In embodiments of the invention, water-based foam and / or paste coatings are made using all textile coating methods (knife coating, rotation coating, transfer coating, spray coating, roller coating techniques, etc.) and lamination techniques. In embodiments of the invention, acrylic, styrene acrylic, styrene butadiene acrylic, polyurethane, vinyl polymers and other polymers used in textile coatings, including but not limited to, are preferred as binder polymers.

[0023] In embodiments of the invention, the coating process can be performed on single or double surfaces of the fabric, in single or multiple layers. Multiple layers of foam paste / coating paste with the same properties can be applied to improve functional properties. In short, the choice of coating process may vary depending on the end-use requirement of the coated fabric and the physical and mechanical properties of the base fabric.

[0024] Silica fume and biobased silica are available in a wide range of colors from white to black, wherein it has been observed in the studies carried out within the scope of the invention that this color variety supports different functional properties. For example, it has been found that the use of dark colored silicas in blackout curtains can eliminate or reduce the existing use of carbon black, the use of white colored silicas can partially or completely eliminate the use of titanium dioxide and other white colored conventional fillers used in functional and technical textile production.

[0025] Another innovative aspect of the invention is the use of recycled silica powders, which have a lower coefficient of thermal conductivity than conventional materials, as a filler material to provide thermal insulation properties to the product in order to "save energy".

[0026] Silica powders are highly porous and have a high surface area. According to the particle size, biobased amorphous silica used within the scope of the invention has a surface area of up to 321 m2 / g; silica fume has a surface area of 15-30 m2 / g, and a certain level of sound absorption (acoustic) feature can also be provided in the coated fabrics. Therefore, the products subject to the invention also have a limited level of sound absorption.

[0027] Within the scope of the invention, coating compositions have been prepared using recycled silica fume and biobased silica at appropriate particle sizes for the production of technical textile surfaces. Stability of the coating chemical, pH and viscosity control are important parameters. The selection of the appropriate coating technique is made taking into account variations in coating materials and desired final results. The coating can be applied on one surface of the fabric, e.g. only on the front side (Figure 1) or on the back (Figure 2), on both surfaces of the fabric (Figure 3) or in multiple layers (Figure 4). In the case of foam coatings, the foam layer is not limited to three layers, but can also consist of four or five layers of foam coating, for example, with one or two intermediate layers of darker color to provide a blackout feature.

[0028] The fabric coated according to a suitable coating method selected is first dried at the appropriate temperature. After drying, the coating is smoothed by cold or hot calendering process under appropriate pressure with crushing rollers. Before winding, the coated hot fabric is passed through cooling rollers. Thus, the fabric is prevented from sticking after winding.

[0029] The manufacturing method according to an embodiment of the invention comprises, in its most basic form, the following process steps: i. Supplying / preparing recycled silica powders of suitable particle size (<50 p), colour (white, all shades of grey and black) and SiO2ratio (>50%), ii. Preparation of foam paste / coating paste formulations containing binder polymer, recycled silica powders, thickener, crosslinker and auxiliary chemicals,

[0030] Composition of foam coating:

[0031] Compound foaming agent 100-1000 g

[0032] Binder polymer 10-100 g

[0033] Biobased silica 10-300 g

[0034] Auxiliary chemicals 5-50 g

[0035] Paste coating composition:

[0036] Binder polymer 50-1000 g

[0037] Biobased silica 10-300 g

[0038] Water 10-500 g

[0039] Auxiliary chemicals 10-100 g iii. Controlling the prepared paste / foam coating formulations (viscosity should be 10-120 dPas, foam density 100-300 g / L and pH 7,5-10), iv. Application of coating processes (preferably using roller coating, rotation coating, transfer coating, spray coating, roller coating techniques and other suitable methods), v. Application of drying and fixing processes after coating (drying at 90-13013, 60-150 s and fixing at 130-18013, 60-240 s), vi. Application of calendering processes after drying (under 5-70 bar pressure) and vii. Cooling of the coated fabric (fabric temperature should be <4013 before winding).

