Sustainable nonwoven textile

Abstract

Aspects of the present disclosure relate to a nonwoven textile that is sustainable and sustainably manufactured. The present subject matter is sustainable in one or more aspects. For example, the nonwoven textile can be manufactured from recycled materials. In other cases, the nonwoven textile itself is recyclable to produce additional or subsequent nonwoven articles. Additionally, the manufacturing process used to make the nonwoven textile can consume less energy than other manufacturing processes.

Description

Technical Field

[0001] This disclosure relates in various aspects to a sustainable nonwoven garment product and a sustainable method for producing sustainable nonwoven garment products. Background Technology

[0002] There are various conventional textiles designed to provide insulation, such as those used in clothing. However, these conventional textiles (e.g., conventional wool) are typically manufactured using processes (e.g., knitting, weaving, etc.) that are less sustainable and / or consume more energy than other textile manufacturing processes. Furthermore, the structure of conventional textiles is often unfavorable for incorporating fibers derived from different categories of recyclable and / or recycled goods, which can limit sustainability.

[0003] While some conventional fiber entanglement processes used in nonwoven textiles may consume less energy than other methods (such as knitting, weaving, braiding, etc.), the nonwoven textiles produced by these processes are generally unsuitable for constructing garments. For example, conventional nonwoven textiles typically lack stretch and resilience, are too heavy, lack drape, have a rough hand feel, and lack insulation properties in situations where increased insulation is required. Furthermore, even in cases where conventional nonwoven textiles are unsuitable for constructing garments, the processes for manufacturing these conventional nonwoven textiles are unsustainable in one or more ways and / or still consume a relatively large amount of energy. Summary of the Invention

[0004] This disclosure relates to a sustainable and sustainably manufactured nonwoven textile. The summary is provided to introduce, in a simplified form, the selected concepts further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help determine the scope of the claimed subject matter. Attached Figure Description

[0005] Example aspects of the subject matter of this disclosure are described in detail with reference to the accompanying drawings, which are briefly described below and incorporated herein by reference. These drawings are submitted together with this disclosure.

[0006] Figure 1 The illustration shows a system for the sustainable production of nonwoven articles according to one aspect of this disclosure.

[0007] Figure 2 The illustration shows one aspect of this disclosure. Figure 1 Some additional details about the system, including sustainable raw material production.

[0008] Figure 3The illustration shows one aspect of this disclosure. Figure 1 Additional details about the system, including sustainable manufacturing processes.

[0009] Figure 4 The illustration shows a first fiber web according to one aspect of the present disclosure.

[0010] Figure 5 The illustration shows a second fiber web according to one aspect of this disclosure.

[0011] Figure 6 The illustration shows a third fiber web according to one aspect of this disclosure.

[0012] Figure 7 The figure illustrates an elastomer layer according to one aspect of the present disclosure.

[0013] Figure 8 Includes a table containing example carbon footprint data of nonwoven textiles according to one aspect of this disclosure.

[0014] Figure 9 The illustrations depict some aspects of sustainable products according to one aspect of this disclosure.

[0015] Figure 10 The illustration shows a timeline of a sustainable system according to one aspect of this disclosure. Detailed Implementation

[0016] The subject matter of this invention is specifically described herein to satisfy legal requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors envision that the claimed or disclosed subject matter may also be embodied in other ways in combination with other current or future techniques to include different steps or combinations of steps similar to those described in this document. Furthermore, although the terms “step” and / or “box” may be used herein to refer to different elements of the method employed, these terms should not be construed as implying any particular order among or between the various steps disclosed herein, unless and only as expressly stated.

[0017] There are various conventional textiles designed to provide insulation, such as those used in clothing. However, these conventional textiles (e.g., conventional wool) are typically manufactured using processes (e.g., knitting, weaving, etc.) that are less sustainable and / or consume more energy than other textile manufacturing processes. Furthermore, the structure of conventional textiles is often unfavorable for incorporating fibers derived from different categories of recyclable and / or recycled goods, which can limit sustainability.

[0018] While some conventional fiber entanglement processes used in nonwoven textiles may consume less energy than other methods (such as knitting, weaving, braiding, etc.), the nonwoven textiles produced by these processes are generally unsuitable for constructing garments. For example, conventional nonwoven textiles typically lack stretch and resilience, are too heavy, lack drape, have a rough hand feel, and lack insulation properties in situations where increased insulation is required. Furthermore, even in cases where conventional nonwoven textiles are unsuitable for constructing garments, the processes for manufacturing these conventional nonwoven textiles are unsustainable in one or more ways and / or still consume a relatively large amount of energy.

[0019] This disclosure relates in various aspects to recyclable nonwoven textiles suitable for clothing and other articles. In some aspects, the nonwoven textile includes a first side formed substantially of a web of first entangled fibers or at least partially of a web of first entangled fibers, and an opposing second side formed substantially of a web of second entangled fibers or at least partially of a web of second entangled fibers. As used herein, the term "substantially" means from about 51% to about 100%. When formed into clothing articles, the first side forms the outward-facing surface of the clothing article, and the second side forms the inward-facing surface of the clothing article. In some aspects, the nonwoven textile also includes an elastomeric layer positioned between the first and second entangled fiber webs. The elastomeric layer imparts tensile and recovery properties to the composite nonwoven textile, making it suitable for clothing articles, such as upper garments and lower garments. In some aspects, the nonwoven textile may also include additional entangled webs (e.g., a web of third entangled fibers, a web of fourth entangled fibers, etc.) laminated together with the elastomeric layer. The properties of different webs and / or the number of webs used to form nonwoven textiles can be adjusted to achieve different desired final properties of the nonwoven textiles, including different desired final properties of each facet of the composite nonwoven textile.

[0020] Typically, the nonwoven textiles disclosed herein are sustainably and / or sustainably produced compared to conventional nonwoven textiles. For example, in one aspect of this disclosure, the nonwoven textiles incorporate fibers from entirely different sources of recycled fibers, providing additional utilization options for a wide range of end-of-life articles. Conversely, conventional textiles and systems may limit the sources of recycled fibers that can be accepted and do not provide non-landfill disposal options for a wide variety of types of goods. In a further aspect, this disclosure includes permanent (e.g., nearly permanent) systems that use raw materials (e.g., polymeric materials) to produce articles and repeatedly reuse the same raw materials (e.g., the same polymeric materials) to produce subsequent generations of articles. Furthermore, these aspects contribute to sustainability through the use and reuse of materials that might otherwise be disposed of in landfills.

[0021] Other aspects of this disclosure relate to nonwoven textiles that include one or more properties that increase their usability for constructing clothing articles. For example, in one aspect of this disclosure, nonwoven textiles may incorporate recycled fibers; recycled fibers are relatively lightweight and possess good thermal properties, tensile strength, as well as resilience, drape, abrasion resistance, and a soft hand feel, making the nonwoven textiles suitable for forming clothing articles suitable for a variety of conditions (e.g., cold weather conditions; or when insulation is desired; or under other conditions). Additionally, the properties of nonwoven textiles can be used to construct a relatively large percentage of clothing articles by weight. In this respect, nonwoven textiles can replace at least some conventional textiles that are often less sustainable and / or consume more energy during production. Therefore, sustainability is improved by constructing articles from a higher percentage by weight of nonwoven textiles, which consume less energy during production. Furthermore, in one aspect of this disclosure, nonwoven textiles suitable for clothing articles and other articles include a relatively low carbon footprint.

[0022] Additional aspects include sustainable nonwoven textiles constructed from shredded-article fibers. In some cases, elements of sustainable nonwoven textiles (e.g., the entanglement structure of the fibers) can leverage the properties of shredded-article fibers to achieve desired characteristics in the nonwoven textile. In other cases, elements of sustainable nonwoven textiles can minimize the impact of shredded-article fibers on potentially less desirable characteristics of the overall nonwoven textile. Typically, shredded-article fibers can be obtained through processes that consume less energy without pelleting and extrusion, and therefore, nonwoven textiles incorporating shredded-article fibers can have a lower carbon footprint.

[0023] In another aspect of this disclosure, the nonwoven textile is composed of one or more recyclable materials, and in some aspects, the nonwoven textile can be fully recyclable. For example, the fibers selected to form the entangled web may include recycled materials, such as recycled polyethylene terephthalate (PET) fibers, commonly referred to as polyester fibers. Additionally, the materials selected to form the elastomer layer can also be fully recyclable. The use of recycled fibers and materials reduces the carbon footprint of the composite nonwoven textile.

[0024] As used herein, the term "clothing article" is intended to encompass articles worn by a wearer. Therefore, they can include upper garments (e.g., shirts, t-shirts, pullovers, hoodies, jackets, coats, etc.) and lower garments (e.g., trousers, shorts, leggings, capri pants, bodysuits, etc.). Clothing articles can also include hats, gloves, sleeves (e.g., arm warmers, calf warmers, etc.), footwear (e.g., shoe uppers), etc. When referring to clothing articles, the term "inward-facing surface" refers to a surface or face that is configured to face the wearer's body surface when the clothing article is worn in the intended manner, and the term "outward-facing surface" refers to a surface or face that is configured to face away from the wearer's body surface and towards the external environment when the clothing article is worn in the intended manner. The term "innermost surface" refers to the surface or face that is closest to the wearer's body surface relative to other layers of the clothing article, and the term "outermost surface" refers to the surface or face that is furthest from the wearer's body surface relative to other layers of the clothing article.

[0025] As used herein, the term "nonwoven textile" refers to fibers held together by mechanical and / or chemical interactions without being knitted, woven, braided, or otherwise structured. The term "nonwoven article" refers to an article constructed from one or more nonwoven textiles, such as finished products, rolls of goods, manufacturing byproducts, etc. Nonwoven articles can be constructed from a single nonwoven textile, multiple nonwoven textiles, or nonwoven textiles combined with other textiles (e.g., knitted, woven, braided, etc.) or materials. In a specific aspect, nonwoven textiles comprise an assembly of fibers mechanically manipulated to form a cushion-like material. In other words, nonwoven textiles are made directly from fibers. Nonwoven textiles can include different layers formed as a cohesive structure, wherein the different layers may have different or similar fiber compositions. The term "fiber web" or "fiber web" refers to a layer prior to a mechanical entanglement process with one or more other fiber layers. A fiber web includes fibers that have undergone a carding and web-laying process, typically aligning the fibers in one or more common directions extending along the x, y plane. The fiber web can also undergo a light needling process or a mechanical entanglement process, which entangles the fibers of the layers to a certain degree, causing the fiber web to form a cohesive structure that can be manipulated (e.g., wound onto a roller, pulled off a roller, laminated, etc.). The terms "entangled fiber web" or "entangled fiber web" when referring to one of the fiber layers refer to a layer that has been mechanically entangled with one or more other layers. Accordingly, an entangled fiber layer can include fibers that were originally present in the fiber web forming the layer, as well as fibers that have been moved into the entangled fiber layer by the entanglement process.

[0026] This paper envisions mechanical entanglement processes for the production of nonwoven textiles that may include needle-thread entanglement (commonly referred to as needle punching) using barbed needles or structured needles, or fluid entanglement. In the aspects envisioned herein, needle punching can be used based on the denier of the fibers used and the ability to fine-tune different parameters associated with the needle punching process. Needling typically uses barbed or spiked needles to reposition a proportion of fibers from a generally horizontal orientation (an orientation extending along the x, y plane) to a generally vertical orientation (z-direction orientation). Referring typically to the needle punching process, a carded, laid-up, and pre-needled web can be layered together with other carded, laid-up, and pre-needled webs, passing between a base plate and a stripping plate positioned on opposite sides of the layered web configuration. Barbed needles fixed to the needle plate move in and out of the layered web configuration, and after the needles have passed through the configuration, the stripping plate strips the fibers from the needles. The distance between the stripping plate and the base plate can be adjusted to control web compression during needle punching. As the woven web configuration moves along the conveyor system in the machine direction or the material flow direction, needle plates repeatedly engage and disengage with the woven web configuration, thereby stitching the length of the woven web configuration. This paper envisions the use of multiple needle plates positioned sequentially at different points along the conveyor system, wherein as the woven web configuration moves in the machine direction, different needle plates can engage the woven web configuration from different faces (e.g., above and below the conveyor system). Each engagement of the needle plate with the woven web configuration is referred to herein as a “pass”. Parameters associated with a particular needle plate can be adjusted to achieve desired properties of the resulting stitched nonwoven textile (e.g., basic weight, thickness, etc.). Different parameters may include stitch density (SD) and penetration depth (PD), where stitch density is the amount of material used per centimeter during the entanglement pass. 2 The number of needles is used, and the penetration depth is the distance the needle travels through the laminated mesh configuration before being pulled out. Parameters related to the needle punching process, such as the spacing between the base plate and the peeling plate, and the conveying speed of the laminated mesh configuration, can also typically be adjusted.

[0027] This paper envisions the use of a five-barbed needle (a needle with five barbs arranged along its length), although other needle types are also envisioned. As the barbs move from the first face of the laminated web configuration to the opposite second face, the barbs on the needle "capture" the fibers, and vice versa. The movement of the needle through the laminated web configuration effectively moves or pushes the fibers captured by the barbs from a position near or at the first face to a position near or at the second face, and further induces physical interactions with other fibers, thereby helping to "lock" the moved fibers into place. In an illustrative aspect, the number of barbs on the needle interacting with the fibers can be based on the needle's penetration depth. For example, when the penetration depth is a first amount, all five barbs can interact with the fibers, and as the penetration depth decreases, fewer than all five barbs (e.g., four barbs, three barbs, two barbs, one barb) can interact with the fibers. In a further illustrative aspect, the size of the barbs can be adjusted based on the denier of the fibers used in the web. For example, the barb size can be selected to engage with low denier (e.g., fine) fibers rather than high denier fibers, so as to cause selective movement of the low denier fibers rather than the high denier fibers. In another example, the barb size can be selected to engage with both low denier and high denier fibers, so as to cause both types of fibers to move through the web.

