Method for producing a fibrous composition and fibrous composition

Abstract

The present invention relates to a method for producing a fibrous composition, wherein at least a first recycled fiber and a second recycled fiber are provided. The invention further relates to a non-woven fibrous composition, which can be produced by means of said method. Further objects of the invention are a carpet comprising a pad which comprises at least a first recycled fiber and a second recycled fiber, as well as a carpet tile comprising a pad which comprises at least a first recycled fiber and a second recycled fiber.

Description

[0001] Method for producing a fibrous composition and fibrous composition

[0002] The present invention relates to a method for producing a fibrous composition comprising recycled fibers. The invention also relates to a non-woven fibrous composition comprising recycled fibers, as well as to a carpet comprising a pad wherein the pad is such a non-woven fibrous composition.

[0003] WO 98 / 36114 discloses a recycling process for complex textile structures, such as floor or wall coverings, to obtain a mixture of fibers of varying lengths. A lap is formed from the obtained fibrous mixture, which undergoes a heat treatment by placing the lap between two conveyors permeable to air.

[0004] AU 2013206077 discloses a method of making a carpet backing layer by recycling used carpet.

[0005] The methods and products of the prior art have the disadvantage that the quality of the produced products can be very dependent on the quality of the recycled products.

[0006] The aim of the present invention is to provide alternative methods and products to those of the prior art, and also in accordance with several of the preferred embodiments to solve one or more disadvantages of the methods and products of the prior art.

[0007] According to its first independent aspect, the invention relates to a method for producing a fibrous composition, comprising at least the steps: providing a first mass of a first recycled fiber; providing a second mass of a second recycled fiber; optionally providing a third mass of a third fiber, wherein the third fiber preferably is a recycled fiber; obtaining a mixture comprising the first mass of a first recycled fiber, the second mass of a second recycled fiber, and the optional third mass of a third fiber; forming a fibrous composition from the mixture. This has the advantage that the quality of the obtained fibrous composition can be better controlled since at least two masses of recycled fiber are used. Depending on the quality of the recycled fibers, the masses can be finetuned to provide a high-quality fibrous composition.

[0008] Preferably, at least one and preferably all of the first recycled fiber, the second recycled fiber, and the optional third fiber are essentially composed of a polymer selected from the list comprising polypropylene (PP), polyamide (PA), and polyester, preferably polyethylene terephthalate (PET). It is thus meant to be understood that the material selected from the above list is the main constituent, however, further minor components are not excluded according to the invention. Of course, the use of other fiber types such as flax, wool, acrylic, or others, are not excluded.

[0009] Preferably, the polymer of which each one of the first recycled fiber, the second recycled fiber and the optional third fiber is essentially composed, is essentially a different polymer. This is meant to be understood that, if the first recycled fiber is selected to be of a polymer A, the second recycled fiber and the optional third recycled fiber are essentially composed of a polymer which is not polymer A. For example, if the first recycled fiber is PP, then the second recycled fiber and the optional third recycled fiber are both not essentially composed of PP, but of PA and PET for example. This has the benefit that different properties of the fibrous composition can be obtained depending on the selected polymers.

[0010] When recycling fibrous products, for example by means of a tearing line, the input recycling fibrous products are decomposed into recycled fibers and other components such as dust, latex and CaCCh. Generally speaking, the recycling does not lead to a perfect decomposition of the input recycling fibrous products, meaning that a complete separation of the individual components is not achieved. This often leads to the recycled fibers having traces of said other components attached to the recycled fibers. For example, recycled fibers resulting from the recycling of carpets can have an amount of latex still attached to the recycled fibers. In some embodiments, the first recycled fiber comprises a first amount of latex. Said first amount of latex can be a result of an imperfect recycling process, where not all of the latex comprised in a recycled product is removed during the recycling process. The first amount of latex can be attached to the first recycled fiber. Preferably, the first amount of latex comprises an inorganic filler such as for example CaCOs or BaSC , preferably CaCOs. Inorganic fillers have the benefit that they are cheap, provide for an increased weight, and that they may improve the sound insulation of the fibrous composition to be produced. Preferably, the first amount of latex is lower than 10 wt%, preferably lower than 5 wt%, more preferably lower than 1 wt%, of the first mass of the first recycled fiber. This has the benefit that the first recycled fiber is more pure, yielding a similar performance as the performance that would be obtained if said first recycled fiber were a virgin fiber. This further has the benefit that the performance can be more accurately predicted beforehand.

[0011] In some embodiments, the second recycled fiber comprises a second amount of latex. Said second amount of latex can be a result of an imperfect recycling process, where not all of the latex comprised in a recycled product is removed during the recycling process. The second amount of latex can be attached to the second recycled fibers. Preferably, the second amount of latex comprises an inorganic filler such as for example CaCOs or BaSO4, preferably CaCOs. Inorganic fillers have the benefit that they are cheap, provide for an increased weight, and that they may improve the sound insulation of the fibrous composition to be produced. Preferably, the second amount of latex is lower than 10 wt%, preferably lower than 5 wt%, more preferably lower than 1 wt%, of the second mass of the second recycled fiber. This has the benefit that the second recycled fiber is more pure, yielding a similar performance as the performance that would be obtained if said second recycled fiber were a virgin fiber. This further has the benefit that the performance can be more accurately predicted beforehand.

[0012] Preferably, the first mass of the first recycled fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, even more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the mixture. Preferably, the first mass of the first recycled fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the mixture.

[0013] Preferably, the second mass of the second recycled fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, even more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the mixture. Preferably, the second mass of the second recycled fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the mixture.

[0014] In a preferred embodiment, the first mass of the first recycled fiber and the second mass of the second recycled fiber are selected so that the ratio of the first mass of the first fiber to the second mass of the second fiber is between 1:9 and 9: 1. This range of ratios is further also referred to as “range of acceptable mixing ratios”. Said ratios provide a fibrous composition with sufficient performance. Said range of ratios further has the benefit that inaccuracies in the selection of the first mass and / or the second mass will likely still fall within the abovementioned range, so that said inaccuracies will still yield a fibrous composition with sufficient performance.

[0015] Preferably, the ratio of the first mass of the first recycled fiber to the second mass of the second recycled fiber is between 1:3 to 3:1. This has the benefit that a fibrous composition is obtained with optimal properties and / or performance.

[0016] Preferably, each one of the first recycled fiber and the second recycled fiber has a fiber length of at least 5 mm, more preferably at least 7 mm, even more preferably at least 10 mm, most preferably at least 15 mm. This has the benefit that the first recycled fiber and the second recycled fiber are long enough to provide a strong connection, e.g. by means of needling.

[0017] In a preferred embodiment, the fibrous composition comprises the optional third mass of the third fiber. Preferably, the third fiber is a non-recycled or virgin fiber. This has the benefit that the third fiber is of very high quality, which is advantageous for the overall performance of the fibrous composition. Preferably, in the case that the third fiber is a non-recycled or virgin fiber, the fiber length of the third fiber is at least 15 mm, more preferably at least 20 mm, even more preferably at least 25 mm, most preferably at least 30 mm. This has the benefit that the third fiber provides a high carrying ability, which can compensate for a possibly reduced carrying ability of the first recycled fiber and second recycled fiber.