[0040] The structural and characteristic features and all advantages of the invention will be more clearly understood by means of the figures given below and the detailed description written by making references to these figures, and therefore, the evaluation should be made by taking these figures and detailed description into consideration.

[0041] Brief description of the Figures

[0042] Figure 1 : Cross-sectional view of the coating on the front surface of the fabric and the internal structure of the coating layer according to an embodiment of the invention.

[0043] Figure 2: Cross-sectional view of the back coating on the back surface of the fabric according to an embodiment of the invention.

[0044] Figure 3: Cross-sectional view of the coating on the front and back surface of the fabric according to an embodiment of the invention.

[0045] Figure 4: Layered view of a multilayer coating (black-out, etc.) according to an embodiment of the invention.

[0046] Figure 5: Schematic representation of the fabric coating process.

[0047] Description of References

[0048] 1 fabric

[0049] 2 coating layers

[0050] 2a primary coating layer

[0051] 2b secondary coating layer

[0052] 2c tertiary coating layer

[0053] 3 binder polymer

[0054] 4 silica powders (silica fume and / or biobased silica)

[0055] 5 auxiliary chemicals

[0056] 6 coating equipment

[0057] 7 foam paste / coating paste

[0058] 8 dryer

[0059] 9 crushing rollers

[0060] 10 cooler cylinders

[0061] 11 coated fabric (product) Detailed Description of the Invention

[0062] In this detailed description, the functional and technical textiles which are the subject matter of the invention, and their preferred embodiments are described only for a better understanding of the subject matter. This invention is based on a sustainability strategy and ecological approach, and functional and technical textiles have been developed by using amorphous silica obtained from biobased wastes (rice, wheat husks, etc.) and silica fume recovered from high temperature furnace chimneys in some industrial productions (such as ferrochrome plants). Ecological product feature with low carbon footprint, energy saving with thermal insulation feature, light- proof feature (in blackout curtains, etc.), a certain level of flame retardancy and partially sound insulation feature are provided in the products produced using the filling materials obtained from recycling, which is the subject of the invention.

[0063] Table 1 . Compositions by weight of the functional and technical textiles which are the subject matter of the invention

[0064] Table 2. Compositions by weight of the coating composition used within the scope of the invention

[0065] The coating layer formed on the fabric surface after the coating process with coating paste / foam paste is the structure that gives the targeted functional properties to the finished product. Coating paste / foam paste mainly consists of water, binder polymer, filling materials and various auxiliary chemicals.

[0066] Binder polymers are organic substances that form a film layer by wrapping around the filling materials and provide a steady adhesion of the materials to the fabric. The hardness or softness that the binding polymer gives to the fabric also varies depending on the molecular chain length of the binding polymer, its crystalline-amorphous structures and glass transition temperatures. While long chains are slightly softer, some decrease in fastness properties can be observed. Therefore, the choice of binder polymer is also an important parameter. In the present invention, among polymeric materials may be used, but are not limited to, acrylic polymers, styrene-acrylic copolymers, vinyl polymers, polyurethanes, silicones or a combination of two or more of these polymers. These binder polymers used enable the silica powders obtained by recycling methods to adherence and adhere to the fabric.

[0067] The fabric acts as a carrier for the coating layer. It may be composed of any kind of natural or synthetic fibers or blends, including but not limited to cotton, polyester, nylon, acrylic and combinations thereof.

[0068] Some chemical substances used in textile coatings, although they do not have a direct effect on the coating process, contribute positively to the coating paste / foam paste in terms of providing various functional properties or assisting the coating. Stabilizers, flame retardants, defoamers, foaming agents, thickeners, coloring pigments, etc. can be described as auxiliary chemicals. In our invention, care has been taken to ensure that all these auxiliary chemicals and binder polymers are compatible with recycled silica powders.