[0028] After entanglement, the nonwoven textile may include a first surface and an opposing second surface, both of which face outwards relative to the inner surface of the nonwoven textile and include the outermost surface of the nonwoven textile. Therefore, when the nonwoven textile is observed, both the first and second surfaces are fully visible. Both the first and second surfaces may extend along generally parallel and offset x- and y-planes. For example, the first surface may be oriented in a first x- and y-plane, and the second surface may be oriented in a second x- and y-plane, which is generally parallel to and offset from the first x- and y-planes.

[0029] As used herein, the term "elastomer layer" refers to a layer having tensile and recovery properties (e.g., elastic resilience) along at least one orientation axis, including both layers having tensile and recovery along a single orientation axis and layers having tensile and recovery along multiple orientation axes. Examples of orientation axes include the length direction, width direction, x-direction, y-direction, and any direction deviating angularly from the length direction, width direction, x-direction, and y-direction. Elastomer layers can be formed from thermoplastic elastomers, such as thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), combinations of TPU and TPEE, etc. Elastomer layers can include spunbond layers, meltblown layers, films, webs, etc. Elastomer layers can be recycled TPEE (rTPEE).

[0030] When referring to fibers, the term denier, or denier per fiber, is a unit of measurement for the linear mass density of a fiber, and more specifically, it is the mass in grams per 9,000 meters of fiber. In one example, the denier of a fiber can be measured using ASTM D1577-07. The fineness (dtex) of a fiber is the mass in grams per 10,000 meters of fiber length. The diameter of a fiber can be calculated based on its denier and / or fineness. For example, the fiber diameter d in millimeters can be calculated using the following formula: d = square root of fineness divided by 100. When referring to the percentage of fiber by weight in a textile, the percentage by weight is based on fibers without any coatings or additional additives (including films).

[0031] The fibers envisioned herein can be formed from a variety of different materials, including polyethylene terephthalate (PET), commonly referred to as polyester. PET fibers can include virgin PET fibers (non-recycled fibers) and recycled PET fibers. Recycled PET fibers include “shredded product fibers” and “re-granulated polymer fibers.” As used herein, shredded product fibers include fibers that are a direct byproduct of shredded fiber-containing products (e.g., knitted, woven, nonwoven, etc.), and re-granulated polymer fibers include fibers extruded from granulated or fragmented byproducts derived from polymer-containing sources (e.g., PET bottles or containers; knitted, woven, nonwoven PET fiber products; roll goods; textile manufacturing waste, etc.).

[0032] As used herein, the term "silicone-coated fiber" can refer to a fiber having a continuous silicone coating such that the silicone coating completely covers the fiber along its length. In one example, the fiber can form a core and the silicone can form a sheath surrounding the core. In other examples, the term "silicone-coated fiber" can refer to a fiber having an intermittent silicone coating in at least some regions along the fiber length. For example, the fiber can be sprayed with a silicone coating. In this regard, if a particular fiber web comprises 100% silicone-coated fiber by weight, it is contemplated that the fibers forming the web can have regions that do not contain a silicone coating. It is contemplated that silicone-coated fibers are incorporated into the fiber web forming a composite nonwoven textile. In other words, after forming the composite nonwoven textile using, for example, a silicone spray finishing agent, the silicone coating on the fiber is not applied to the fiber.

[0033] As used herein, the term "color" or "color property" in relation to nonwoven textiles generally refers to the observable color of the fibers forming the textile. These aspects envision that the color can be any color that can be provided to the fiber using dyes, pigments, and / or colorants known in the art. Accordingly, fibers can be configured to have a color, including but not limited to red, orange, yellow, green, blue, indigo, violet, white, black, and their hues. In one example aspect, the fiber color can be imparted during fiber formation (often referred to as pre-spinning dyeing). In pre-spinning dyeing, the color is added to the fiber while it is being extruded, such that the color is integrated into the fiber, rather than being added to the fiber in a post-formation step.

[0034] The aspects related to color also envision determining whether one color differs from another. In these aspects, color can include digital color values, which can be determined using instruments that objectively measure and / or calculate the color value of an object's color by standardizing and / or quantifying factors that may affect color perception. Such instruments include, but are not limited to, spectroradiometers, spectrophotometers, etc. Therefore, the aspects herein envision that the "color" of textiles provided by fibers can include digital color values ​​measured and / or calculated using spectroradiometers and / or spectrophotometers. Furthermore, digital color values ​​can be associated with a color space or color model, which is a specific color organization that provides the color representation of the digital color values, and thus, each digital color value corresponds to a single color represented in the color space or color model.

[0035] In these respects, if the digital color values ​​of each color are different, it can be determined that one color is different from another. Such determination can be made by measuring and / or calculating, for example, the digital color value of a first textile having a first color using a spectroradiometer or spectrophotometer, measuring and / or calculating the digital color value of a second textile having a second color using the same instrument (i.e., if a spectrophotometer is used to measure the digital color value of the first color, then a spectrophotometer is used to measure the digital color value of the second color), and comparing the digital color value of the first color with the digital color value of the second color. In another example, this determination can be made by measuring and / or calculating the digital color value of a first region of a textile using a spectroradiometer or spectrophotometer, measuring and / or calculating the digital color value of a second region of a textile having a second color using the same instrument, and comparing the digital color value of the first color with the digital color value of the second color. If the digital color values ​​are not equal, then the first color or first color characteristic is different from the second color or second color characteristic, and vice versa.

[0036] Furthermore, it can be envisioned that the visual difference between two colors can be related to the percentage difference between the numerical color values ​​of the first and second colors, and that the visual difference will be greater as the percentage difference between the color values ​​increases. Additionally, the visual difference can be based on a comparison between color representations of color values ​​in a color space or model. For example, when the first color has a numerical color value corresponding to the represented color being black or dark blue, and the second color has a numerical color value corresponding to the represented color being red or yellow, the visual difference between the first color (represented as red) and the second color (represented as yellow) is greater than the visual difference between the first color (represented as red) and the second color (represented as yellow).

[0037] As used herein, the term "pilling" or "pilling" refers to the formation of small balls or ends of fibers on the positive side of a nonwoven textile. Pills can extend away from the surface plane of the textile. Typically, during normal washing and abrasion, forces (e.g., abrasive forces) cause fiber ends to migrate across the surface of the nonwoven textile and become entangled with other fiber ends, thus forming pills. The pilling resistance of textiles can be measured using standardized tests such as random tumbling and the Martindale pilling test.

[0038] This document provides various measurements of the pre-wound web and the resulting composite nonwoven textile. The thickness of the resulting composite nonwoven can be measured using a precision thickness gauge. For example, to measure thickness, the textile can be placed on a flat anvil, and a pressure foot can be pressed against the textile from the top surface under a standard fixed load. The dial indicator on the precision thickness gauge provides a thickness indication in millimeters (mm). The basic weight is measured using the ISO 3801 test standard and is expressed in grams per square meter (gsm). The stiffness of the textile, which typically corresponds to drape, is measured using the ASTM D4032 (2008) test standard and is expressed in kilogram-forces (Kgf). The textile growth and recovery are measured using the ASTM 2594 test standard and expressed as a percentage. As used herein, the term “stretch” refers to a textile property measured as an increase over a specified distance under specified tension and is typically expressed as a percentage of the original reference distance (i.e., rest length or width). As used herein, the term "growth" refers to the increase in a specified reference distance (i.e., rest length or width) over a period of time after the tension is released following extension to a specified tension, and is usually expressed as a percentage of the original reference distance. As used herein, "recovery" refers to the ability of a textile to return to its original reference distance (i.e., its rest length or width), and is also expressed as a percentage of the original reference distance. Thermal resistance, which typically corresponds to insulation characteristics, is measured using the ISO 11092 test standard, in units of RCT (m²). 2 *K / W).

[0039] When relevant data are available, the carbon footprint and other measurements related to the sustainability of nonwoven textiles (e.g., related to the methods used to manufacture nonwoven textiles) are based on the Higg index. If no data is available under the Higg index for the process used to manufacture nonwoven textiles, the carbon footprint attributable to that process is determined based on a “kg CO2e manual assessment” by manufacturing 6000 meters of textile (60 gsm, 1.65 meters wide) to calculate the mass (kg) of material. The energy consumed in the manufacturing stage (kWh) is measured and used to calculate kWh / kg. The kWh / kg value is multiplied by the carbon energy grid emission factor (for the relevant location specified by the International Energy Agency) to determine the kg CO2e value.

[0040] Unless otherwise stated, all measurements provided herein were taken at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar).

[0041] Figure 1 A high-level schematic diagram of a sustainable system 110 for the production and recycling of nonwoven articles 112 is illustrated. As used herein, nonwoven articles 112 may include finished products, rolls of goods, manufacturing by-products, and other such articles. System 110 includes sustainable raw materials 114 (e.g., textile fibers) used by sustainable manufacturing processes 116 (e.g., processes and equipment) to produce nonwoven articles 112. Additionally, system 110 includes a sustainable raw material generation process 118 that recycles nonwoven articles 112 and external articles 120 to produce raw materials 114 for the manufacture of subsequent articles.

[0042] In one aspect of this disclosure, system 110 reuses recyclable goods from various different categories to generate raw materials for future products. For example, system 110 recycles “in-flow” nonwoven articles 112 manufactured by system 110. Additionally, in-flow nonwoven articles 112 may include various different categories of recyclable goods, such as clothing articles 122; gears, equipment, and bags 124; and rolled goods 126 (e.g., unsold inventory, surplus, last season's stock, waste, etc.). Furthermore, system 110 recycles external or “outflow” articles 120 that are not produced by manufacturing process 116 and are still usable or absorbable by system 110 to generate raw materials. In this sense, outflow articles 120 represent another, completely different category of recyclable goods, and outflow articles 120 may include at least some recyclable goods categories similar to in-flow articles 112, as well as different recyclable goods categories (e.g., plastic bottles 128). By using a variety of different categories of recyclable goods, aspects of this disclosure provide additional utilization options for a variety of end-of-life products through the use and reuse of materials that may be discarded in landfills.

[0043] In some aspects, system 110 may utilize new virgin materials (e.g., undepicted virgin PET) to produce at least parts of articles. These materials may be integrated into system 110 and reused in subsequent articles where possible. In other aspects, system 110 may restrict the use of materials or components that are not reusable in process 118 or some other role, which do not utilize sustainable raw materials. For example, certain types of fasteners may be used to construct article 112, in which case the fasteners may be removed from end-of-life articles and reused in subsequent articles where possible.

[0044] Figure 2 The diagram shows Figure 1 This describes some aspects of the sustainable raw material production process 118. Typically, inbound nonwoven products 112 and outbound products 120 are provided as inputs to the sustainable raw material production process 118. In some aspects, inbound nonwoven products 112 may include finished products 130 (e.g., garments 122, bags 124, etc.) and / or rolls of goods and / or manufacturing byproducts of the manufacture of rolls of goods 126, which are manufactured via sustainable manufacturing process 116. Outbound products 120 may include finished products, rolls of goods, and manufacturing byproducts manufactured outside the sustainable manufacturing system. As used herein, the term "finished product" may include garments, equipment such as bags, and other such articles. As used herein, the term "roll of goods and its manufacturing byproducts" may include, for example, unused rolls of textiles manufactured by sustainable manufacturing process 116, scraps cut from rolls, byproducts of the manufacturing process, etc.

[0045] Inbound nonwoven products 112 can be obtained in various ways. For example, consumers of inbound nonwoven products 112 can return the products to system 110. In some cases, consumers can return products purchased on credit, products at their respective end-of-life points, etc. Additionally, retailers and / or manufacturers can proactively solicit inbound nonwoven products 112 through collection programs, delivery, incentive programs, etc. In some cases, textile manufacturers can return unused rolls (e.g., extra, surplus inventory, slow-moving inventory, last season's, etc.). Manufacturers can also proactively collect by-products produced throughout the sustainable manufacturing process for input back into the system.

[0046] Even if the outflowing products 120 are not manufactured through sustainable manufacturing process 116, they can still be used in sustainable raw material production process 118. At least some of the outflowing products 120 can be obtained in a manner similar to that described above for inflowing nonwoven products 112. For example, in some aspects, the manufacturers and / or retailers of the outflowing products 120 may be different from the manufacturers and / or retailers of the inflowing nonwoven products 112. However, the outflowing products 120 can still be used as inputs to sustainable raw material production process 118. In some aspects, one or more of the outflowing products 120 may include a category of recyclable goods different from the category of inflowing nonwoven products 112. In one example aspect, the outflowing products 120 may include non-cargo PET-containing products 136, such as bottles, clam shells, and other containers, while the inflowing nonwoven products 112 may include cargo. As used herein, the term "cargo" refers to the actual finished product or commodity as opposed to the packaging of the finished product or commodity, such as clothing, bags, interior decorations, etc. Conversely, as used herein, the term "non-goods" refers to articles that are not finished products or products but can be associated with or used to produce finished products (such as packaging, displays, etc.). In some aspects, outflowed articles 120 may include non-nonwoven textiles, such as knitted and woven textiles. By utilizing a variety of different categories of recyclable goods from various sources, aspects of this disclosure provide additional utilization options for a variety of end-of-life articles through the use and reuse of materials that may be discarded in landfills.