[0018] Alternatively, the third fiber can be a recycled fiber. This has the benefit that the circularity of materials is increased, leading to less material waste. The third fiber can comprise a third amount of latex. Said third amount of latex can be a result of an imperfect recycling process, where not all of the latex comprised in a recycled product is removed during the recycling process. The third amount of latex can be attached to the third fibers. Preferably, the third amount of latex comprises an inorganic filler such as for example CaCOs or BaSC , preferably CaCOs. Inorganic fillers have the benefit that they are cheap, provide for an increased weight, and that they may improve the sound insulation of the fibrous composition to be produced. Preferably, the third amount of latex is lower than 10 wt%, preferably lower than 5 wt%, more preferably lower than 1 wt%, of the third mass of the third fiber. This has the benefit that the third fiber is more pure, yielding a similar performance as the performance that would be obtained if said third fiber were a virgin fiber. This further has the benefit that the performance can be more accurately predicted beforehand.

[0019] Preferably, the third mass of the third fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, even more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the mixture. Preferably, the third mass of the third fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the mixture. Preferably, in the case that the third fiber is a recycled fiber, the fiber length of the third fiber is at least 5 mm, more preferably at least 7 mm, even more preferably at least 10 mm, most preferably at least 15 mm.

[0020] The method for producing a fibrous composition further preferably comprises the step of adding a binder fiber to the mixture, wherein the binder fiber is provided for binding in a thermal process step the first recycled fiber, the second recycled fiber and the optional third fiber into the fibrous composition. Preferably, the binder fiber is a bi-component fiber, wherein the bi-component fiber is a fiber comprising two different polymers. The bi-component fiber can be of the so-called core-sheath type, wherein the bi-component fiber comprises a core and a sheath, wherein the material of the sheath has a lower activation temperature than the material of the core. Preferably, the activation temperature of the binder fiber is lower than the activation temperature of the first recycled fiber, the second recycled fiber and the optional third fiber. This has the benefit that the thermal process can be regulated to activate the binder fiber while not activating the first recycled fiber, the second recycled fiber or the optional third fiber. In preferred embodiments, the activation temperature is the glass transition temperature or the melting temperature of the material.

[0021] Preferably, the binder fiber comprises a copolyester.

[0022] Preferably, the binder fiber is provided in the mixture in an amount of less than 30 wt%, preferably less than 20 wt%, more preferably less than 15 wt%, and most preferably less than 10 wt%. It is remarked that the material of the binder fiber is not taken into account for the determination of the masses and ratios of the first recycled material, the second recycled material, and the optional third material, in the mixture.

[0023] Preferably, the step of forming the fibrous composition comprises at least the step of forming a fiber mat from the mixture. This can be performed by placing a desired number of layers of the mixture on top of, alternatively adjacent to, each other. In this regard, the placing of the layers may be performed in one single direction. This has the benefit that the process is relatively easy and does not require highly sophisticated machinery. Alternatively, the laying of the layers may be performed by placing consecutive layers of the mixture in different, preferably perpendicular, directions. This has the benefit that directional properties may be provided to the fibrous composition to be produced. Any known method in the state of the art, such as airlay for example, is suitable for this step.

[0024] Preferably, the step of forming the fibrous composition comprises the step of consolidating the fiber mat, preferably by applying heat and / or pressure to the fiber mat. This has the benefit that the void content of the fiber mat is reduced and that mechanical properties are improved.

[0025] Preferably, the step of forming the fibrous composition comprises the step of, at least partially, entangling the fibers in the fiber mat, preferably by needling. The fibers in the fiber mat at least include the first recycled fiber, the second recycled fiber, the optional third fiber and the binder fiber if present. This step has the benefit that the fibers in the fiber mat form an interconnected web, providing an enhanced mechanical performance of the fiber mat. As an alternative for, or additionally to, needling, the fibers may be entangled by means of hydroentanglement.

[0026] Preferably, the step of forming the fibrous composition comprises the step of increasing the temperature of the fiber mat to activate the binder fibers, preferably by means of an oven. This has the benefit that the fibers in the fiber mat form a stronger interconnected web. Alternatively or in addition to an oven, the temperature can be increased by means of radiation, preferably infrared radiation. The binder fibers are activated at their activation temperature. In the case of a bi-component binder fiber, the temperature is preferably increased to a temperature which is at least equal to the lowest activation temperature of the constitutive materials of the bi-component fiber. Preferably, the temperature does not exceed the activation temperature of the first recycled fiber, the second recycled fiber, the optional third fiber and, if the binder fiber is a bi-component fiber, the activation temperature of the material of the bi-component fiber with the highest activation temperature. This has the benefit that the first recycled fiber, the second fiber and the optional third fiber are not activated and / or degraded by the thermal process step. In a preferred embodiment, the method for producing a fibrous composition comprises at least the steps: determining the available mass of the first recycled fiber; determining the available mass of the second recycled fiber; optionally determining the available mass of the third fiber; selecting and providing the first mass of the first recycled fiber based on the available mass of the first recycled fiber; selecting and providing the second mass of the second recycled fiber based on the available mass of the second recycled fiber; optionally selecting and providing the third mass of the third fiber based on the available mass of the third fiber; wherein the first mass of the first recycled fiber, the second mass of the second recycled fiber, and the optional third mass of the third fiber, are selected based on at least one of, or a combination of, the criteria contained in the list of: a performance criterion of the fibrous composition to be obtained; the masses of fibers that remain available of the first recycled fiber, of the second recycled fiber, and of the optional third fiber, after the selection of the masses from the first recycled fiber, of the second recycled fiber, and of the optional third fiber for forming the mixture.

[0027] Preferably, the first recycled fiber, the second recycled fiber and the optional third fiber are stored in a storage installation, for example in separate containers. This has the advantage that the first recycled fiber, the second recycled fiber and the optional third fiber can be easily weighed, and can be protected from the surroundings such as dust and humidity.

[0028] Preferably, the selected masses are chosen in order to maximize the amount of fibrous compositions that can be obtained, wherein each of the obtained fibrous compositions fulfills a performance criterion. This has the benefit that each of the obtained fibrous compositions is of high quality, while simultaneously the available masses are optimally utilized. Preferably, the performance criterion is a range of acceptable mixing ratios of the first recycled fiber and the second recycled fiber, wherein the acceptable mixing ratios are between 1:9 and 9: 1. Applying a range of acceptable mixing ratios has the advantage that subsequent fibrous compositions are of high quality, while allowing an optimization of the use of the available masses across the different fibrous compositions.

[0029] Preferably, the method comprises the optional step of selecting and providing the third mass of the third fiber, characterized in that the ranges of acceptable mixing ratios of the first recycled fiber and the third fiber are between 1:9 and 9: 1. Applying a range of acceptable mixing ratios has the advantage that subsequent fibrous compositions are of high quality, while allowing an optimization of the use of the available masses across the different fibrous compositions.