[0069] The light-blocking opaque layer in dimming materials is obtained by mixing a black pigment such as carbon black into the coating paste / foam paste. In order to reduce the known harmful effects of carbon black, the present invention uses silica fume and biobased silica in a dark smoky-black color obtained from recycling. Thus, it has been an innovative application for sustainable production and reduction of carbon emissions and greenhouse gas emissions in the textile sector under the main heading of clean and circular economy. In multi-coating layers, layers 2a and 2c in Figure 4 given as an example may contain a white pigment such as titanium dioxide (TiO2) or colored pigments to provide a decorative background. These layers, which are colored or generally white in color, prevent the intermediate layer (2b) from being visible on the surface if it is black in color. Furthermore, the use of white colored silica fume in the present invention has also contributed to the reduction of the amount of TiO2currently used and to thermal insulation.

[0070] The distribution and agglomeration of the solid particles used in the foam paste / coating paste are important during the application of the invention. As the particle size increases, it is observed that the powder materials used in the foam coating are not evenly distributed. For this reason, attention was paid to ensure that the particle size of the silica powders supplied was <50 p. Recycled silica powders (4) have low thermal conductivity due to their high silicium dioxide (SiO2) content. These properties provide a significant advantage in thermal insulation and energy saving. It is therefore of great importance that the recycled silica powders supplied in the present invention contain a high proportion of SiO2(preferably >90%).

[0071] Thickeners can also be used in the formulation to increase the viscosity and adjust the rheology of coating pastes. Suitable viscosity range is 10-120 dPas.

[0072] The pH value is one of the important parameters affecting the properties of the coating. Most of the water-based coatings are formulated between pH 7.5-10. This pH range is important for the binder polymers to work together with fillers, pigments and auxiliary chemicals. Furthermore, any change in pH can cause an increase or decrease in the viscosity of the foam paste / coating paste. The pH value also has a significant effect on the stability of the binder polymer.

[0073] In preferred embodiments of the invention:

[0074] - the particle size of the recycled silica supplied in the coating paste / foam paste is <50 p (preferably <25 p),

[0075] - SiO2content is minimum 50% (preferably >90%),

[0076] - viscosity range is 10-120 dPas,

[0077] - pH range is 7,5-10,

[0078] - drying at 90-13012, 60-150 sec,

[0079] - fixation at 130-180X3, 60-240 sec,

[0080] - calendaring under 5-70 bar pressure,

[0081] - foam density is 100-300 g / L

[0082] The color of the silica powder to be used in the final coating layer should be as close to white or light tones as possible, which will provide advantages in terms of sunlight reflection, thermal insulation and easy coloring. For the blackening feature, it is important that the silica powders are as dark as possible in order to partially or completely eliminate the use of carbon black.

[0083] Foam coating and paste coating can be applied in combination in different layers. For example, a protective paste can be coated on the foam coating layer. A paste coating can be applied on the other surface of the foam coated part to provide coverage and this layer can be colored to make the product decorative. Since recycled silica powders (4) have inherent flame retardancy, they provide ecological and economic advantages by reducing the use of flame retardant chemicals.

[0084] As a preferred embodiment of the invention, black-out coatings may comprise a multi-layer coating comprising three or four layers of foam coating, a protective paste coating and a paste coating on the front side. In the present invention, auxiliary chemicals such as flame retardants, light stabilizers, preservatives, antimicrobials, surfactants, foaming agents and stabilizers, pH control agents may be used to impart various functional properties to the multilayer coating sample as in Figure 4. Such auxiliary chemicals must be compatible with each other.

[0085] According to some other preferred exemplary embodiments of the invention, it can also be applied as a back coating to improve the flame retardancy of upholstery fabrics and the flame retardancy and thermal insulation properties of thick drapery (Figure 2). Furthermore, the invention can also be used in vertical curtains for similar purposes. Again, the fabrics coated according to the present invention can be laminated and used in different areas.

[0086] Experimental Studies

[0087] The results of comparative analyses of functional and technical textiles coated with recycled silica fume and / or biobased silica within the scope of the invention are given below:

[0088] EXAMPLE 1: Foam Coating Recipe (Recipe 1)

[0089] Coatings were carried out using the knife coating technique. However, the application of this recipe is not limited to the knife coating technique, but can also be performed with other suitable coating techniques. For foam coatings, the blade distance can be 0.2-1.5 mm and the blade angle can be + / - 30 degrees.