[0047] like Figure 2 As shown, the sustainable raw material production process 118 may include material recycling 137 and material recovery 150. In one aspect of material recycling 137, materials (e.g., PET, rPET, TPEE, or rTPEE) included in the inflow nonwoven article 112 and / or the outflow article 120 are re-granulated 138, such as by converting the material into fragments or pellets (e.g., by shredding, melting, etc.). The pellets or fragments can then be converted into different forms of raw materials 114 that can be used to manufacture articles. For example, the re-granulated polymer can be extruded 140 into fibers 142, which can be cut into staples or used as filaments.

[0048] It is also conceivable that additional steps can be performed to affect the properties of the fiber. For example, in some cases, when converting the article into scrap or pellets, a crystallinity modifier (e.g., isophthalic acid (IPA)) can be added to the polymer in various amounts to affect stretchability, transparency, colorability (the ability to produce a desired color), etc. In some instances, the extruded fiber 142 contains a crystallinity modifier in the range of about 3% to about 13%, about 5% to about 10%, or about 5% by weight. In other cases, polymer extrusion 140 may include a liquor dyeing process 144 for adding color to the fiber. As used herein, the term “about” means within ±5% of the indicated value. In illustrative terms, the percentage of IPA by weight can be measured using the ASTM D2690-98 test standard. For example, this concept is... Figure 2 As shown, solid-lined fibers 146 represent fibers of a first color, and dashed-lined fibers 148 represent fibers of a second color different from the first color. Based on the controllability of the process included in material recycling 137, the extruded fibers 142 typically exhibit a relatively high degree of uniformity within tolerances for certain properties, such as denier and short fiber length.

[0049] On the other hand, the sustainable raw material production process 118 includes material recovery 150, wherein one or more materials or raw materials are recovered directly from the product through mechanical separation (e.g., product shredding). For example, the product may be shredded (or otherwise mechanically separated or manipulated) until the material (e.g., fiber, ink, web, fiber block, etc.) is combable. As used herein, the term "combable" refers to the size at which the shredded material can be combed. Thus, mechanical separation 152 produces shredded product fibers 154, the size, length, color, etc. of which may vary depending on the type and / or style of the product after mechanical separation or blending.

[0050] Typically, the length of shredded product fibers is much more variable than that of extruded fibers. For example, fibers may break randomly and non-uniformly during mechanical separation 152, resulting in some fibers that are shorter and / or longer than others. Typically, once incorporated into the article, shredded product fibers will include an average short fiber length and a relatively large standard deviation compared to extruded fibers. For example, the average short fiber length of shredded product fibers 154 may range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm; and the standard deviation may be from about 5 mm to about 30 mm, from about 5 mm to about 20 mm, or from about 5 mm to about 10 mm. Additionally, in other aspects, shredded product fibers 154 may include incompletely separated but still combable fiber clumps 158, as well as combinations of shredded product fibers 154 with other materials 160 (e.g., inks, silicone, elastomer materials, etc.). Additionally, due to the shredding process, shredded product fibers may have uneven fiber ends. For example, virgin or re-extruded fibers may have fiber ends with a generally flat surface at an angle of approximately 90 degrees to the sides of the fiber. In contrast, shredded product fibers may have fiber ends with a non-flat and / or flat surface, which typically forms an angle of approximately greater than or less than 90 degrees to the sides of the fiber.

[0051] Shredded product fibers 154 offer a variety of sustainability advantages. For example, they can reuse existing products that might otherwise end up in landfills. Additionally, products made using shredded product fibers may have a lower carbon footprint by omitting certain processes associated with material production (e.g., re-granulation, extrusion, coloring, etc.).

[0052] Figure 3The illustration depicts a sustainable manufacturing process 116. In one aspect, extruded fibers 142, shredded product fibers 154, or any combination thereof are transformed into a fiber web via a fiber web forming process 162. For example, fibers 142 and 154 may undergo processes such as carding 164, cross-laying 166, needle stitching 168, and slitting 170. In some aspects, reusable byproducts 172 are captured from the fiber web forming process 162 and fed back into system 110, such as into sustainable raw material generation processes 118 and / or sustainable raw material 114. An example of reusable byproduct 172 includes loose fibers 174 that enter the fiber web forming process 162 but are not sufficiently entangled and thus fall out of the fiber web. Loose fibers 174 may be reintroduced into the system at various stages, including carding 164. In another example, fibers arranged near the web edge may not be entangled in the manner required for incorporation into the nonwoven textile. For example, the fibers may have a small amount of entanglement and / or inconsistent entanglement. Accordingly, the fiber web may be slit 170, in which the edge 176 along each edge of the web is removed. In some cases, the configuration of the edge 176 (e.g., the amount of entanglement) allows the edge 176 to be reintroduced at the carding machine 164 without prior mechanical separation.

[0053] A fiber web is constructed using a fiber web forming process 162. The fiber web can possess various properties as needed, and multiple fiber webs (e.g., laminates 180) can be entangled together to form a nonwoven textile 198 or a composite nonwoven textile. In some aspects, one or more properties of the fiber web are selected or controlled to contribute to the overall properties of the nonwoven textile 198. For example, Figure 4 , Figure 5 and Figure 6 The illustrations depict different fiber webs 200, 300, and 400 before entanglement with other fiber webs, such as those used in the construction of nonwoven textiles 198. Figure 3 )hour.

[0054] For examples, see reference Figure 4The properties associated with the first fiber web 200 can be selected to achieve the desired final properties of the composite nonwoven textile 198. When entangled with other webs, the first fiber web 200 is envisioned to form the first face of the nonwoven textile 198; and when the nonwoven textile 198 is formed into a garment article, the first face is envisioned to form the outward-facing surface of the garment article, and in some respects, the outermost surface of the garment article. Therefore, the properties associated with the first fiber web 200 include, for example, durability and abrasion resistance, as well as moderate coverage. In an example aspect, the first fiber web 200 has a basic weight of about 35 grams per square meter (gsm) to about 150 gsm, about 35 gsm to about 65 gsm, about 40 gsm to about 60 gsm, about 45 gsm to about 55 gsm, or about 50 gsm. As used herein, the term “about” means within approximately ±10% of the indicated value. After the first fiber web 200 is combined with other fiber webs and / or elastomer layers, a resulting nonwoven textile with a basic weight within the desired range is provided for the basic weight of the first fiber web 200 within this range.

[0055] The first fiber web 200 is formed of fibers 210, which may be oriented generally in a common direction due to carding and cross-laying processes. In one example aspect, fibers 210 may comprise uncoated PET fibers (recycled or virgin), although other types of virgin and recycled uncoated fibers (e.g., polyamide, cotton, etc.) are contemplated herein. In one example aspect, fibers 210 may comprise 100% by weight of uncoated recycled fibers, such as 100% by weight of recycled PET fibers. However, in other aspects, fibers 210 may, as needed, comprise 100% by weight of virgin fibers, or other combinations of virgin and recycled fibers. The short fiber lengths of fibers 210 may range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. Using such fiber lengths increases the possibility of obtaining the desired entanglement. For example, below 40 mm, the fibers may not have sufficient length for entanglement, and above 60 mm, the fibers may not actually be entangled when the needle is withdrawn from the nonwoven fabric during entanglement. In one example, fiber 210 may include a uniform length, such as when the fiber is formed from virgin extruded or re-extruded PET and cut to a defined length. In other aspects, fiber 210 may include variations in short fiber length, such as when fiber 210 originates from a shredded fiber source.

[0056] Fiber 210 may include deniers greater than or equal to about 1.2D, or about 1.2D to about 3.5D, about 1.2D to about 1.7D, about 1.3D to about 1.6D, or about 1.5D. Utilizing deniers within this range makes fiber 210 less prone to breakage, which in turn improves the durability and abrasion resistance of the first side of the composite nonwoven textile 198. Furthermore, selecting a denier within this range while still achieving the basic weight of the first fiber web 200 provides good, uniform coverage of the first side, which helps enhance the durability characteristics of the first side. In this example, selecting a denier greater than, for example, 3.5D while still maintaining the basic weight of the first fiber web 200 may not provide uniform coverage of the first side.

[0057] In one example, the fibers 210 used to form the first fiber web 200 may include a first color or a first color characteristic. The first color characteristic may be imparted to the fibers 210 during an extrusion process, for example, when the fibers 210 are formed to be pre-dyed. In one example, the color characteristic may be white, although other colors are also contemplated herein. Using pre-dyed fibers to form the composite nonwoven textile 198 eliminates the post-forming dyeing step, which further contributes to reducing the carbon footprint of the nonwoven textile 198.

[0058] Figure 5 A second fiber web 300 is depicted prior to entanglement with other fiber webs. In an example aspect, properties associated with the second fiber web 300 can be selected to achieve the desired final properties of the composite nonwoven textile 198. When entangled with other fiber webs, the second fiber web 300 is envisioned to form an opposing second side of the composite nonwoven textile 198; and when the composite nonwoven textile 198 is formed into a garment article, the second side is envisioned to form the inward-facing surface of the garment article, and in some respects, the innermost surface of the garment article. Accordingly, properties associated with the second fiber web 300 include, for example, a soft hand feel or texture. In an example aspect, the second fiber web 300 has a basic weight of approximately 20 grams per square meter (gsm) to approximately 150 gsm, approximately 35 gsm to approximately 65 gsm, approximately 40 gsm to approximately 60 gsm, approximately 45 gsm to approximately 55 gsm, or approximately 50 gsm. In an example aspect, the second fiber web 300 has a basic weight substantially the same as that of the first fiber web 200. After the second fiber web 300 is combined with other fiber webs and / or elastomer layers, a resulting nonwoven textile with a basic weight within the desired range is provided for the second fiber web 300 within this range.

[0059] In one aspect, the second fiber web 300 is formed of two types of fibers, such as fibers 310 and 312, which may be oriented in a generally common direction due to the carding and cross-laying process. In one example aspect, fiber 310 may comprise uncoated PET fibers (recycled or virgin), although other types of virgin and recycled uncoated fibers (e.g., polyamide, cotton, etc.) are also contemplated herein. In one example aspect, fiber 310 may comprise 100% recycled uncoated fibers by weight, such as 100% recycled uncoated PET fibers by weight. However, in other aspects, fibers 310 and / or 312 may, as needed, comprise 100% virgin fibers by weight, or other combinations of virgin and recycled fibers.

[0060] Fibers 312 are shown in dashed lines to indicate that they have characteristics different from those of fibers 310. For example, fibers 312 may include silicone-coated fibers. Fibers 312 may be coated with silicone before being incorporated into the second fiber web 300. In example aspects, the second fiber web 300 may comprise approximately 10% to approximately 100% by weight of fibers 312, approximately 40% by weight of fibers 310 and approximately 60% by weight of fibers 312, approximately 45% by weight of fibers 310 and approximately 55% by weight of fibers 312, approximately 50% by weight of fibers 310 and approximately 50% by weight of fibers 312, approximately 55% by weight of fibers 310 and approximately 45% by weight of fibers 312, or approximately 60% by weight of fibers 310 and approximately 40% by weight of fibers 312. In one specific aspect, the second fiber web 300 may comprise approximately 50% by weight of fibers 310 and approximately 50% by weight of fibers 312. When stating that the second fiber web 300 may comprise approximately 100% by weight of fibers 312, it is envisioned that the fibers 312 may be intermittently coated with silicone along their length. The use of fibers 312 within the aforementioned range provides a good hand feel to the second surface formed by the second fiber web 300. It also provides good drape to the composite nonwoven textile 198. In other words, the resulting nonwoven textile 198 is not as stiff as conventional nonwoven textiles used in clean and personal hygiene spaces. Furthermore, the use of fibers 310 and 312 within the aforementioned range reduces the amount of needle force required to entangle the web of fibers described herein, as the silicone-coated fibers may move more easily during entanglement. When silicone-coated fibers below the aforementioned range are incorporated, the second surface may feel dry and uncomfortable during wear. Conversely, when silicone-coated fibers above the aforementioned range are incorporated, the second surface may feel smooth, which may also cause discomfort to the wearer. Furthermore, using silicone-coated fibers above the aforementioned range may make the combing process difficult, as the comb needles may not be able to engage with the fibers through friction to obtain a uniform combed web.

[0061] Using silicone-coated fibers 312 can reduce or eliminate the need to add silicone finishing agents to the composite nonwoven textile 198 in post-forming processing steps. As is known in the textile industry, it is common practice to add silicone softening finishing agents to knitted or woven products in post-forming processing steps. By eliminating this step, the carbon footprint of the composite nonwoven textile 198 is further reduced.

[0062] The short fiber length of each of fibers 310 and 312 may range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. Similar to fiber 210, this length provides optimal entanglement. In one example, fibers 310 and / or 312 may include uniform lengths, such as when the fibers are formed from virgin extruded or re-extruded PET and cut to defined lengths. In other aspects, fibers 310 and / or 312 may include variations in short fiber lengths, such as when fibers 310 and / or 312 originate from a shredded fiber source.