[0030] Preferably, the method comprises a step wherein an assessment is made of how many mixtures with acceptable mixing ratios can be made, and which one of the first recycled fiber, of the second recycled fiber and of the optional third fiber will be depleted first. With depleted is meant that there is too little of the material for a mixture of a minimum size or volume to be formed. Preferably, based on said assessment, the method comprises the step of providing feedback to an operator and / or to a recycling apparatus, wherein the feedback at least comprises the information of which one of the first recycled fiber, of the second recycled fiber, or of the optional third fiber, will be depleted first. Preferably, the method also comprises the step of controlling a recycling apparatus, either automatically or by an operator, wherein the recycling apparatus generates additional material of the fiber which will be depleted first. This has the benefit that the manufacturing of the fibrous composition can continue undisturbed, and thus that more fibrous composition can be manufactured.

[0031] Preferably, the method comprises the step of substituting, at least a part of, the recycled fiber by virgin fiber. This has the benefit that, in the scenario that there is insufficient material of the first recycled fiber or the second recycled fiber, that virgin fiber that is essentially composed of the same polymer may be used in order to prolong the manufacturing of the fibrous composition. The fibrous composition obtained through the method of the first independent aspect also forms an inventive aspect of the present invention. Embodiments of the first independent aspect thus also apply to embodiments of the second independent aspect, in as much as they are not contradictory. Therefore, according to a second independent aspect, the invention relates to a non-woven fibrous composition, characterized in that it comprises a first recycled fiber, a second recycled fiber, and an optional third, preferably recycled, fiber.

[0032] Preferably, at least one and preferably all of the first recycled fiber, the second recycled fiber, and the optional third fiber are essentially composed of a polymer selected from the list comprising polypropylene (PP), polyamide (PA), and polyester, preferably polyethylene terephthalate (PET). It is thus meant to be understood that the material selected from the above list is the main constituent, however, further minor components are not excluded according to the invention. Of course, the use of other fiber types such as flax, wool, acrylic, or others, are not excluded.

[0033] Preferably, the polymer of which each one of the first recycled fiber, the second recycled fiber and the optional third fiber is essentially composed, is essentially composed of a different polymer. This is meant to be understood that, if the first recycled fiber is selected to be of a polymer A, the second recycled fiber and the optional third recycled fiber are essentially composed of a polymer which is not polymer A. For example, if the first recycled fiber is PP, then the second recycled fiber and the optional third recycled fiber are both not essentially composed of PP, but of PA and PET for example. This has the benefit that different properties of the fibrous composition can be obtained depending on the selected polymers.

[0034] The first recycled fiber and / or the second recycled fiber and / or the optional third fiber can comprise latex. The latex can be a result of an imperfect recycling process, where not all of the latex comprised in a recycled product is removed during the recycling process. The latex can be attached to the first recycled fiber and / or to the second recycled fiber and / or to the optional third fiber. Preferably, the latex comprises an inorganic filler such as for example CaCOs or BaSC , preferably CaCOs. Inorganic fillers have the benefit that they are cheap, provide for an increased weight, and that they may improve the sound insulation of the fibrous composition to be produced.

[0035] Preferably, the non-woven fibrous composition comprises fillers, preferably CaCOs and / or colorants and / or latex and / or cork particles. The latex comprised in the first recycled fiber and / or the second recycled fiber and / or the optional third fiber, as well as the inorganic fillers comprised in the latex, are not considered here as fillers. The fillers have the benefit that they may attribute desired properties to the non-woven fibrous composition such as for example an aesthetic appearance or an improved sound dampening.

[0036] In a preferred embodiment, the non-woven fibrous composition comprises a binder fiber, wherein the binder fiber binds the fibers comprised in the non-woven fibrous composition. Preferably, the binder fiber is a bi-component fiber, wherein the bicomponent fiber is a fiber comprising two different polymers. The bi-component fiber can be of the so-called core-sheath type, wherein the bi-component fiber comprises a core and a sheath, wherein the material of the sheath has a lower activation temperature than the material of the core. Preferably, the activation temperature of the binder fiber is lower than the activation temperature of the first recycled fiber, the second recycled fiber and the optional third fiber. This has the benefit that the thermal process can be regulated to activate the binder fiber while not activating the first recycled fiber, the second recycled fiber or the optional third fiber. In preferred embodiments, the activation temperature is the glass transition temperature or the melting temperature of the material.

[0037] Preferably, the binder fiber comprises a copolyester.

[0038] Preferably, the binder fiber is contained in the non-woven fibrous composition in an amount of less than 30 wt%, preferably less than 20 wt%, more preferably less than 15 wt%, and most preferably less than 10 wt%. Preferably, the first recycled fiber provides at least 10 wt%, more preferably at least 20 wt%, even more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the non-woven fibrous composition. Preferably, the first recycled fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the non-woven fibrous composition.

[0039] Preferably, the second recycled fiber provides at least 10 wt%, preferably at least 20 wt%, more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the non-woven fibrous composition. Preferably, the second recycled fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the non-woven fibrous composition.

[0040] Preferably, the ratio of first recycled fiber to second recycled fiber is between 1:9 and 9: 1, more preferably between 1:3 and 3: 1.

[0041] In preferred embodiments, the non-woven fibrous composition comprises the optional third fiber. Preferably, said third fiber provides at least 10 wt%, preferably at least 20 wt%, more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the non-woven fibrous composition. Preferably, said third fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the non-woven fibrous composition.

[0042] Preferably, the first recycled fiber, the second recycled fiber and the optional third fiber comprised in the non-woven fibrous composition are entangled, preferably by means of needling. Alternatively, the entanglement may be by means of hydroentanglement.

[0043] Preferably, the non-woven fibrous composition is a non-woven fiber felt. The non-woven fibrous composition can have any shape, however, a rectangular or square shape is preferred. The non-woven fibrous composition can have an average thickness of more than 0.1 mm, preferably more than 0.5 mm, more preferably more than 1 mm, even more preferably more than 2 mm, and most preferably more than 3 mm. Preferably, the non-woven fibrous composition has an average thickness of about 3.5 mm. This has the benefit that the non-woven fibrous composition can provide a good sound and thermal insulation, and has shock absorbing properties. Preferably, the density of the non-woven fibrous composition is more than 250 g / m2, more preferably more than 350 g / m2, even more preferably more than 500 g / m2, most preferably more than 750 g / m2. Preferably, the density of the non-woven fibrous composition is about 350 g / m2. Alternatively, the density of the non-woven fibrous composition can be about 800 g / m2. This provides the non-woven fibrous composition with good mechanical properties and good dimensional stability.

[0044] A carpet comprising the inventive non-woven fibrous composition of the second independent aspect of the invention is of course also inventive. Therefore, in accordance with a third independent aspect, the invention relates to a carpet comprising a face yarn, a primary backing and a pad. characterized in that the pad is a non-woven fibrous composition in accordance with the second independent aspect.