[0090] For drying and fixing processes, it can be worked at 90-15013 for 90-150 seconds. After drying process, calendering process can be applied with 5-70 bar pressure to make the surface smooth.

[0091] In order to compare the flammability effect of silica fumes with conventional fillers, coatings were made under similar conditions and tests were applied to each according to BS 5852 Source 0 (cigarette test). When the burning distances were evaluated (Table 3), it was seen that the lowest burning distance belonged to the coatings containing silica fume and biobased silica. These results suggest that the use of silica fume and biobased silica will help to reduce the amount of halogenated flame retardant chemicals, which have ecological drawbacks.

[0092] Table 3. Burning lengths (cm) of coatings made with different types of filler material according to BS 5852 Source 0 (cigarette test)

[0093] The opacity properties of dark silica fume and biobased silica were also evaluated for use in the development of black-out fabrics. For this purpose, the black-out property of the coated samples was visually tested according to DIN 14501 standard. It was clearly seen that blackout effect was observed especially in the fabrics where dark silica fume and biobased silica were used. In addition, the light and solar properties of the fabrics also support the black-out effect as a result of the tests performed with UV-VIS-NIR spectrophotometer according to TS EN ISO 410 standard. As can be seen in Table 4, Tv and Ts values are 0.0%. Table 4. UV-VIS-NIR spectrophotometer measurement results

[0094] Tv: Visible region transmittance

[0095] Rv: Visible region reflectance

[0096] Av: Visible region absorbance Ts: Solar transmittance

[0097] Rs: Solar Reflectance

[0098] As: Solar absorbance

[0099] Tuv: Ultraviolet transmittance EXAMPLE 2: Paste Coating Recipe (Recipe 2) These studies were carried out to investigate the usability of white colored silica fume instead of classical filler materials such as titanium dioxide, calcite, kaolin, synthetic silica etc. in protective paste and decorative front side paste coating recipes on foam coatings, paste coatings for roller blinds, back coatings of upholstery fabrics and thick curtains, coatings of vertical curtains and coatings of other functional / technical textiles. The aim here is to use a recycled material that is more economical than these fillers and to improve the heat and sound insulation and flame retardancy properties of the coating.

[0100] The whiteness values of the coated samples were measured by UV-VIS spectrophotometer and compared (Table 5).

[0101] Table 5. Whiteness index measurement results

[0102] According to the measurement results; it was concluded that there was no significant whiteness difference with the use of white silica fume instead of opened titanium dioxide (titanium dioxide dispersed with water) and white silica fume can be used partially or completely in coatings instead of white pigments such as titanium dioxide, calcium carbonate, etc., thus contributing to heat and sound insulation and flame retardancy properties.

[0103] The light and solar properties of the coated samples were also determined by UV-VIS-NIR spectrophotometer according to TS EN ISO 410 standard (Table 6). The obtained reflectance values (Rv and Rs) support the whiteness values.

[0104] Table 6. UV-VIS-NIR spectrophotometer measurement results

[0105] EXAMPLE 3: Multilayer Coating Recipe Specific to Black-out In this group of sample applications, the amount of FR was reduced by 20-30% and coatings were made by using coating pastes containing dark silica fume and / or biobased silica instead of carbon black. The coating results obtained according to the recipe containing the standard flame-retardant chemical (FR) (100%) were evaluated in terms of opacity and flame retardancy properties.

[0106] Flammability tests were carried out according to BS 5867 and the results of burn length (cm) are given in Table 7. Table 7. Burning lengths (cm) of FR coatings according to BS 5867

[0107] According to the results; it was revealed that silica fume and biobased silica contribute FR to the coatings and by reducing the amount of halogenated flame retardant, the same flame retardancy levels as the conventional recipe with 100% FR additive were achieved. Furthermore, the black-out property was tested according to DIN 14501 standard. It is also clearly seen that the black-out effect is achieved in fabrics where dark colored silica fume and / or biobased silica is used.

Claims

CLAIMS1. A functional or technical textile surface offering ecological product feature with low carbon footprint, energy saving with thermal insulation feature, light-proofing feature (in blackout curtains, etc.), certain level of flame retardancy and partially sound insulation feature, characterized by comprising; at least one coating layer comprise recycled amorphous "silica fume" and / or "biobased silica" on at least one surface of selected fabric.