[0063] Each of fibers 310 and 312 may include a denier of about 1D or less. For example, the denier may be about 0.1D, about 0.2D, about 0.3D, about 0.4D, about 0.5D, about 0.6D, about 0.7D, about 0.8D, or about 0.9D. In a illustrative context, the denier of fibers 310 and 312 may be about 0.6D to about 1.0D, about 0.7D to about 0.9D, or about 0.8D. Utilizing a denier within this range helps to provide a soft feel or hand texture to the second surface formed by the second fiber web 300. Furthermore, selecting a denier within this range provides good coverage of the second surface while still achieving the basic weight of the second fiber web 300.

[0064] In one example, each of fibers 310 and 312 used to form the second fiber web 300 may include color characteristics that may be the same or different. In another example, both fibers 310 and 312 include the first color characteristics of fiber 210. Similar to fiber 210, each of fibers 310 and 312 may be pre-dyed, thereby further reducing the need for a post-forming dyeing step on the resulting composite nonwoven textile.

[0065] Figure 6An optional third fiber web 400 is depicted prior to entanglement with other webs. When incorporated into the composite nonwoven textile 198, the third fiber web 400 is envisioned positioned between the first fiber web 200 and the second fiber web 300. In an example, properties associated with the third fiber web 400 can be selected to achieve desired final properties of the composite nonwoven textile 198. In an example, the third fiber web 400 can be incorporated into the composite nonwoven textile 198 to achieve a desired basic weight, a desired thickness, desired thermal insulation properties, etc. As further explained below, to impart visual appeal to the composite nonwoven textile 198, the fibers 410 forming the third fiber web 400 may have different color characteristics than the fibers used to form the first fiber web 200 and the second fiber web 300. Similar to the first fiber web 200 and the second fiber web 300, the third fiber web 400 has a basic weight of about 20 gsm to about 150 gsm, about 35 gsm to about 65 gsm, about 40 gsm to about 60 gsm, about 45 gsm to about 55 gsm, or about 50 gsm. After the third fiber web 400 is combined with other fiber webs and / or elastomer layers, a resulting nonwoven textile with a basic weight within the desired range is provided for the third fiber web 400 within this range.

[0066] The third fiber web 400 is formed of fibers, such as fiber 410, which may be oriented generally in a common direction due to carding and cross-laying processes. In one example aspect, fiber 410 may comprise uncoated PET fibers (recycled or virgin), although other types of virgin and recycled uncoated fibers (e.g., polyamide, cotton, etc.) are contemplated herein. In one example aspect, fiber 410 may comprise 100% by weight of uncoated recycled fibers, such as 100% by weight of recycled uncoated PET fibers. However, in other aspects, fiber 410 may, as needed, comprise 100% by weight of virgin fibers, or other combinations of virgin and recycled fibers. Similar to fibers 210, 310, and 312, the short fiber length of fiber 410 may range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. In one example aspect, fiber 410 may comprise a uniform length, such as when the fibers are formed from virgin extruded PET or re-extruded PET and cut to a defined length. In other respects, fiber 410 may include variations in short fiber length, such as when fiber 410 originates from a shredded fiber source.

[0067] Fiber 410 may include deniers greater than or equal to about 1.2D, about 1.2D to about 3.5D, about 1.3D to about 1.6D, or about 1.5D. Utilizing deniers within this range makes fiber 410 less prone to breakage, which in turn improves the durability and abrasion resistance of the composite nonwoven textile 198. Since the third fiber web 400 is positioned between the first fiber web 200 and the second fiber web 300 during use, a soft hand feel is less important than, for example, the second fiber web 200. Choosing a denier within this range while still achieving the basic weight of the third fiber web 400 improves the overall coverage and / or opacity of the composite nonwoven textile 198.

[0068] In an example, the fibers 410 used to form the third fiber web 400 may include a second color characteristic different from the first color characteristic. This is in Figure 4 The image is depicted using diagonal shading. This paper envisions that fiber 410 is dyed before spinning, thereby further reducing the carbon footprint of the composite nonwoven textile 198. In other respects, such as when fiber 410 is shredded article fiber, the second color characteristic can be produced by inks, dyes, or other colorants previously applied to fiber 410. As will be explained in more detail below, during the entanglement of the first fiber web 200, the second fiber web 300, and the third fiber web 400, fiber 410 can move more towards the first surface than towards the second surface, making the second color characteristic more visually discernible or distinguishable on the first surface compared to the second surface.

[0069] Figure 7An elastomer layer 500 is depicted, which is not necessarily formed from a fiber web, and the elastomer layer 500 may still be bonded to or laminated between fiber webs. In example aspects, the basic weight of the elastomer layer 500 may be about 20 gsm to about 150 gsm, about 50 gsm to about 70 gsm, about 55 gsm to about 65 gsm, or about 60 gsm. The basic weight of the elastomer layer 500 can be selected to achieve the desired basic weight of the resulting composite nonwoven textile. Various aspects of this document envision the elastomer layer 500 being formed from thermoplastic elastomers (such as thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), combinations of TPU and TPEE, etc.). The elastomer layer may include a spunbond layer, a meltblown layer, a film, a web, etc. In a particular example aspect, the elastomer layer 500 may include a TPEE spunbond layer, while in another particular aspect, the elastomer layer 500 may include a TPU meltblown layer. Typically, the elastomer layer 500 is chosen to provide the desired tensile and recovery properties to the composite nonwoven textile 198, while generally maintaining structural integrity during entanglement. The elastomer layer 500 may also be chosen to have a low base weight to maintain the low base weight, breathability, and permeability of the resulting composite nonwoven textile 198, which contributes to the comfort characteristics of clothing articles formed from the composite nonwoven textile 198, and to have flexibility to reduce the stiffness of the composite nonwoven textile 198. The elastomer layer 500 is envisioned to have color properties. In an example aspect, the color property could be a first color property associated with fibers 210, 310, and 312, although other color properties are also envisioned herein.

[0070] Return to reference Figure 3 , Figure 3The diagram depicts fiber webs 200, 300, and 400, and an elastomer layer 500, which can be used to construct a laminate 180 of a nonwoven textile 198. In one aspect of this disclosure, the laminate 180, consisting of layers (e.g., fiber webs, elastomer layers, etc.) or "multi-layers," is arranged on a conveying system 182 that conveys the laminate 180 during multi-layer stitching 184. In one aspect of this disclosure, the laminate 180 includes a first fiber web 200, a second fiber web 300, an optional third fiber web 400, and an elastomer layer 500. However, the laminate may comprise any combination of layers with one or more layers added or omitted. As described above, each of the fiber webs 200, 300, and 400 has been combed and laid out to achieve the desired basic weight. Similarly, each of the webs 200, 300, and 400 has been lightly stitched to achieve a cohesive structure. Since the fibers in each of the first fiber web 200, the second fiber web 300, and the third fiber web 400 are typically in a loose web state, they can move during needle entanglement. In an example, the conveying system 182 can convey the laminate configuration 180 at rates of about 1.0 m / min to about 3 m / min, about 2.0 m / min to about 2.5 m / min, about 2.1 m / min to about 2.4 m / min, or about 2.3 m / min. This rate provides the desired level of entanglement through the needle bed to produce the desired final properties of the composite nonwoven textile (e.g., base weight, thickness, growth, and recovery). Slower rates may result in increased entanglement, thus affecting the desired final properties of the nonwoven textile, and increased rates may result in insufficient entanglement, which also affects the desired final properties of the nonwoven textile 198.

[0071] In one aspect, the multilayer stitch 184 includes one or more passages through one or more needle plates. Stitching can proceed from one side of the stack 180 toward the other side and vice versa. For example, passage 186 extends from the first fiber web 200 toward the second and third fiber webs, and passage 188 extends from the second fiber web 300 toward the third and first fiber webs. The needles used in the needle plates of the multilayer stitch 184 can be selected to optimally interact with a specific denier of the fibers used in the first fiber web 200, the second fiber web 300, and the third fiber web 400. They can also be selected to include a desired number of barbs to achieve a desired degree of entanglement.

[0072] In an example, the first pathway (e.g., 186) extends from the first fiber web 200 toward the second fiber web 300 and functionally has the effect of moving fibers from the first fiber web 200 and entangled them into the third fiber web 400 and the second fiber web 300, and further moving fibers from the third fiber web 400 and entangled them into the second fiber web 300. The first pathway in this direction (e.g., as indicated by 186) helps ensure that the needle is filled with fibers from at least the first fiber web 200 before contacting the elastomer layer 500, which reduces the likelihood of the needle cutting the elastomer layer 500 and affecting the resulting growth and recovery properties of the composite nonwoven textile 198.

[0073] In terms of examples, the first pathway can have approximately 40 n / cm. 2 Approximately 60 N / cm 2 Approximately 45 N / cm 2 Approximately 55 N / cm 2 or approximately 50 N / cm 2 The needle density. The penetration depth of the first passage can range from about 10 mm to about 14 mm, from about 11 mm to about 13 mm, or about 12 mm. In an example aspect, this amount of penetration depth will approximately engage all the barbs of the needle. In one example aspect, all barbs may include five barbs. This penetration depth ensures that the needle completely passes through the laminate configuration 180, such that the fibers in each of the fiber webs 200, 300, and 400 are engaged with the needle. In other words, having a penetration depth as described for the first passage ensures that at least some fibers from the first fiber web 200 are entangled with the fibers of the third fiber web 400 and with the fibers of the second fiber web 200, and that at least some fibers of the third fiber web 400 are entangled with the fibers of the second fiber web 200. In an example aspect, there is an inverse relationship between needle density and penetration depth. This is to avoid overworking and possible breakage of the fibers. In other words, when the penetration depth is higher, the needle density is lower to avoid possible breakage of the fibers. After the first path, the thickness of the laminate configuration 180 may decrease due to the z-direction movement and entanglement of fibers from different webs.

[0074] In another aspect, the second pathway, which follows the first pathway (i.e., temporally after the first pathway), proceeds alternately from both sides of the laminate configuration (both 186 and 188). In other words, the second pathway proceeds from the first fiber web 200 toward the second fiber web 300, and from the second fiber web 200 toward the first fiber web 300. Therefore, the second pathway is used to move fiber 210 from the first fiber web 200 into the third fiber web 400 and into the second fiber web 300. The second pathway also moves fiber 410 from the third fiber web 400 through the elastomer layer 500 and into the second fiber web 300. The second pathway moves fiber 310 through the elastomer layer 500 and into the first fiber web 200.

[0075] The second pathway, with needle insertion from top to bottom, has a strength of approximately 40 N / cm. 2 Approximately 60 N / cm 2 Approximately 45 N / cm 2 Approximately 55 N / cm 2 or approximately 50 N / cm 2 The stitch density. Maintaining a relatively low stitch density helps prevent over-processing of the elastomer layer 500 and thus helps maintain the desired growth and recovery properties of the resulting composite nonwoven textile 198. The penetration depth of the second passage is approximately 6 mm to approximately 8 mm. In one example aspect, the penetration depth of the second passage from direction 186 is approximately 6 mm, and the penetration depth from direction 188 is approximately 8 mm. In another example aspect, the penetration depth of the second passage from direction 186 is approximately 8 mm, and the penetration depth from direction 188 is approximately 6 mm. Because the thickness of the laminate configuration 180 during the second passage has been slightly reduced due to the first passage, the penetration depth of the second passage is reduced. It is envisioned that the penetration depth of the second passage is sufficient to allow the needle to completely pass through the laminate configuration 180. In one example aspect, when the penetration depth is 8 mm, it is envisioned that there are three joints in the needle barbs, and when the penetration depth is 6 mm, it is envisioned that there are two joints in the needle barbs. After completing multiple second passages, the laminate configuration 180 has a further reduced thickness compared to the laminate configuration after the first passage. The final result of the second pathway is the further entanglement of the fibers in the first fiber web 200, the second fiber web 300, and the third fiber web 400.

[0076] In a further aspect, the multi-layer stitching 184 includes a third passage that occurs after the second passage (i.e., temporally after the second passage) and proceeds in a direction of 188 from the second fiber web 300 toward the first fiber web 200. The stitch density of the third passage is approximately 175 stitches / cm². 2 Approximately 225 N / cm 2 Approximately 180 N / cm 2 Approximately 220 N / cm2 Approximately 190 N / cm 2 Approximately 210 N / cm 2 or approximately 200 N / cm 2 Compared to channels with lower stitch density, such as the first and second channels, the higher stitch density of the third channel achieves a more uniform texturing or finishing of the laminate configuration 180. The penetration depth of the third channel is approximately 1 mm to approximately 5 mm, approximately 2 mm to approximately 4 mm, or approximately 3 mm. In an example, this is an engagement of a barb of a needle. One purpose or result of the third channel is to tuck some fibers present on the surface of the second fiber web 300 into the laminate configuration 180 without generating more tangles. In other words, the third channel helps reduce fuzz on the surface of the second fiber web 300.