[0045] In a preferred embodiment, the pad forms the bottom of the carpet. This has the benefit that carpet has good anti-slip properties and that no further bottom layers are needed to improve the carpet’s stability and / or anti-slip behavior, making the carpet more economical. Preferably, from bottom to top, the carpet comprises the pad, the primary backing and the face yarn.

[0046] The bottom surface of the pad is preferably visible at the bottom surface of the carpet. This has the benefit that the pad provides the carpet with anti-slip properties and a relatively soft basis which makes walking on the carpet comfortable.

[0047] Preferably, the carpet further comprises a pre-coat at the bottom side of the primary backing for anchoring the face yarn to the primary backing. Preferably, said pre-coat substantially consists of latex, preferably a styrene butadiene copolymer (SBR), a styrene acrylate latex or an acrylate latex. Preferably, the pre-coat comprises a hot melt adhesive (HMA) that contains a tackifying resin or agent alone or in combination with polyethylene. In various embodiments, the pre-coat comprises an aqueous-latex based polymer configured to support the face yarn within the primary backing upon drying. In certain embodiments, the pre-coat comprises butadiene acrylate based polymers, vinyl acetate ethylene, vinyl acetate-ethane copolymers, and / or latex based compounds. The pre-coat may include one or more other compositions, such as inert filler materials. The inert filler material may be made from carbonates such as calcium carbonate (CaCCh), cesium carbonate (CsCCh), strontium carbonate (SrCCh), and magnesium carbonate (MgCCh); sulfates such as barium sulfate (BaSCh); oxides such as iron oxide (FC2O3 or FesC ), aluminum oxide (AI2O3), tungsten oxide (WO3), titanium oxide (TiC ), silicon oxide (SiCh); silicates, such as clay; metal salts; fly ash and the like.

[0048] Preferably, the pre-coat is present in an amount of at least 300 g / m2, more preferably at least 400 g / m2, even more preferably at least 500 g / m2, most preferably at least 600 g / m2. Preferably, the filler in the pre-coat is present in an amount of at least 200 g / m2, more preferably at least 300 g / m2, most preferably at least 400 g / m2. Preferably, the filler is present in an amount of about 70 wt% of the pre-coat.

[0049] Preferably, the carpet further comprises a glue layer at the bottom side of the primary backing for connecting the primary backing to the pad. Preferably, the glue layer comprises hot melt, bitumen or latex, wherein the latex preferably is an SBR latex, or an acrylate latex (e.g. a styrene acrylate latex). Preferably, the glue layer further comprises at least one filler, preferably CaCCh. The filler has the benefit that it is cheap, and can reduce the cost of the glue layer.

[0050] Preferably, the glue layer is present in an amount of at least 1000 g / m2, more preferably at least 1500 g / m2, even more preferably at least 2000 g / m2, most preferably at least 2500 g / m2. Preferably, the filler in the pre-coat is present in an amount of at least 500 g / m2, more preferably at least 1000 g / m2, most preferably at least 1500 g / m2. Preferably, the filler is present in an amount of about 70 wt% of the glue layer. The primary backing is preferably selected from a woven polypropylene fabric or a nonwoven fabric, preferably a nonwoven polyester fabric.

[0051] Preferably, the carpet comprises a glass scrim. Said glass scrim is preferably provided between the primary backing and the pad and / or below the pad. This has the advantage that the carpet is dimensionally stable and more resistant to loads, at least loads in the plane of the carpet.

[0052] The average thickness of the pad is preferably more than 0.1 mm, preferably more than 0.5 mm, more preferably more than 1 mm, even more preferably more than 2 mm, and most preferably more than 3 mm. Preferably, the pad has an average thickness of about 3.5 mm. This has the benefit that the pad provides a cushion so that it feels comfortable to walk on the carpet, while keeping the cost thereof low due to the recycled materials. A further benefit is that the pad, and therefor also the carpet, provides a good sound and thermal insulation.

[0053] According to a preferred embodiment, the pad provides at least 10%, preferably at least 20%, more preferably at least 30%, most preferably at least 40% of the average thickness of the carpet. Preferably, the pad provides about 35% of the average thickness of the carpet. This has the benefit that the carpet can be relatively cheap, since the pad, which comprises recycled fibers, provides a significant portion of the thickness of the carpet.

[0054] Preferably, the carpet has an average thickness of at least 2 mm, more preferably at least 5 mm, even more preferably at least 10 mm, and most preferably at least 15 mm. This has the advantage that the carpet is sufficiently sturdy for usage, and provides a good sound and thermal insulation.

[0055] The average density of the pad is preferably at least 250 g / m2, more preferably at least 350 g / m2, even more preferably at least 500 g / m2, most preferably at least 750 g / m2. Preferably, the density of the pad is about 350 g / m2. Alternatively, the density of the pad can be about 800 g / m2. The average density of the carpet is preferably at least 1500 g / m2, more preferably at least 2500 g / m2, even more preferably at least 3500 g / m2, most preferably at least 4500 g / m2. This has the benefit that it is dimensionally stable and does not easily move during use.

[0056] Preferably, the carpet comprises more than 30 wt%, more preferably more than 40 wt%, even more preferably more than 50 wt%, most preferably more than 60 wt%, of filler, wherein the filler preferably is or comprises CaCOs. This has the benefit that a carpet with a high weight is obtained which has improved dimensional stability and is unlikely to simply slide, e.g. when walking on the carpet.

[0057] Preferably, the face yarn is selected from a polypropylene fiber or multifilament yarn, a polyester fiber of multifilament yam, or a polyamide fiber or multifilament yam.

[0058] In a preferred embodiment, the fibers from the face yarn essentially are composed of a polymer out of which the first recycled fiber or the second recycled fiber are provided. This has the benefit that the carpet is dimensionally stable. A further benefit is that the face yarn in this preferred embodiment is essentially composed of a recycled fiber, further increasing the circularity of fibrous materials.

[0059] Preferably, the carpet is a tufted carpet or a bonded carpet. Preferably, the carpet is a broadloom carpet or a carpet tile.

[0060] The inventors surprisingly found that the dimensional stability of a carpet comprising at least a first recycled fiber is dependent on the dimensions of said carpet. Without being bound to theory, the inventors believe that the reason for this is that more imperfections may be present in a carpet of larger size, resulting in a reduced dimensional stability. The carpet obtained in AU 2013206077 is of a large dimension, which results in a carpet that may suffer from dimensional instability. Therefore, the invention, in accordance with a fourth independent aspect, relates to a carpet tile, wherein the carpet tile comprises a face yam, a primary backing, and a pad provided below the primary backing, wherein the pad comprises at least a first recycled fiber, characterized in that the size of the carpet tile is smaller than 150 cm by 150 cm, preferably smaller than 100 cm by 100 cm, more preferably smaller than 80 cm by 80 cm, even more preferably smaller than 60 cm by 60 cm, most preferably smaller than 40 cm by 40 cm. Preferably, the carpet tile has a size of about 50 cm by 50 cm. This has the advantage that a carpet tile with a good dimensional stability is obtained. Alternatively, the carpet tile may have a rectangular shape with a size of about 100 cm by 25 cm.