2. The functional or technical textile according to claim 1 , characterized by comprising; a fabric layer of 25-45% preferably 30% by weight and a coating paste and / or foam paste coating layer of 55-75% preferably 70% by weight.

3. The functional or technical textile according to claim 1 , characterized by comprising; said coating comprises binder polymer of 30-70% by weight, "silica fume" and / or "biobased silica" of 10-30% by weight, auxiliary chemicals of 10-30% by weight.

4. The functional or technical textile according to claim 1 , characterized in that; said fabric is a textile surface produced by knitting, weaving, nonwoven (nonwoven surface) techniques from natural or synthetic fibers consisting of cotton, polyester, nylon, acrylic, rayon and combinations thereof, in weight 50-500 g / m2.

5. The functional or technical textile according to claim 1 , characterized in that; said binder polymer is acrylic polymers, styrene-acrylic copolymers, vinyl polymers, polyurethanes, silicones or a combination of two or more of these polymers.

6. The functional or technical textile according to claim 1 , characterized by comprising; amorphous "biobased silica" and / or "silica fume" recovered from high temperature stove / furnace chimneys, obtained from rice, wheat and other cereal husks with a particle size below 50 p, white, all shades of grey and / or black in color and containing >50% SiO2.

7. The functional or technical textile according to claim 1 , characterized in that; said auxiliary chemicals are thickeners, crosslinkers, light stabilizers, preservatives, antimicrobials, surfactants, flame retardants, defoamers, foaming agents and foam stabilizers, coloring pigments, pH control chemicals or a combination of two or more of these chemicals.

8. The functional or technical textile according to claim 1 , characterized in that; the coating composition viscosity range is 10-120 dPas, the foam density is 100-300 g / L, the pH range is between 7,5-10.

9. The functional or technical textile according to claim 1 , characterized by comprising; a coating layer of coating paste and / or foam paste coated on a single surface or double surface, single-layer or multi-layer, by means of knife coating, rotation coating, transfer coating, spray coating, roller coating techniques or lamination method.

10. The functional or technical textile according to claim 1 , characterized in that; it has been subjected to drying at 90-130X3 for 60-150 s a fter coating, fixing at 130-180X3 for 60-240 s, calendering under 5-70 bar pressure and cooling to a fabric temperature <40X3 before winding.

11. The functional or technical textiles according to claim 1 , characterized in that; black-out curtains, dim-out curtains, roller blinds, vertical blinds, thick curtains, upholstery fabrics or other functional and technical textile surfaces with coating.

12. A functional or technical textile production method as claimed in any one of the preceding claims, characterized by comprising the following process steps i. Preparation of recycled silica powders of suitable particle size, color and SiO2ratio, ii. Preparation of foam paste / coating paste formulations containing binder polymer, recycled silica powders, thickener, crosslinker and auxiliary chemicals, iii. Controlling of the prepared paste / foam coating formulations, iv. Application of the coating processes to the fabric in the selected technique, v. Drying and fixing processes after coating, vi. Crushing of fabrics by calendering after coating, vii. Cooling and winding of the coated fabric.

13. The method according to claim 12, characterized in that; in the process step (i), suitable particle size <50 p, white, all shades of grey and black color and SiO2ratio >50% recycled silica powders are provided.

14. The method according to claim 12, characterized in that; in process step (iii) the viscosity is 10-120 dPas, pH is 7.5-10, foam density is 100-300 g / L.

15. The method according to claim 12, characterized in that; in the process step (iv), the coating method is knife coating, rotation coating or roller coating.

16. The method according to claim 12, characterized in that; in the process step (v), the drying is at 90-13013 , 60-150 s and the fixing is at 130-18013 , 60-240 s.

17. The method according to claim 12, characterized in that; in the process step (vi), calendering is carried out under a pressure of 5-70 bar.

18. The method according to claim 12, characterized in that; in process step (vii), the fabric temperature is <4013 before winding.

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