[0077] In addition, the multi-layer stitching 184 includes a fourth passage that occurs after the third passage (i.e., temporally after the third passage) and proceeds in a direction 186 from the first fiber web 200 toward the second fiber web 300. Similar to the third passage, the stitch density of the fourth passage is approximately 175 stitches / cm². 2 Approximately 225 N / cm 2 Approximately 180 N / cm 2 Approximately 220 N / cm 2 Approximately 190 N / cm 2 Approximately 210 N / cm 2 or approximately 200 N / cm 2 Similar to the third channel, the fourth channel has a penetration depth of approximately 1 mm to approximately 5 mm, approximately 2 mm to approximately 4 mm, or approximately 3 mm. In an example, this is represented by a barb of the joining needle. The purpose of the fourth channel is to tuck some fibers present on the surface of the first fiber web 200 into the laminated configuration without generating further entanglement. In other words, the fourth channel helps reduce fuzz on the surface of the first fiber web 200. Overall, the stitch density of the composite nonwoven textile 198 is approximately 550, the overall stitch density on the side formed by the first fiber web 200 is approximately 300, and the overall stitch density on the side formed by the second fiber web 300 is approximately 250.

[0078] In an additional aspect of this disclosure, the multilayer stitching 184 may optionally include a Dilour-type process or passage, which may be an addition to the four passages described above, or may replace one of these passages (e.g., replacing the third or fourth passage). In the Dilour passage, a needle with a forked tip is used from the direction 186 toward the second fiber web 300. The needle captures fibers and pushes them into a set of brushes positioned adjacent to the second surface (the outward-facing surface of the fiber web 300). As the stacked configuration continues to move in the machine direction, the fibers held by this set of brushes are pulled out of the brushes. After being pulled out of the set of brushes, the fibers and fiber loops held by this set of brushes have a common orientation in the z-direction relative to, for example, the surface plane of the second fiber web 300.

[0079] Following the fourth path, the entanglement process can be completed, and the nonwoven formation 178 may include additional processes 190 to further enhance usability and aesthetics. For example, the needle-punched laminate may be ironed 192, embossed 194, receive a water-based or oil-based coating 196, or any combination thereof.

[0080] The aforementioned entanglement parameters (e.g., needle selection, number of channels, channel direction, needle density per channel, and penetration depth) are selected to achieve the desired final properties of the composite nonwoven textile 198. Typically, the composite nonwoven textile 198 includes the desired properties based on the characteristics selected for each of the first fiber web 200, the second fiber web 300, and the third fiber web 400 (basic weight, fiber denier, short fiber length, silicone coating, fiber type, etc.), the characteristics selected for the elastomer layer 500 (type of thermoplastic elastomer, construction (film meltblown, spunbond, web, etc.)), and the selection of the aforementioned entanglement parameters. For example, the composite nonwoven textile 198 may have a final thickness of about 1.8 mm to about 2.7 mm, about 1.9 mm to about 2.6 mm, or about 2.0 mm to about 2.5 mm. The composite nonwoven textile 198 may have a base weight of about 40 gsm to about 450 gsm, about 100 gsm to about 350 gsm, about 150 gsm to about 190 gsm, or about 180 gsm. The final base weight may be affected by the number of layers (fiber web number) used in the construction, fiber loss due to peeling, machine drafting, etc. As an example, the composite nonwoven textile 198 may have a thermal resistance of about 50 RCT to about 95 RCT, about 55 RCT to about 90 RCT, about 60 RCT to about 85 RCT, or about 65 RCT to about 80 RCT. Therefore, as shown, the composite nonwoven textile 198 can exhibit the insulating properties associated with typical knitted fleece, but with a lower base weight.

[0081] Due to the 500 elastomer layer, composite nonwoven textile 198 can exhibit minimal growth characteristics and good recovery properties. Using the ASTM D2594 test standard, the growth of composite nonwoven textile 198 in the length direction (i.e., the machine direction) can be less than or equal to about 5%, less than or equal to about 4%, less than or equal to about 3%, less than or equal to about 2%, less than or equal to about 1%, less than or equal to about 0.1%, or less than or equal to 0%. The growth of composite nonwoven textile 198 in the width direction (i.e., the machine transverse direction) can be less than or equal to about 10%, less than or equal to about 9%, less than or equal to about 8%, less than or equal to about 7%, less than or equal to about 6%, less than or equal to about 5%, less than or equal to about 4%, less than or equal to about 3%, less than or equal to about 2%, less than or equal to about 1%, less than or equal to about 0.1%, or less than or equal to 0%. Using ASTM D2594 testing standards, the recovery of composite nonwoven textile 198 is within approximately 10% of its rest length and width, approximately 9% of its rest length and width, approximately 8% of its rest length and width, approximately 7% of its rest length and width, approximately 6% of its rest length and width, approximately 5% of its rest length and width, approximately 4% of its rest length and width, approximately 3% of its rest length and width, approximately 2% of its rest length and width, or approximately 1% of its rest length and width. The stiffness of composite nonwoven textile 198 related to the drape of textile 198 is less than or equal to approximately 0.4 kgf, less than or equal to approximately 0.3 kgf, less than or equal to approximately 0.2 kgf, or less than or equal to approximately 0.1 kgf.

[0082] In some examples, the aforementioned characteristics (e.g., basic weight, thickness, thermal resistance, growth and recovery, and stiffness) make the composite nonwoven textile 198 suitable for a variety of articles, as indicated by arrow 199a. Examples of articles include clothing articles (e.g., upper garments, lower garments, hats, and footwear), as well as other finished products such as bags. Specifically, the composite nonwoven textile 198 described herein is suitable for lightweight, warm clothing articles suitable for cool to cold weather conditions. In some cases, as indicated by arrow 199b, the production of sustainable articles 112 may result in some surplus nonwoven textiles, such as sheets 177 from which patterns are cut, or unused rolls of goods 179 are retained (e.g., stockpiled, substandard, defective, slow-moving, last season's inventory, etc.). According to one aspect of this disclosure, both sustainable articles 112 and sheets 177, as well as rolled goods 179, are fed into system 110 for the production of sustainable raw materials, and because these articles include the aforementioned nonwoven fiber construction, they are well-suited for material recycling 137 or material recovery 150.

[0083] As stated above, various aspects of this disclosure relate to sustainability and nonwoven textiles with a relatively low carbon footprint based on the energy consumed during their production. Figure 8 This includes a list of parameters (kg CO2e) for each stage of the nonwoven forming process 178 according to one aspect of this disclosure. Additionally, Figure 8 This includes example calculations based on an example nonwoven textile 198 comprising fiber webs 200, 300, and 400 and an elastomer layer 500. In one aspect, fiber webs 200, 300, and 400 collectively comprise about 85% to about 90% by weight, or about 88% by weight, of nonwoven textiles, and each of the fiber webs comprises about 25% to about 35% by weight, or about 29.33% by weight, of nonwoven textiles.

[0084] In other respects, the carbon footprint CO2e / kg can differ. Figure 8 As shown in the diagram. For example, if material recovery 150 with mechanical separation 152 is used to produce fibers for some or all of the fiber portions (e.g., instead of material recycling with re-granulation and extrusion), the carbon value based on the HIGG index is approximately 0.42 kg CO2e, which reduces the carbon footprint. In one case, the first fiber web 200 and the second fiber web 300 comprise fibers produced by material recycling, while the third fiber web 400 can be formed from fibers produced by material recovery 150, which will correspondingly reduce the carbon footprint by adjusting the values ​​associated with material recycling (e.g., 2 / 3 (1.51) of fiber webs 200 and 300 plus 1 / 3 (0.42) of fiber web 400). It is further envisioned that fibers can be recovered directly from byproducts (e.g., 174 and 176) of the fiber web forming process 162, which have a substantially zero carbon value associated with the raw material generation process 118, due to the fact that they can be directly incorporated into the carding process. Additionally, other post-processing steps can be performed, such as embossing, including a carbon value of approximately 0.04 based on a manual assessment of kg CO2e. Furthermore, other steps may be omitted. Figure 8 Some of the post-processing steps listed, such as oil-based coatings, reduce the carbon footprint to approximately 4.30 CO2e / kg of nonwoven material.

[0085] Figure 9 The illustration shows additional aspects of clothing item 910, including nonwoven textiles 912 derived from sustainable manufacturing processes 116. Although Figure 9 The upper body clothing is described, but regarding... Figure 9 One or more aspects described may also be applied to other clothing products (e.g., bottom garments, footwear, etc.); other nonwoven products; and nonwoven rolls. Figure 9A cross-sectional view of nonwoven textile 912 is illustrated. This corresponding cross-sectional view represents nonwoven textile 912 when a dilour path is taken during manufacturing. In one aspect, nonwoven textile 910 may include... Figure 3 One or more structures of the described composite nonwoven textile 198. For example, nonwoven textile 912 may include a first entangled fiber web 914, a second entangled fiber web 916, a third entangled fiber web 918, and an elastomer layer 920. For illustrative purposes, such as to help understand how they correspond to fiber webs 200, 300, and 400 (in the example), entangled fiber webs 914, 916, and 918 are outlined and individually identified. Figure 9 As depicted, as a result of the multi-layered sewing process 184, these entangled fiber webs may actually include several fibers passing through two or all three fiber webs.

[0086] The nonwoven textile 912 also includes a plurality of fibers. For example, a first plurality of fibers 930 is identified by a bounding box; a second plurality of fibers 932 is identified by a bounding box; a third plurality of fibers 934 is identified by a bounding box; a fourth plurality of fibers 936 is identified by a bounding box; and a fifth plurality of fibers 938 is identified by a bounding box. The plurality of fibers may be arranged in one of the entangled fiber webs, such as a plurality of 930, 932, and 934. Alternatively, the plurality of fibers may be arranged in multiple entangled fiber webs, such as a plurality of 936 and 938.

[0087] According to one aspect of this disclosure, nonwoven textile 912 may include fibers derived from or produced (e.g., through sustainable raw material production process 118) from different categories of recyclable goods. For example, a plurality of 930 may originate from a first category of recyclable goods (e.g., PET bottles or rolls of goods), while a plurality of 934 may originate from a second category of recyclable goods (e.g., PET clothing). Multiple fibers may be produced using the same production method (e.g., material recycling 137 or material recovery 150), or alternatively, multiple fibers may be produced using different production methods. For example, multiple fibers 930 and 938 may both be produced from different categories of recyclable goods using material recycling 137. In a different aspect, multiple fibers 936 and 932 may both be produced from different categories of recyclable goods (e.g., knitted clothing and nonwoven rolls of goods) using material recovery 150. Furthermore, multiple fibers 932 may be produced using material recovery 150, while multiple fibers 934 may be produced using material recycling 137. In this way, clothing products 910 and nonwoven textiles 912 provide opportunities for the use and reuse of a variety of different materials and products that would otherwise be disposed of in landfills.

[0088] exist Figure 9In the garment article 910, there are an outermost surface or face 922 and an innermost surface or face (in... Figure 9 (Not visible in the image). Additionally, the nonwoven textile 912 includes a first surface 924 and a second surface 926. Furthermore, according to one aspect of this disclosure, the outermost surface 922 includes the first surface 924, and the innermost surface includes the second surface 926. Therefore, the inclusion of other materials in the garment article 910 may be relatively limited. For example, the nonwoven textile 912 may include a percentage of the garment article 910 ranging from about 50% to about 100%, about 60% to about 90%, or about 70% to about 80% by weight. In other aspects, the nonwoven textile 912 may include more than 50% of the garment article 910 by weight, more than 60% by weight, more than 70% by weight, more than 80% by weight, or more than 90% by weight.

[0089] As indicated above, the outermost surface 922 may include a first surface 924, and thereby the nonwoven textile 912 may contribute a visual effect (e.g., color) to the garment article 910. For example, in one aspect of this disclosure, when the first surface 924 is observed, at least some portions of the fibers from the tangled fiber web 918 (e.g., corresponding to the fiber web 400) are visible and contribute to the visual effect. The fibers from the tangled fiber web 918 can be seen through the spaces between the fibers in the tangled fiber web 914. In other cases, the visible portions of the fibers from the tangled fiber web 918 may be positioned or arranged (e.g., produced by multilayer stitching 184) closer to the first surface 924 than the interface between the tangled fiber webs 914 and 918, and thereby they are visible when the first surface 924 is observed.

[0090] According to one aspect of this disclosure, color can be added to selected portions (e.g., all portions of the outermost surface 922) of the outermost surface 922 by including a color in the entangled fiber web 918 that is different from the color in the entangled fiber web 914. For example, in one case, the entangled fiber web 914 may comprise extruded fibers that are solution-dyed or otherwise colored with a first color (e.g., white). Additionally, the entangled fiber web 918 may comprise shredded product fibers that include a second color (e.g., black, gray, red, etc.) different from the first color, the second color being produced by a combination of one or more colors included in the shredded product fibers (e.g., similar hues with different shades or hues). In this example, the use of shredded product fibers provides the desired aesthetics (e.g., color) while also improving sustainability (e.g., reducing carbon footprint) because producing shredded product fibers (e.g., shredded product fibers 154 using material recovery 150) generally consumes less energy than material recycling 137 (e.g., regranulation 138 and extrusion 140). Additionally, if the shredded product fibers include potentially undesirable properties (e.g., clumps, other materials 160, etc.), the effects of these properties are reduced, minimized, and / or eliminated because the shredded product fibers are in the entangled fiber web 918 between the other entangled fiber webs 914 and 916.