[0061] Preferred embodiments for the first recycled fiber of the fourth independent aspect preferably correspond to preferred embodiments for the first recycled fiber in the nonwoven fibrous composition in accordance with the second independent aspect and / or the third independent aspect.

[0062] Preferred embodiments of the pad comprised in the carpet tile of the fourth independent aspect may correspond to preferred embodiments of the pad comprised in the carpet of the third independent aspect and / or to the non-woven fibrous composition of the second independent aspect, as long as this does not lead to contradictions. The pad comprised in the carpet tile of the fourth independent aspect may be manufactured by means of the method of the first independent aspect, as long as this does not lead to contradictions.

[0063] In a preferred embodiment, the pad forms the bottom of the carpet tile. This has the benefit that the carpet tile has good anti-slip properties and that no further bottom layers are needed to improve the carpet tile’s stability and / or anti-slip behavior, making the carpet tile more economical. Preferably, from bottom to top, the carpet tile comprises the pad, the primary backing and the face yam.

[0064] The bottom surface of the pad is preferably visible at the bottom surface of the carpet tile. This has the benefit that the pad provides the carpet tile with anti-slip properties and a relatively soft basis which makes walking on the carpet tile comfortable.

[0065] Preferably, the carpet tile further comprises a pre-coat at the bottom side of the primary backing for anchoring the face yarn to the primary backing. Preferably, said pre-coat substantially consists of latex, preferably a styrene butadiene copolymer (SBR) or an acrylate latex, e.g. a styrene acrylate latex. Preferably, the pre-coat comprises a hot melt adhesive (HMA) that contains a tackifying resin or agent alone or in combination with polyethylene. In various embodiments, the pre-coat comprises an aqueous-latex based polymer configured to support the face yam within the primary backing upon drying. In certain embodiments, the pre-coat comprises butadiene acrylate based polymers, vinyl acetate ethylene, vinyl acetate-ethane copolymers, and / or latex based compounds. The pre-coat may include one or more other compositions, such as inert filler materials. The inert filler material may be made from carbonates such as calcium carbonate (CaCCh), cesium carbonate (CsCCh), strontium carbonate (SrCCh), and magnesium carbonate (MgCCh); sulfates such as barium sulfate (BaSCh); oxides such as iron oxide (FC2O3 or FesC ), aluminum oxide (AI2O3), tungsten oxide (WO3), titanium oxide (TiC ), silicon oxide (SiCh); silicates, such as clay; metal salts; fly ash and the like.

[0066] Preferably, the pre-coat is present in an amount of at least 300 g / m2, more preferably at least 400 g / m2, even more preferably at least 500 g / m2, most preferably at least 600 g / m2. Preferably, the filler in the pre-coat is present in an amount of at least 200 g / m2, more preferably at least 300 g / m2, most preferably at least 400 g / m2. Preferably, the filler is present in an amount of about 70 wt% of the pre-coat.

[0067] Preferably, the carpet tile further comprises a glue layer at the bottom side of the primary backing for connecting the primary backing to the pad. Preferably, the glue layer comprises hot melt, bitumen or latex, wherein the latex preferably is an SBR latex or an acrylate latex, e.g. a styrene acrylate latex. Preferably, the glue layer further comprises at least one filler, preferably CaCCh. The filler has the benefit that it is cheap, and can thus limit the cost of the glue layer.

[0068] Preferably, the glue layer is present in an amount of at least 1000 g / m2, more preferably at least 1500 g / m2, even more preferably at least 2000 g / m2, most preferably at least 2500 g / m2. Preferably, the filler in the pre-coat is present in an amount of at least 500 g / m2, more preferably at least 1000 g / m2, most preferably at least 1500 g / m2. Preferably, the filler is present in an amount of about 70 wt% of the glue layer. The primary backing is preferably selected from a woven polypropylene fabric or a nonwoven fabric, preferably a nonwoven polyester fabric.

[0069] Preferably, the carpet tile comprises a glass scrim. Said glass scrim is preferably provided between the primary backing and the pad and / or below the pad. This has the advantage that the carpet tile is dimensionally stable and more resistant to loads in the plane of the carpet.

[0070] The average thickness of the pad is preferably more than 0.1 mm, preferably more than 0.5 mm, more preferably more than 1 mm, even more preferably more than 2 mm, and most preferably more than 3 mm. Preferably, the pad has an average thickness of about 3.5 mm. This has the benefit that the pad provides a cushion so that it feels comfortable to walk on the carpet tile, while keeping the cost thereof low due to the recycled materials. A further benefit is that the pad, and therefor also the carpet tile, provides a good sound and thermal insulation.

[0071] According to a preferred embodiment, the pad provides at least 10%, preferably at least 20%, more preferably at least 30%, most preferably at least 40% of the average thickness of the carpet tile. Preferably, the pad provides about 35% of the average thickness of the carpet. This has the benefit that the carpet tile can be relatively cheap, since the pad, which comprises at least the first recycled fiber, provides a significant portion of the thickness of the carpet tile.

[0072] Preferably, the carpet tile has an average thickness of at least 2 mm, more preferably at least 5 mm, even more preferably at least 10 mm, and most preferably at least 15 mm. This has the advantage that the carpet tile is sufficiently sturdy for usage, and provides a good sound and thermal insulation.

[0073] The average density of the pad is preferably at least 250 g / m2, more preferably at least 350 g / m2, even more preferably at least 500 g / m2, most preferably at least 750 g / m2. Preferably, the density of the pad is about 350 g / m2. Alternatively, the density of the pad can be about 800 g / m2.

[0074] The average density of the carpet tile is preferably at least 1500 g / m2, more preferably at least 2500 g / m2, even more preferably at least 3500 g / m2, most preferably at least 4500 g / m2. This has the benefit that it is dimensionally stable and does not easily move during use.

[0075] Preferably, the carpet tile comprises more than 30 wt%, more preferably more than 40 wt%, even more preferably more than 50 wt%, most preferably more than 60 wt%, of filler, wherein the filler preferably is or comprises CaCOs- This has the benefit that a carpet tile with a high weight is obtained which has improved dimensional stability and is unlikely to simply slide, e.g. when walking on the carpet tile.

[0076] Preferably, the face yam is selected from a polypropylene fiber or multifilament yarn, a polyester fiber of multifilament yam, or a polyamide fiber or multifilament yam.

[0077] In a preferred embodiment, the fibers from the face yam essentially are composed of a polymer out of which the first recycled fiber is provided. This has the benefit that the carpet tile is dimensionally stable. A further benefit is that the face yarn in this preferred embodiment is essentially composed of a recycled fiber, further increasing the circularity of fibrous materials.

[0078] Preferably, the carpet tile is a tufted carpet tile or a bonded carpet tile.

[0079] With the intention of better showing the characteristics according to the invention, in the following, as an example without limitative character, some embodiments are described, with reference to the accompanying drawings, wherein: figure 1 schematically shows an embodiment of a carpet according to the third independent aspect; figure 2 shows some steps in a method in accordance with the first aspect of the invention for producing a fibrous composition. In the following, a non-limitative example of a part of the method according to the first independent aspect of the invention, is provided.

[0080] EXAMPLE 1

[0081] It is started from a mass of 1000 kg of a first recycled fiber, 1000 kg of mass of a second recycled fiber, and 1000 kg of mass of a third fiber. The first recycled fiber is essentially composed of PP, the second recycled fiber is essentially composed of PA, and the third fiber is essentially composed of PET. Acceptable mixing ratios of the first recycled fiber to the second recycled fiber are between 1:9 and 9: 1. Acceptable mixing ratios of the first recycled fiber to the third fiber are between 1:9 and 9: 1. Table 1 shows the available masses of the first recycled fiber, the second recycled fiber and the third fiber throughout the production of fibrous compositions.

[0082] A first mixture is obtained by providing 100 kg of the first recycled fiber, 500 kg of the second recycled fiber, and 300 kg of the third fiber. A first fibrous composition (FC1) with a total mass of 900 kg is produced. The available masses of the first recycled fiber, the second recycled fiber and the third fiber are determined. A second mixture is obtained by providing 425 kg of the first recycled fiber, 150 kg of the second recycled fiber, and 325 kg of the third fiber. A second fibrous composition (FC2) is obtained with a total mass of 900 kg. The available masses of the first recycled fiber, the second recycled fiber and the third fiber are determined. A third mixture is obtained by providing 350 kg of the first recycled fiber, 200 kg of the second recycled fiber, and 350 kg of the third fiber. A third fibrous composition (FC3) is obtained with a total mass of 900 kg. The available masses of the first recycled fiber, the second recycled fiber and the third fiber are determined. A fourth mixture is obtained by providing 125 kg of the first recycled fiber, 150 kg of the second recycled fiber, and 25 kg of the third fiber. A fourth fibrous composition (FC4) is obtained with a total mass of 300 kg. The available masses of the first recycled fiber, the second recycled fiber and the third fiber are determined. Since the available masses of the first recycled fiber, the second recycled fiber and the third fiber are all equal to zero, no more fibrous composition can be produced. All three of the first fibrous composition, the second fibrous composition and the third fibrous composition have the same total mass and meet the same performance criteria, wherein the performance criteria are the ranges of acceptable mixing ratios. The fourth fibrous composition has a lower total mass, however, still meets the same acceptable mixing ratios as the first fibrous composition, the second fibrous composition and the third fibrous composition.

[0083] Table 1: Evolution of the masses of the first recycled fiber, the second recycled fiber and the third fiber for production of fibrous compositions. All masses are in kilogram.

[0084] Figure 1 schematically illustrates a carpet 100 in accordance with the third independent aspect of the invention, wherein the carpet 100 comprises a face yarn 101, a primary backing 102 and a pad 105. The pad 105 forms the bottom of the carpet 100. The bottom surface of the pad 105, wherein the bottom surface is the surface opposite to the primary backing 102, is visible at the bottom surface of the carpet 100.

[0085] The pad 105 comprises a first recycled fiber which essentially is composed of PA and a second recycled fiber which essentially is composed of PP. The first recycled fiber comprises latex attached to the first recycled fiber. The first recycled fiber provides about 40 wt% of the pad 105, and the second recycled fiber provides about 50 wt% of the pad 105. The pad 105 further comprises binder fibers in an amount of about 10 wt%. The binder fibers are bi-component fibers of the core-sheath type. The pad 105 in figure 1 corresponds to the fibrous composition 205 obtained by the method of figure 2.

[0086] The carpet 100 further comprises a pre-coat layer 103 at the bottom of the primary backing 102 that binds the face yarn 101 to the primary backing 102, and a glue layer 104 at the bottom side of the primary backing 102 for connecting the primary backing 102 to the pad 105. The pre-coat layer 103 substantially consists of an SBR latex. The glue layer 104 comprises an SBR latex and CaCCh as filler.

[0087] The carpet 100 comprises about 50 wt% of filler, wherein the filler comprises CaCOs- The face yarn 101 is a polypropylene fiber. The carpet 100 is a tufted carpet. The primary backing 102 is a nonwoven fabric.

[0088] The average thickness of the pad 105 is 3.5 mm. The carpet 100 has an average thickness of 10 mm. The average density of the pad 105 is 800 g / m2. The average density of the carpet 100 is 3500 g / m2.

[0089] Figure 2 schematically represents a method for producing a fibrous composition 205 according to the first independent aspect of the present invention. The method starts with a first step S 1 wherein a first mass Ml of a first recycled fiber is provided, a second mass M2 of a second recycled fiber M2 is provided, and a third mass M3 of a third fiber is provided. The providing of the third mass M3 of a third fiber is shown in dashed lines to indicate that this is optional according to the invention. The first recycled fiber is essentially composed of PA, the second recycled fiber is essentially composed of PP, and the third fiber is essentially composed of recycled PET. The masses Ml, M2 and M3 are selected based on the available masses of the first recycled fiber, the second recycled fiber and the third fiber, respectively, as well as based on acceptable mixing ratios that fulfill a selected performance criterion. The method continues with the step S2 wherein a mixture is obtained of the first mass Ml of the first recycled fiber, the second mass M2 of the second recycled fiber and the third mass M3 of the third fiber. The step S2 further also comprises adding binder fibers to the mixture. In the shown embodiment of the method, the binder fibers are bi-component fibers of the core-sheath type. Next, a fiber mat is formed from the mixture in step S3 by means of airlaying. The fiber mat is consolidated in step S4. Next, in step S5, the fibers in the fiber mat are entangled by means of needling. Fibers in the fiber mat refers to the first mass Ml of the first recycled fiber, the second mass M2 of the second recycled fiber, the third mass of the third fiber, and the binder fibers. In the step S6, the temperature is increased to activate the binder fibers, whereby the temperature is increased to a temperature above the activation temperature of the sheath of the bi-component binder fibers, but below the activation temperature of the core of the bi-component binder fibers, of the first recycled fiber, of the second recycled fiber and of the third fiber. In this case, the activation temperature is the melting temperature. At the end of the steps S1-S6, a fibrous composition 205 is obtained. The fibrous composition 205 can be used as pad 105 in the carpet 100 of figure 1.

[0090] The present invention is in no way limited to the above described embodiments, but such method may be realized according to different variants without leaving the scope of the present invention.