[0091] Reference Figure 10 , Figure 10 A permanent (e.g., near-permanent) clothing product system utilizing a sustainability platform 1010 provided by system 110 is schematically illustrated. As used in this disclosure, a “permanent system” describes a system that regenerates or self-generates at least some inputs without relying on external sources and is not necessarily unlimited or infinitely cyclical or periodic. For example, the sustainability platform includes a sustainable raw material generation process 118, sustainable raw materials 114, and a sustainable manufacturing process 116 that can be continuously used over time for repeated recycling of nonwoven products. Thus, at any given point in time after system 110 uses products 1014 that no longer exist to generate raw materials for manufacturing nonwoven products 1012, there is also a potential future nonwoven product 1016 that will be manufactured by generating raw materials from nonwoven products 1012. As used herein, “no longer existing articles” describes articles (e.g., 112 and 120) that once existed and have been fed back into system 110 for sustainable raw material production process 118 (e.g., after being discarded, traded, exchanged, or otherwise submitted to or collected by system 110).

[0092] In other words, the permanent system includes a first garment article (e.g., a nonwoven article 1012) comprising a nonwoven textile (e.g., 1018) constructed from a first set of fibers, at least a portion of which originates from a second set of fibers 1020 previously formed from a garment article 1014 that no longer exists. The first set of fibers is arranged in a first fiber entanglement (e.g., nonwoven), and the second set of fibers 1020 is included in a fiber arrangement different from the first fiber entanglement (e.g., knitted, woven, or nonwoven before material recycling or recovery). Furthermore, a third set of fibers may originate from the first set of fibers and be arranged in a second fiber entanglement 1022, different from the first fiber entanglement 1018, to construct a second nonwoven garment article (e.g., 1016). In some cases, the fibers can be re-granulated in each cycle. In other aspects, the fibers can be repeatedly recovered, such that the same set of fibers can be used for multiple generations of articles without being re-granulated. In this respect, the repeatedly recovered fibers may be referred to as a common set of fibers. In other words, a common set of fibers includes one or more fibers that have been reused in different clothing products, while different clothing products include clothing products that no longer exist.

[0093] Some aspects of this disclosure have already been described with reference to the examples provided in the accompanying drawings. Additional aspects of this disclosure will now be described, which may be related subject matter included at the time of filing in one or more claims or clauses of this application, or in one or more related applications, but are not limited to the subject matter described only in the following sections of this specification. These additional aspects may include features illustrated in the drawings, features not illustrated in the drawings, and any combination thereof. In describing these additional aspects, reference may be made to the elements depicted in the drawings for illustrative purposes.

[0094] As used herein and in conjunction with the claims listed below, the term "any one of the clauses" or similar variations thereof are intended to be interpreted as allowing the features of the claim / clause to be combined in any combination. For example, exemplary clause 4 may indicate a method / apparatus according to any one of clauses 1 to 3, which is intended to be interpreted as allowing the features of clauses 1 and 4 to be combined, the elements of clauses 2 and 4 to be combined, the elements of clauses 3 and 4 to be combined, the elements of clauses 1, 2, and 4 to be combined, the elements of clauses 2, 3, and 4 to be combined, and / or other variations. Furthermore, the term "any one of the clauses" or similar variations thereof are intended to include other variations of "any one of the clauses" or such terms, as indicated in some of the examples provided above.

[0095] The following terms are the aspects envisioned in this document.

[0096] Clause 1: A clothing article comprising: a nonwoven textile; the nonwoven textile having a first plurality of fibers and a second plurality of fibers; the first plurality of fibers comprising a first polyester polymer, wherein the first polyester polymer has been previously incorporated into a first existing article of recyclable goods from a first category; and the second plurality of fibers comprising a second polyester polymer, wherein the second polyester polymer has been previously incorporated into a second existing article of recyclable goods from a second category, which is different from the first category of recyclable goods.

[0097] Clause 2. The clothing article according to Clause 1, wherein the fibers of the first plurality of fibers comprise re-granulated polymer fibers extruded from granulation by-products derived from the first existing article, and wherein the fibers of the second plurality of fibers are re-granulated polymer fibers extruded from granulation by-products derived from the second existing article.

[0098] Clause 3. The clothing article according to Clause 1, wherein the fibers of the first plurality of fibers include shredded article fibers as a byproduct of the shredding of the first existing article, and wherein the fibers of the second plurality of fibers include shredded article fibers as a byproduct of the shredding of the second existing article.

[0099] Clause 4. The clothing article according to Clause 1, wherein the fibers of the first plurality of fibers comprise re-granulated polymer fibers extruded from granulation by-products derived from the first existing article, and wherein the fibers of the second plurality of fibers comprise shredded article fibers as shredded by-products of the second existing article.

[0100] Clause 5. A garment article according to any one of Clauses 1 to 4, wherein the garment article includes an outermost surface, the outermost surface including the first surface of the nonwoven textile.

[0101] Clause 6. The garment article as described in Clause 5, wherein the garment article includes an innermost surface, the innermost surface including a second surface of the nonwoven textile.

[0102] Clause 7. The clothing article according to Clause 5 or Clause 6, wherein the nonwoven textile comprises a first fiber web entangled with a second fiber web; wherein the first fiber web comprises the first plurality of fibers, the first face of the nonwoven textile, and re-granulated polymer fibers extruded from a granulation by-product derived from the first existing article; and wherein the second fiber web comprises the second plurality of fibers and includes shredded article fibers as a shredded by-product of the second existing article.

[0103] Clause 8. The garment article according to Clause 7, wherein the first plurality of fibers comprises a first color dyed by a spun dye, and wherein the fibers of the second plurality of fibers comprise a second color different from the first color.

[0104] Clause 9. The clothing article according to any one of Clauses 1 to 8, wherein at least one of the first plurality of fibers and the second plurality of fibers comprises at least about 5% by weight of a crystallinity modifier.

[0105] Clause 10. Clothing articles according to any one of Clauses 1 to 9, wherein the nonwoven textile comprises a percentage of the clothing article in the range of about 50% to 100% by weight.

[0106] Clause 11. Clothing articles according to any one of Clauses 1 to 10, wherein the recyclable goods of the first and second categories are selected from at least one of plastic bottles, clothing articles and rolls of textiles.

[0107] Clause 12. Clothing articles according to any one of Clauses 1 to 10, wherein the recyclable goods of the first and second categories are selected from at least one of clothing articles and rolls of textiles.

[0108] Clause 13. The clothing article according to Clause 1, wherein the fibers of the first plurality of fibers comprise virgin polyester, and wherein the fibers of the second plurality of fibers are re-granulated polymer fibers extruded from granulation by-products derived from the second existing article.

[0109] Clause 14. A permanent system for a garment article, comprising: a first garment article comprising a nonwoven textile constructed of a first set of fibers, at least a portion of the first set of fibers being derived from a second set of fibers previously formed in a garment article no longer existing, wherein the first set of fibers is arranged in a first fiber entanglement; wherein the second set of fibers comprises a fiber arrangement different from the first fiber entanglement; and wherein a third set of fibers is capable of being derived from the first set of fibers for arrangement in a second fiber entanglement different from the first fiber entanglement to construct a second nonwoven garment article.

[0110] Clause 15. A permanent system for clothing articles according to Clause 14, wherein the first fiber entanglement is a first fiber web, the fiber arrangement is a second fiber web, and the second fiber entanglement is a third fiber web.

[0111] Clause 16. A permanent system for clothing articles according to Clause 14, wherein the first fiber entanglement is a first fiber web, the fiber arrangement is a knitted textile, and the second fiber entanglement is a second fiber web.

[0112] Clause 17. A permanent system for clothing articles as described in Clause 14, wherein the first fiber entanglement is a first fiber web, the fiber arrangement is a woven textile, and the second fiber entanglement is a second fiber web.

[0113] Clause 18. A permanent system for clothing articles according to any one of Clauses 14 to 17, wherein the first group of fibers is a re-granulated polymer fiber extruded from a granulation byproduct derived from the second group of fibers, and wherein the third group of fibers is a re-granulated polymer fiber extruded from a granulation byproduct derived from the first group of fibers.

[0114] Clause 19. A permanent system for clothing articles according to any one of Clauses 14 to 17, wherein the first group of fibers, the second group of fibers, and the third group of fibers share a common set of fibers.

[0115] Clause 20. A permanent system of clothing articles according to any one of Clauses 14 to 19, wherein the first clothing article includes an outermost surface, the outermost surface including a first surface of the nonwoven textile; and wherein the first clothing article includes an innermost surface, the innermost surface including a second surface of the nonwoven textile.

[0116] Clause 21. A method of manufacturing a roll of nonwoven textile product, the method comprising: converting a first article having a first fiber into a second fiber, wherein the first fiber comprises a first polyester polymer and wherein the first article comprises a first category of recyclable product; converting a second article comprising a third fiber into a fourth fiber, wherein the third fiber comprises a second polyester polymer and wherein the second article comprises a second category of recyclable product different from the first category of recyclable product; and entanglement of the second fiber with the fourth fiber, wherein the entanglement forms the roll of nonwoven textile product.

[0117] Clause 22. The method according to Clause 21, wherein converting the first article comprises granulating the first fiber and extruding the second fiber, and wherein converting the second article comprises granulating the third fiber and extruding the fourth fiber.

[0118] Clause 23. The method according to Clause 21, wherein converting the first article comprises shredding the first article, at least a subset of the second fiber comprises at least a subset of the first fiber; and wherein converting the second article comprises shredding the second article, at least a subset of the fourth fiber comprises at least a subset of the third fiber.

[0119] Clause 24. The method according to Clause 21, wherein converting the first article comprises granulating the first fiber and extruding the second fiber, and wherein converting the second article comprises shredding the second article, and at least a subset of the fourth fiber comprises at least a subset of the third fiber.

[0120] Clause 25. The method according to any one of Clause 24 further comprises: dyeing the second fiber solution to include a first color; constructing a first fiber web from the second fiber having the first color; constructing a second fiber web from the fourth fiber having a second color different from the first color, wherein entanglement of the second fiber with the fourth fiber includes needle punching the first fiber web and the second fiber web.

[0121] Clause 26. The method according to any one of Clauses 21 to 25, wherein entanglement of the second fiber with the fourth fiber comprises constructing a fiber web from the second fiber and the fourth fiber and sewing the fiber web.

[0122] Clause 27. The method according to any one of Clauses 21 to 26, wherein the recyclable goods of the first and second categories are plastic bottles, clothing articles or rolls of textiles.

[0123] Clause 28. The method according to any one of Clauses 21 to 27, wherein the recyclable goods of the first and second categories are garment articles and textile rolls.

[0124] Clause 29. A garment article comprising: a nonwoven textile comprising a plurality of fibers; said plurality of fibers having an average short fiber length of about 50 mm and a standard deviation of short fiber length, wherein said standard deviation of short fiber length is in the range of about 5 mm to about 25 mm.

[0125] Clause 30. The garment article as described in Clause 29, wherein the garment article includes an outermost surface, the outermost surface including the first surface of the nonwoven textile.

[0126] Clause 31. The garment article according to Clause 29 or 30, wherein the plurality of fibers comprises a first plurality of fibers arranged in a first fiber web, and the nonwoven textile comprises a second plurality of fibers arranged in a second fiber web entangled with the first fiber web; wherein the first surface comprises the second fiber web; wherein the fibers of the second plurality of fibers comprise a first color dyed with a spinning solution; and wherein the fibers of the first plurality of fibers comprise a second color having an appearance different from the first color.

[0127] Clause 32. The clothing article according to Clause 31, wherein the fibers of the second plurality of fibers include a hue, and include a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

[0128] Clause 33. A garment article according to any one of Clauses 29 to 32, wherein the plurality of fibers comprise a percentage of the nonwoven textile in the range of about 25% to about 30% by weight.

[0129] Clause 34. Clothing articles pursuant to any one of Clauses 29 to 33, wherein the nonwoven textile comprises at least 50% of the clothing articles by weight.

[0130] Clause 35. Clothing articles according to any one of Clauses 29 to 34, wherein the fibers of said plurality of fibers comprise virgin polyester.

[0131] Clause 36. A garment article comprising: a nonwoven textile comprising a first side and a second side; the first side comprising the outermost side of the garment article; the second side comprising the innermost side of the garment article, comprising at least about 50% by weight of the fibers of the nonwoven textile comprising re-granulated polymer fibers extruded from granulation by-products derived from products containing polyethylene terephthalate (PET), shredded article fibers as shredded by-products of PET-containing products, or any combination thereof.

[0132] Clause 37. The clothing article as described in Clause 36, wherein the nonwoven textile has a stiffness in the range of about 0.3 kgf to about 0.5 kgf.

[0133] Clause 38. Clothing articles according to Clause 36 or 37, wherein the re-granulated polymer fibers comprise at least 5% by weight of a crystallinity modifier.

[0134] Clause 39. The garment article according to any one of Clauses 36 to 38, wherein the shredded article fibers have an average short fiber length of about 50 mm and a standard deviation of about 5 mm to about 30 mm.

[0135] Clause 40. The clothing article according to any one of Clauses 36 to 39, wherein the nonwoven textile comprises a first fiber web entangled with a second fiber web; wherein the first fiber web comprises the re-granulated polymer fibers and the first face of the nonwoven textile; and wherein the second fiber web comprises the shredded product fibers.

[0136] Clause 41. The clothing article according to any one of Clauses 36 to 40, wherein the re-granulated polymer fiber comprises a first color dyed with a spinning solution, and wherein the shredded article fiber comprises a second color different from the first color.

[0137] Clause 42. A garment article according to any one of Clauses 36 to 41, wherein the fibers of the shredded article fibers comprise a hue, and comprise a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

[0138] Clause 43. Clothing articles according to any one of Clauses 36 to 42, wherein the nonwoven textile comprises a percentage of more than 50% by weight of the clothing article.