Claims

Claims1.- Method for producing a fibrous composition, comprising at least the steps: providing a first mass of a first recycled fiber; providing a second mass of a second recycled fiber; optionally providing a third mass of a third fiber, wherein the third fiber preferably is a recycled fiber; obtaining a mixture comprising the first mass of a first recycled fiber, the second mass of a second recycled fiber, and the optional third mass of a third fiber; forming a fibrous composition from the mixture.2.- Method for producing a fibrous composition according to claim 1, characterized in that at least one and preferably all of the first recycled fiber, the second recycled fiber, and the optional third fiber are essentially composed of a polymer selected from the list comprising polypropylene (PP), polyamide (PA), and polyester, preferably polyethylene terephthalate (PET).3.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that each one of the first recycled fiber, the second recycled fiber and the optional third fiber essentially are composed of a different polymer.4.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that the first recycled fiber comprises a first amount of latex.5.- Method for producing a fibrous composition according to claim 4, characterized in that the first amount of latex is attached to the first recycled fibers.6.- Method for producing a fibrous composition according to any one of claims 4 to 5, characterized in that the first amount of latex comprises an inorganic filler, preferably CaCO3.7.- Method for producing a fibrous composition according to any one of claims 4 to 6, characterized in that the first amount of latex is lower than 10 wt%, preferably lower than 5 wt%, more preferably lower than 1 wt%, of the first mass of the first recycled fiber.8.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that the second recycled fiber comprises a second amount of latex.9.- Method for producing a fibrous composition according to claim 8, characterized in that the second amount of latex is attached to the second recycled fibers.10.- Method for producing a fibrous composition according to any one of claims 8 to 9, characterized in that the second amount of latex comprises an inorganic filler, preferably CaCO3.11.- Method for producing a fibrous composition according to any one of claims 8 to 10, characterized in that the second amount of latex is lower than 10 wt%, preferably lower than 5 wt%, more preferably lower than 1 wt%, of the second mass of the second recycled fiber.12.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that the first mass of the first recycled fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the mixture.13.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that the first mass of the first recycled fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the mixture.14.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that the second mass of the second recycled fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the mixture.15.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that the second mass of the second recycled fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the mixture.16.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that the first mass of the first recycled fiber and the second mass of the second recycled fiber are selected so that the ratio of the first mass of the first fiber to the second mass of the second fiber is between 1:9 and 9:1.17.- Method for producing a fibrous composition according to claim 16, characterized in that the ratio of the first mass of the first recycled fiber to the second mass of the second recycled fiber is between 1:3 and 3: 1.18.- Method for producing a fibrous composition according to any one of the previous claims, wherein the fibrous composition comprises the optional third mass of the third fiber, characterized in that the third fiber is a non-recycled or a virgin fiber.19.- Method for producing a fibrous composition according to any one of the previous claims 1 to 17, wherein the fibrous composition comprises the optional third mass of the third fiber, characterized in that the third fiber is a recycled fiber.20.- Method for producing a fibrous composition according to claim 19, characterized in that the third fiber comprises a third amount of latex.21.- Method for producing a fibrous composition according to claim 20, characterized in that the third amount of latex is attached to the third fibers.22.- Method for producing a fibrous composition according to any one of claims 20 to21, characterized in that the third amount of latex comprises an inorganic filler, preferably CaCOs.23.- Method for producing a fibrous composition according to any one of claims 20 to22, characterized in that the third amount of latex is lower than 10 wt%, preferably lower than 5 wt%, more preferably lower than 1 wt%, of the third mass of the third fiber.24.- Method for producing a fibrous composition according to any one of the preceding claims 18 to 23, characterized in that the third mass of the third fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt% of the mixture.25.- Method for producing a fibrous composition according to any one of the preceding claims 18 to 24, characterized in that the third mass of the third fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt% of the mixture.26.- Method for producing a fibrous composition according to any one of the preceding claims, characterized in that the method further comprises the step of adding a binder fiber to the mixture, wherein the binder fiber is provided for binding in a thermal process step the first recycled fiber, the second recycled fiber and the optional third fiber in the fibrous composition.27.- Method for producing a fibrous composition according to claim 26, characterized in that the binder fiber is a bi-component fiber, wherein the bi-component fiber is a fiber comprising two different polymers.28.- Method for producing a fibrous composition according to any one of claims 26 to27, characterized in that the binder fiber comprises a copolyester.29.- Method for producing a fibrous composition according to any one of claims 26 to28, characterized in that the binder fiber is provided in the mixture in an amount of less than 30 wt%, preferably less than 20 wt%, more preferably less than 15 wt%, and most preferably less than 10 wt%.30.- Method for producing a fibrous composition according to any one of claims 26 to29, characterized in that the forming of the fibrous composition comprises at least the step of forming a fiber mat from the mixture.31.- Method for producing a fibrous composition according to claim 30, characterized in that the forming of the fibrous composition comprises the step of consolidating the fiber mat.32.- Method for producing a fibrous composition according to any one of claims 30 to 31, characterized in that the forming of the fibrous composition comprises the step of, at least partially, entangling the fibers in the fiber mat, preferably by needling.33.- Method for producing a fibrous composition according to any one of the claims 30 to 32, characterized in that the forming of the fibrous composition comprises the step of increasing the temperature of the fiber mat to activate the binder fibers, preferably by means of an oven.34.- Method for producing a fibrous composition according to any one of the preceding claims, comprising at least the steps: determining the available mass of the first recycled fiber; determining the available mass of the second recycled fiber; optionally determining the available mass of the optional third fiber; selecting and providing the first mass of the first recycled fiber based on the available mass of the first recycled fiber; selecting and providing the second mass of the second recycled fiber based on the available mass of the second recycled fiber; optionally selecting and providing the third mass of the third fiber based on the available mass of the third fiber; characterized in that the first mass of the first recycled fiber, the second mass of the second recycled fiber, and the optional third mass of the third fiber, are selected based on at least one of, or a combination of, the criteria contained in the list of: a performance criterion of the fibrous composition to be obtained; the masses of fibers that remain available of the first recycled fiber, of the second recycled fiber, of the optional third fiber, after the selection of the masses from the first recycled fiber, of the second recycled fiber, of the optional third fiber for forming the mixture.35.- Method for producing a fibrous composition according to claim 34, characterized in that the selected masses are chosen in order to maximize the amount of fibrous compositions that can be obtained, wherein each of the obtained fibrous compositions fulfills a performance criterion.36.- Method for producing a fibrous composition according to any one of claims 34 to35, characterized in that the performance criterion is a range of acceptable mixing ratios of the first recycled fiber and the second recycled fiber, wherein the acceptable mixing ratios are between 1:9 and 9: 1.37.- Method for producing a fibrous composition according to any one of claims 34 to36, wherein the method comprises the optional step of selecting the third mass of the third fiber, characterized in that the range of acceptable mixing ratios of the first recycled fiber and the third fiber is between 1:9 and 9: 1.38.- Non-woven fibrous composition characterized in that it comprises a first recycled fiber, a second recycled fiber, and an optional third, preferably recycled, fiber.39.- Non-woven fibrous composition according to claim 38, characterized in that at least one and preferably all of the first recycled fiber, the second recycled fiber, and the optional third fiber are essentially composed of a polymer selected from the list comprising polypropylene (PP), polyamide (PA), and polyester, preferably polyethylene terephthalate (PET).40.- Non-woven fibrous composition according to any one of claims 38 to 39, characterized in that each one of the first recycled fiber, the second recycled fiber and the third fiber essentially are composed of a different polymer.41.- Non-woven fibrous composition according to any one of claims 38 to 40, characterized in that the first recycled fiber and / or the second recycled fiber and / or the optional third fiber comprises latex.42.- Non-woven fibrous composition according to claim 41, characterized in that the latex is attached to the first recycled fiber and / or to the second recycled fiber and / or to the optional third fiber.43.- Non-woven fibrous composition according to claim 42, characterized in that the latex comprises an inorganic filler, preferably CaCOs.44.- Non-woven fibrous composition according to any one of claims 38 to 43, characterized in that the non-woven fibrous composition comprises fillers, preferably CaCOs and / or colorants and / or latex and / or cork particles.45.- Non-woven fibrous composition according to any one of claims 38 to 44, characterized in that the non-woven fibrous composition comprises a binder fiber, wherein the binder fiber binds the fibers comprised in the non-woven fibrous composition.46.- Non-woven fibrous composition according to claim 45, characterized in that the binder fiber is a bi-component fiber, wherein the bi-component fiber is a fiber comprising two different polymers.47.- Non-woven fibrous composition according to any one of claims 45 to 46, characterized in that the binder fiber comprises a copolyester.48.- Non-woven fibrous composition according to any one of claims 45 to 47, characterized in that the binder fiber is contained in the non-woven fibrous composition in an amount of less than 30 wt%, preferably less than 20 wt%, more preferably less than 15 wt%, and most preferably less than 10 wt%.49.- Non-woven fibrous composition according to any one of claims 38 to 48, characterized in that the first recycled fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt%, of the non-woven fibrous composition.50.- Non-woven fibrous composition according to any one of claims 38 to 49, characterized in that the first recycled fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt%, of the non-woven fibrous composition.51.- Non-woven fibrous composition according to any one of claims 38 to 50, characterized in that the second recycled fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt%, of the non-woven fibrous composition.52.- Non-woven fibrous composition according to any one of claims 38 to 51, characterized in that the second recycled fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt%, of the non-woven fibrous composition.53.- Non-woven fibrous composition according to any one of claims 38 to 52, characterized in that the ratio of first recycled fiber to second recycled fiber is between 1:9 and 9: 1, preferably between 1:3 and 3: 1.54.- Non-woven fibrous composition according to any one of claims 38 to 53, wherein the non-woven fibrous composition comprises a third fiber, characterized in that the third fiber provides at least 5 wt%, preferably at least 10 wt%, more preferably at least 20 wt%, more preferably at least 30 wt%, even more preferably at least 40 wt%, most preferably at least 50 wt%, of the non-woven fibrous composition.55.- Non-woven fibrous composition according to any one of claims 38 to 54, wherein the non-woven fibrous composition comprises a third fiber, characterized in that the third fiber provides less than 90 wt%, preferably less than 80 wt%, more preferably less than 70 wt%, even more preferably less than 60 wt%, most preferably less than 50 wt%, of the non-woven fibrous composition.56.- Non-woven fibrous composition according to any one of claims 38 to 55, characterized in that the first recycled fiber, the second recycled fiber and the optional third fiber are entangled in the non-woven fibrous composition, preferably by means of needling.57.- Non-woven fibrous composition according to any one of claims 38 to 56, characterized in that the non-woven fibrous composition is a non-woven fiber felt.58.- Carpet, wherein the carpet comprises a face yam, a primary backing, and a pad provided below the primary backing, characterized in that the pad is a non-woven fibrous composition as in any one of the preceding claims 38 to 57.59.- Carpet according to claim 58, characterized in that the pad forms the bottom of the carpet.60.- Carpet according to any of the preceding claims 58 to 59, characterized in that the bottom surface of the non-woven fibrous composition is visible at the bottom surface of the carpet.61.- Carpet according to any one of claims 58 to 60, characterized in that the carpet further comprises a pre-coat at the bottom side of the primary backing for anchoring the face yam to the primary backing and / or a glue layer at the bottom side of the primary backing for connecting the primary backing to the pad.62.- Carpet according to claim 61, wherein the carpet comprises a glue layer at the bottom side of the primary backing for connecting the primary backing to the pad, characterized in that the glue layer comprises hot melt, bitumen or latex, wherein the latex preferably is a styrene butadiene (SBR) latex or an acrylate latex (e.g. a styrene acrylate latex), wherein the glue layer is used for attaching the pad in the carpet.63.- Carpet according to claim 62, characterized in that the glue layer further comprises at least one filler, preferably CaCCh.64.- Carpet according to any one of claims 61 to 63, wherein the carpet comprises a precoat at the bottom of the primary backing for connecting the primary backing to the pad, characterized in that the pre-coat preferably substantially consists of latex, preferably a styrene butadiene copolymer or an acrylate latex (e.g. a styrene acrylate latex).65.- Carpet according to any one of claims 58 to 64, characterized in that the primary backing is selected from a woven polypropylene fabric or a nonwoven fabric.66.- Carpet according to any one of claims 58 to 65, characterized in that the carpet comprises a glass scrim, wherein the glass scrim is preferably provided between the primary backing and the pad, or below the pad.67.- Carpet according to any one of claims 58 to 66, characterized in that the average thickness of the pad is at least 0.1 mm, preferably at least 0.5 mm, more preferably at least 1 mm, even more preferably at least 2 mm, most preferably at least 3 mm.68.- Carpet according to any one of claims 58 to 67, characterized in that the pad provides at least 10%, preferably at least 20%, more preferably at least 30%, most preferably at least 40% of the average thickness of the carpet.69.- Carpet according to any one of claims 58 to 68, characterized in that the carpet has an average thickness of at least 2 mm, preferably at least 5 mm, more preferably at least 10 mm, most preferably at least 15 mm.70.- Carpet according to any one of claims 58 to 69, characterized in that the average density of the pad is at least 250 g / m2, preferably at least 350 g / m2, more preferably at least 500 g / m2, most preferably at least 750 g / m2.71.- Carpet according to any one of claims 58 to 70, characterized in that the average density of the carpet is at least 1500 g / m2, preferably at least 2500 g / m2, more preferably at least 3500 g / m2, most preferably at least 4500 g / m2.72.- Carpet according to any one of claims 58 to 71, characterized in that the face yarn is selected from a polypropylene fiber or multifilament yarn, a polyester fiber of multifilament yam, or a polyamide fiber or multifilament yam.73.- Carpet according to any one of claims 58 to 72, characterized in that the fibers from the face yarn essentially are composed of a polymer out of which the first recycled fiber or the second recycled fiber are provided.74.- Carpet according to any one of claims 58 to 73, characterized in that the carpet is a tufted carpet or a bonded carpet.75.- Carpet according to any one of claims 58 to 74, characterized in that the carpet is a broadloom carpet or a carpet tile.

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