[0139] Clause 44. A nonwoven textile comprising: a first fiber web entangled with a second fiber web; the first fiber web comprising reconstituted polymer fibers having a first color, wherein the first fiber web includes a face oriented away from the second fiber web; and the second fiber web comprising shredded article fibers having a second color different from the first color, wherein at least a portion of the shredded article fibers entangled with the reconstituted polymer fibers and having the second color is observable from a viewing position oriented toward the face.

[0140] Clause 45. The nonwoven textile according to Clause 44 further includes at least a third fiber web entangled with the second fiber web, wherein the third fiber web comprises re-granulated polymer fibers, and wherein the second fiber web is positioned between the first fiber web and the third fiber web.

[0141] Clause 46. The nonwoven textile as described in Clause 44 or 45, wherein the face of the first fiber web comprises the outermost face of the garment article.

[0142] Clause 47. The nonwoven textile as described in Clause 46, wherein the surface comprises at least 75% of the outermost surface by surface area.

[0143] Clause 48. The nonwoven textile according to any one of Clauses 44 to 47, wherein the fibers of the shredded product fibers comprise a hue, and comprise a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

[0144] Clause 49. A nonwoven textile comprising: a first fiber web entangled with a second fiber web, both the first and second fiber webs comprising re-granulated polymer fibers extruded from granulation by-products of PET-containing products, shredded article fibers as shredded by-products of PET-containing products, or any combination thereof; and an elastomeric layer positioned between the first and second fiber webs, the elastomeric layer comprising a recycled thermoplastic elastomer.

[0145] Clause 50. The nonwoven textile as described in Clause 49, wherein the nonwoven textile has a stiffness in the range of about 0.3 kgf to about 0.5 kgf.

[0146] Clause 51. The nonwoven textiles as described in Clause 49 or 50, wherein the fibers of the re-extruded polymer fibers comprise at least 5% by weight of a crystallinity modifier.

[0147] Clause 52. The nonwoven textile according to any one of Clauses 49 to 51, wherein the shredded product fibers comprise an average short fiber length of about 50 mm and a standard deviation of about 5 mm to about 30 mm.

[0148] Clause 53. The nonwoven textile according to any one of Clauses 49 to 52, wherein the nonwoven textile has about 45M 2 *K / W approximately 95M 2 Thermal resistance (Rct) within the range of *K / W.

[0149] Clause 54. The nonwoven textile product according to any one of Clauses 40 to 53, wherein the nonwoven textile product has a basic weight in the range of about 160 GSM to about 200 GSM.

[0150] Clause 55. The nonwoven textile according to any one of Clauses 49 to 54, wherein the re-granulated polymer fiber, the shredded product fiber, or the combination comprises at least about 50% by weight of the nonwoven textile.

[0151] Clause 56. A method of manufacturing a roll of nonwoven textile product, the method comprising: forming a first fiber web to be needled with a second fiber web; pre-needling the first fiber web before needled with the second fiber web; trimming the edges of the first fiber web after the pre-needling and before the needled; and combing the edges to form a third fiber web for manufacturing the roll of nonwoven textile product.

[0152] Clause 57. The method according to Clause 56 further includes: constructing a fourth fiber web and a fifth fiber web; constructing a multilayer comprising an elastomeric layer disposed between the third fiber web and the fourth fiber web, and comprising the fourth fiber web disposed between the elastomeric layer and the fifth fiber web; and sewing the multilayer to form a nonwoven textile.

[0153] Clause 58. The method according to Clause 56 or 57, wherein the nonwoven textile has about 45M 2 *K / W approximately 95M 2 Thermal resistance (Rct) within the range of *K / W.

[0154] Clause 59. The method according to any one of Clauses 56 to 58, wherein the nonwoven textile has a basic weight in the range of about 160 GSM to about 200 GSM.

[0155] Clause 60. The method according to Clause 57, wherein constructing the fifth fiber web includes combing another edge trimmed from another fiber web.

[0156] Clause 61. The method according to Clause 57, wherein constructing the fourth fiber web comprises carding and pre-needling shredded product fibers.

[0157] Clause 62. A clothing article comprising: a nonwoven textile having a surface area of ​​approximately 45 m. 2 *K / W approximately 95M 2 * Thermal resistance (Rct) in the K / W range and basic weight in the range of about 160 GSM to about 200 GSM, including at least about 50% by weight of the fibers of the said nonwoven textile comprising re-extruded polymer fibers extruded from granulation by-products derived from PET-containing products, shredded article fibers as shredded by-products of PET-containing products, or any combination thereof.

[0158] Clause 63. The clothing article as described in Clause 62, wherein the nonwoven textile has a stiffness in the range of about 0.3 kgf to about 0.5 kgf.

[0159] Clause 64. Clothing articles according to Clause 62 or 63, wherein the re-extruded polymer fibers comprise at least 5% by weight of a crystallinity modifier.

[0160] Clause 65. A garment article according to any one of Clauses 62 to 64, wherein the shredded article fibers comprise an average short fiber length of about 50 mm and a standard deviation of about 5 mm to about 30 mm.

[0161] Clause 66. A garment article according to any one of Clauses 62 to 65, wherein the garment article includes an outermost surface, the outermost surface including a first surface of the nonwoven textile.

[0162] Clause 67. A garment article according to any one of Clauses 62 to 66, wherein the garment article includes an innermost surface, the innermost surface including a second surface of the nonwoven textile.

[0163] Clause 68. The garment article according to Clause 67, wherein the nonwoven textile comprises a first fiber web entangled with a second fiber web; wherein the first fiber web comprises the re-extruded polymer fibers and a first face of the nonwoven textile; and wherein the second fiber web comprises the shredded product fibers.

[0164] Clause 69. The clothing article according to Clause 68, wherein the re-extruded polymer fiber comprises a first color dyed with a spinning solution, and wherein the shredded article fiber comprises a second color having an appearance different from the first color.

[0165] Clause 70. Clothing articles pursuant to any one of Clauses 66 to 69, wherein the nonwoven textile comprises a percentage of the clothing article by weight greater than 50%.

[0166] Clause 71. A method for manufacturing garment articles by means of a process that produces a total CO2e / kg nonwoven textile of less than about 4.60 kg CO2e / kg, wherein the process comprises: constructing a first fiber web and a second fiber web; constructing an elastomer layer; constructing a multilayer comprising the elastomer layer disposed between the first fiber web and the second fiber web; sewing the multilayer, wherein the sewing forms the nonwoven textile; and producing at least a portion of the garment article from the nonwoven textile constructed by the process.

[0167] Clause 72. The method according to Clause 71, wherein the process includes ironing the nonwoven textile to produce an ironed nonwoven textile for making at least the portion thereof of the garment article.

[0168] Clause 73. The method according to Clause 72, wherein the total amount is less than about 4.30 kg CO2e / kg nonwoven textile.

[0169] Clause 74. The method according to Clause 72, wherein the process includes embossing the ironed nonwoven textile for making at least the portion of the garment article, and wherein the total amount is less than about 4.34 kg CO2e / kg nonwoven textile.

[0170] Clause 75. The method according to Clause 72, wherein the process includes applying an oil-based coating to the ironed nonwoven textile, the ironed nonwoven textile being used to make at least the portion of the garment article, and wherein the total amount is less than about 4.42 kg CO2e / kg nonwoven textile.

[0171] Clause 76. The method according to any one of Clauses 71 to 75, wherein the at least portion of the clothing article includes the outermost surface of the clothing article.

[0172] Clause 77. The method according to any one of Clauses 71 to 76, wherein the at least portion of the clothing article includes the innermost surface of the clothing article.

[0173] Clause 78. The method according to any one of Clauses 71 to 77, wherein the at least portion of the clothing article comprises at least 50% of the clothing article by weight.

[0174] Clause 79. The method according to any one of Clauses 71 to 78, wherein the process includes constructing a third fiber web; and wherein constructing the multilayer includes distributing the second fiber web between the elastomer layer and the third fiber web.

[0175] Clause 80. The method according to any one of Clauses 71 to 79, wherein the nonwoven textile has about 45M 2 *K / W approximately 95M 2 Thermal resistance (Rct) within the range of *K / W.

[0176] Clause 81. The method according to any one of Clauses 71 to 80, wherein the nonwoven textile has a basic weight in the range of about 160 GSM to about 200 GSM.

[0177] Clause 82. The method according to any one of Clauses 71 to 81, wherein the nonwoven textile has a stiffness in the range of about 0.3 kgf to about 0.5 kgf.

[0178] Clause 83. The method according to any one of Clauses 71 to 82, wherein the process comprises converting post-consumer PET-containing articles into pellets and manufacturing short fibers for solution dyeing from said pellets.

[0179] Clause 84. The method according to any one of Clauses 71 to 83, wherein the process includes constructing a third fiber web, and the construction of the first and third fiber webs includes converting a post-consumer PET-containing article into pellets and manufacturing short fibers for solution dyeing from the pellets.

[0180] Clause 85. The method according to Clause 84, wherein constructing the second fiber web comprises: shredding the garment article to produce shredded article fibers, combing the shredded article fibers, and pre-stitching the shredded article fibers to form the second fiber web; wherein constructing the multilayer comprises arranging the second fiber web between the elastomer layer and the third fiber web; and wherein the total amount is less than about 4.07 CO2e / kg nonwoven textile.

[0181] Clause 86. A method of manufacturing a garment article, the method comprising: constructing a roll of nonwoven textiles by a process that produces a total CO2e / kg nonwoven textile content of less than about 4.07 CO2e / kg nonwoven textiles, the roll of nonwoven textiles comprising nonwoven textiles wound on a core, wherein the process comprises: constructing a first fiber web, a second fiber web, and a third fiber web; constructing an elastomer layer; constructing a multilayer comprising the elastomer layer disposed between the first fiber web and the second fiber web, and comprising a second fiber web disposed between the elastomer layer and the third fiber web; sewing the multilayer, wherein the sewing forms the nonwoven textiles; and producing at least a portion of a garment article from the nonwoven textiles constructed by the process.

[0182] Clause 87. The method according to Clause 86, wherein constructing the second fiber web comprises: shredding the garment article to produce shredded article fibers, combing the shredded article fibers, and pre-stitching the shredded article fibers to form the second fiber web.

[0183] Clause 88. The method according to Clause 86 or 87, wherein the process includes ironing the nonwoven textile to produce an ironed nonwoven textile for making at least the portion thereof of the garment article.

[0184] Clause 89. The method according to any one of Clauses 86 to 88, wherein the at least portion of the clothing article includes the outermost surface of the clothing article.

[0185] Clause 90. The method according to any one of Clauses 86 to 89, wherein the at least portion of the clothing article includes the innermost surface of the clothing article.

[0186] Clause 91. The method according to any one of Clauses 86 to 90, wherein the at least portion of the clothing article comprises at least 50% of the clothing article by weight.

[0187] Clause 92. The method according to any one of Clauses 86 to 91, wherein the nonwoven textile has about 45M 2 *K / W approximately 95M2 Thermal resistance (Rct) within the range of *K / W.

[0188] Clause 93. The method according to any one of Clauses 86 to 92, wherein the nonwoven textile has a basic weight in the range of about 160 GSM to about 200 GSM.

[0189] Clause 94. A method of manufacturing a garment article, comprising: positioning an elastomeric layer between a first fiber web and a second fiber web, wherein the elastomeric layer includes a peripheral edge defining a two-dimensional shape and terminating within a range of the elastomeric layer, and wherein both the first fiber web and the second fiber web include respective article portions aligned with the elastomeric layer and respective excess portions extending beyond the peripheral edge; cutting the first fiber web and the second fiber web at a transition from the respective article portions to the respective excess portions; constructing a first garment article using the respective article portions and the elastomeric layer; and forming at least a third fiber web from at least one of the respective excess portions, the third fiber web being used to construct a second garment article.

[0190] Clause 95. The method according to Clause 94, wherein forming the third network includes combing through at least one of the respective redundant portions.

[0191] Clause 96. The method according to Clause 94, wherein forming the third web comprises shredding at least one of the respective excess portions into shredded fibers and combing the shredded fibers.

[0192] Clause 97. A garment article comprising: a nonwoven textile comprising a plurality of fibers, said plurality of fibers including an average short fiber length of about 50 mm and a standard deviation of short fiber length ranging from about 5 mm to about 25 mm.

[0193] Clause 98. The garment article as described in Clause 97, wherein the garment article includes an outermost surface, the outermost surface including the first surface of the nonwoven textile.

[0194] Clause 99. The garment article according to Clause 98, wherein the plurality of fibers includes a first plurality of fibers disposed in a first fiber web and a second plurality of fibers disposed in a second fiber web entangled with the first fiber web, wherein the first surface includes the first fiber web.

[0195] Clause 100. The garment article according to Clause 99, wherein the fibers of the first plurality of fibers comprise a first color dyed with a spun dye, and wherein the fibers of the second plurality of fibers comprise a second color having an appearance different from the first color.

[0196] Clause 101. The clothing article according to Clause 100, wherein the fibers of the second plurality of fibers include a hue, and include a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

[0197] Clause 102. A garment article according to any one of Clauses 97 to 101, wherein the plurality of fibers comprise a percentage of the nonwoven textile in the range of about 25% to about 30% by weight.

[0198] Clause 103. Clothing articles as described in Clause 102, wherein the nonwoven textile comprises at least 50% of the clothing articles by weight.

[0199] Clause 104. Clothing articles according to any one of Clauses 97 to 103, wherein the fibers of said plurality of fibers comprise virgin polyester.

[0200] Clause 105. A garment article comprising: a nonwoven textile comprising a first side and an opposing second side; the first side comprising the outermost side of the garment article; and the second side comprising the innermost side of the garment article, comprising at least about 50% by weight of fibers of the nonwoven textile comprising a first plurality of fibers and a second plurality of fibers, the first plurality of fibers comprising an average short fiber length of about 50 mm and a short fiber length standard deviation of about 5 mm to about 30 mm, and the second plurality of fibers comprising a uniform short fiber length of about 50 mm.

[0201] Clause 106. The clothing article as described in Clause 105, wherein the first plurality of fibers are derived from a shredded fiber source.

[0202] Clause 107. The clothing article according to any one of Clauses 105 to 106, wherein said second plurality of fibers comprises one or more of virgin extruded polyethylene terephthalate (PET) and re-extruded PET.

[0203] Clause 108. A garment article according to any one of Clauses 105 to 107, wherein said second plurality of fibers comprises a first color dyed with a spinning solution.

[0204] Clause 109. The clothing article as described in Clause 108, wherein the first plurality of fibers includes a second color having an appearance different from the first color.

[0205] Clause 110. The clothing article as described in Clause 109, wherein the second color comprises a hue and a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

[0206] Clause 111. A method of manufacturing a nonwoven textile, the method comprising: forming a first plurality of fibers having an average short fiber length of about 50 mm and a short fiber length standard deviation of about 5 mm to about 30 mm; forming a second plurality of fibers having a uniform short fiber length of about 50 mm; using the first plurality of fibers and the second plurality of fibers to form a first fiber web and a second fiber web; and entangled the first fiber web and the second fiber web to form the nonwoven textile.

[0207] Clause 112. The method of manufacturing a nonwoven textile as described in Clause 111, wherein the first plurality of fibers are formed by shredding the article.

[0208] Clause 113. A method of manufacturing a nonwoven textile according to any one of Clauses 111 to 112, wherein the first plurality of fibers comprises one or more fiber blocks and one or more non-fiber materials.

[0209] Clause 114. The method of manufacturing nonwoven textiles as described in Clause 113, wherein the one or more non-fibrous materials include one or more inks and elastomer materials.

[0210] Clause 115. A method of manufacturing a nonwoven textile according to any one of Clauses 111 to 114, wherein the second plurality of fibers are formed by re-extrusion granulation of polyethylene terephthalate (PET).

[0211] Clause 116. The method of manufacturing nonwoven textiles according to Clause 115, wherein after the granulated PET is extruded again, the extruded fibers are cut into uniform lengths to form the second plurality of fibers.

[0212] Clause 117. A garment article comprising: a nonwoven textile comprising a first side and an opposing second side; the first side comprising the outermost side of the garment article; and the second side comprising the innermost side of the garment article, comprising at least about 50% by weight of the fibers of the nonwoven textile comprising re-granulated polymer fibers extruded from granulation by-products derived from products containing polyethylene terephthalate (PET), shredded article fibers as shredded by-products of PET-containing products, or any combination thereof.

[0213] Clause 118. The clothing article as described in Clause 117, wherein the nonwoven textile has a stiffness in the range of about 0.3 kgf to about 0.5 kgf.

[0214] Clause 119. Clothing articles according to any one of Clauses 117 to 118, wherein the re-granulated polymer fiber comprises at least 5% by weight of a crystallinity modifier.

[0215] Clause 120. The garment article according to any one of Clauses 117 to 119, wherein the shredded article fibers have an average short fiber length of about 50 mm and a standard deviation of about 5 mm to about 30 mm.

[0216] Clause 121. The clothing article according to any one of Clauses 117 to 120, wherein the nonwoven textile comprises a first fiber web entangled with a second fiber web; wherein the first fiber web comprises the re-granulated polymer fibers and the first face of the nonwoven textile; and wherein the second fiber web comprises the shredded product fibers.

[0217] Clause 122. The clothing article according to any one of Clauses 117 to 121, wherein the re-granulated polymer fiber comprises a first color dyed by a spinning solution, and wherein the shredded article fiber comprises a second color different from the first color.

[0218] Clause 123. The garment article as described in Clause 122, wherein the shredded article fibers comprise a hue, and comprise a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

[0219] Clause 124. Clothing articles according to any one of Clauses 117 to 123, wherein the nonwoven textile comprises a percentage of more than 50% by weight of the clothing article.

[0220] Clause 125. A nonwoven textile comprising: a first fiber web entangled with a second fiber web; the first fiber web comprising reconstituted polymer fibers having a first color, wherein the first fiber web includes a face oriented away from the second fiber web; and the second fiber web comprising shredded article fibers having a second color different from the first color, wherein at least a portion of the shredded article fibers entangled with the reconstituted polymer fibers and having the second color is observable from a viewing position oriented toward the face.

[0221] Clause 126. The nonwoven textile of claim 125 further comprises a third fiber web entangled with at least the second fiber web, wherein the third fiber web comprises re-granulated polymer fibers, and wherein the third fiber web is positioned between the first fiber web and the second fiber web.

[0222] Clause 127. The nonwoven textile according to any one of Clauses 125 to 126, wherein the face of the first fiber web comprises the outermost face of the garment article.

[0223] Clause 128. The nonwoven textile as described in Clause 127, wherein the surface comprises at least 75% of the outermost surface by surface area.

[0224] Clause 129. The nonwoven textile according to any one of Clauses 125 to 128, wherein the fibers of the shredded product fibers comprise a hue, and comprise a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

[0225] Clause 130. A nonwoven textile comprising: a first fiber web entangled with a second fiber web, both the first and second fiber webs comprising re-granulated polymer fibers extruded from granulation by-products of PET-containing products, shredded article fibers as shredded by-products of PET-containing products, or any combination thereof; and an elastomeric layer positioned between the first and second fiber webs, the elastomeric layer comprising a recycled thermoplastic elastomer.

[0226] Clause 131. The nonwoven textile as described in Clause 130, wherein the nonwoven textile has a stiffness in the range of about 0.3 kgf to about 0.5 kgf.

[0227] Clause 132. The nonwoven textile according to any one of Clauses 130 to 131, wherein the fibers of the re-extruded polymer fibers comprise at least 5% by weight of a crystallinity modifier.

[0228] Clause 133. The nonwoven textile according to any one of Clauses 130 to 132, wherein the shredded product fibers have an average short fiber length of about 50 mm and a standard deviation of about 5 mm to about 30 mm.

[0229] Clause 134. The nonwoven textile according to any one of Clauses 130 to 133, wherein the nonwoven textile has about 45M 2 *K / W approximately 95M 2 Thermal resistance (Rct) within the range of *K / W.

[0230] Clause 135. A nonwoven textile product according to any one of Clauses 130 to 134, wherein the nonwoven textile product has a basic weight in the range of about 160 GSM to about 200 GSM.

[0231] Clause 136. The nonwoven textile according to any one of Clauses 130 to 135, wherein the re-granulated polymer fiber, the shredded product fiber, or the combination comprises at least about 50% by weight of the nonwoven textile.

[0232] Clause 137. A permanent system for a garment article, comprising: a first garment article comprising a nonwoven textile constructed of a first set of fibers, at least a portion of the first set of fibers being derived from a second set of fibers previously formed in a garment article no longer present, wherein the first set of fibers is arranged in a first fiber entanglement; wherein the second set of fibers comprises a fiber arrangement different from the first fiber entanglement; and wherein a third set of fibers is capable of being derived from the first set of fibers for arrangement in a second fiber entanglement different from the first fiber entanglement to construct a second nonwoven garment article.

[0233] Clause 138. A permanent system for clothing articles according to Clause 137, wherein the first fiber entanglement is a first fiber web, the fiber arrangement is a second fiber web, and the second fiber entanglement is a third fiber web.

[0234] Clause 139. A permanent system for clothing articles as described in Clause 137, wherein the first fiber entanglement is a first fiber web, the fiber arrangement is a knitted textile, and the second fiber entanglement is a second fiber web.

[0235] Clause 140. A permanent system for clothing articles as described in Clause 137, wherein the first fiber entanglement is a first fiber web, the fiber arrangement is a woven textile, and the second fiber entanglement is a second fiber web.

[0236] Clause 141. A permanent system for clothing articles according to any one of Clauses 137 to 140, wherein the first group of fibers is a re-granulated polymer fiber extruded from a granulation byproduct derived from the second group of fibers, and wherein the third group of fibers is a re-granulated polymer fiber extruded from a granulation byproduct derived from the first group of fibers.

[0237] Clause 142. A permanent system for clothing articles according to any one of Clauses 137 to 141, wherein the first group of fibers, the second group of fibers, and the third group of fibers share a common set of fibers.

[0238] Clause 143. A permanent system for clothing articles according to any one of Clauses 137 to 142, wherein the first clothing article includes an outermost surface, the outermost surface including a first surface of the nonwoven textile, and wherein the first clothing article includes an innermost surface, the innermost surface including a second surface of the nonwoven textile.

[0239] Clause 144. A permanent system for clothing articles, comprising: a first clothing article formed of a first nonwoven textile, the first nonwoven textile being constructed of a first set of fibers, at least a portion of the first set of fibers originating from a second set of fibers previously formed and no longer present in the clothing article, the first set of fibers comprising one or more fibers having an average short fiber length and a short fiber length standard deviation of about 5 mm to about 30 mm, and fibers having a uniform short fiber length; and a second clothing article formed of a second nonwoven textile, the second nonwoven textile being constructed of a third set of fibers, at least a portion of the third set of fibers originating from the first set of fibers of the first clothing article, the second set of fibers comprising one or more fibers having an average short fiber length and a short fiber length standard deviation of about 5 mm to about 30 mm, and fibers having a uniform short fiber length.

[0240] Clause 145. A permanent system for clothing articles according to Clause 144, wherein the first set of fibers is arranged in a first fiber web, and wherein the third set of fibers is arranged in a second fiber web.

[0241] Clause 146. A permanent system for clothing articles according to any one of Clauses 144 to 145, wherein the second group of fibers comprises a fiber arrangement.

[0242] Clause 147. A permanent system for clothing articles according to Clause 146, wherein the fiber arrangement of said second group of fibers comprises a fiber web, a knitted textile, or a woven textile.

[0243] Clause 148. A permanent system for clothing articles according to any one of Clauses 144 to 147, wherein the first group of fibers comprises one or more of shredded fibers and re-granulated polymer fibers extruded from granulation byproducts derived from the second group of fibers.

[0244] Clause 149. A permanent system for clothing articles according to any one of Clauses 144 to 148, wherein the third group of fibers comprises one or more of shredded fibers and re-granulated polymer fibers extruded from granulation byproducts derived from the first group of fibers.

[0245] Clause 150. A permanent system for clothing articles according to any one of Clauses 144 to 149, wherein the first clothing article includes an outermost surface, the outermost surface including a first surface of the first nonwoven textile, and wherein the first clothing article includes an innermost surface, the innermost surface including a second surface of the first nonwoven textile.

[0246] Clause 151. A permanent system for clothing articles according to any one of Clauses 144 to 150, wherein the second clothing article includes an outermost surface comprising a first surface of the second nonwoven textile, and wherein the second clothing article includes an innermost surface comprising a second surface of the second nonwoven textile.

[0247] Clause 152. A method of manufacturing a garment article, the method comprising: obtaining a first set of fibers from a garment article that no longer exists, wherein the garment article is formed from a second set of fibers; arranging the first set of fibers in a first fiber web comprising a first nonwoven textile; forming the first nonwoven textile into a first garment article; after forming the first garment article, obtaining a third set of fibers from the first garment article; arranging the third set of fibers in a second fiber web different from the first fiber web, the second fiber web comprising a second nonwoven textile; and forming the second nonwoven textile into a second garment article.

[0248] Clause 153. The method of manufacturing a garment article as described in Clause 152, wherein the garment article that no longer exists includes the fiber arrangement of the second group of fibers.

[0249] Clause 154. The method of manufacturing clothing articles according to Clause 153, wherein the fiber arrangement includes one or more of fiber webs, knitted textiles and woven textiles.

[0250] Clause 155. A method of manufacturing clothing articles according to any one of Clauses 152 to 154, wherein the first group of fibers, the second group of fibers and the third group of fibers share a common set of fibers.

[0251] Clause 156. A method of manufacturing clothing articles according to any one of Clauses 152 to 155, wherein the first group of fibers is a re-granulated polymer fiber extruded from a granulation by-product derived from the second group of fibers, and wherein the third group of fibers is a re-granulated polymer fiber extruded from a granulation by-product derived from the first group of fibers.

[0252] As can be seen from the foregoing, this subject matter is well adapted to achieve all the aforementioned purposes and objectives, as well as other obvious and inherent advantages of the structure. It should be understood that certain features and sub-combinations are useful and can be employed without reference to other features and sub-combinations. This is contemplated by and within the scope of the claims. Since many possible embodiments of the subject matter can be made without departing from the scope of this disclosure, it should be understood that everything set forth herein or shown in the accompanying drawings should be interpreted as illustrative rather than restrictive.

Claims

1. A clothing product, comprising: A nonwoven textile comprising a plurality of fibers having an average short fiber length ranging from 40 mm to 60 mm and a short fiber length standard deviation ranging from 5 mm to 30 mm, wherein the plurality of fibers comprises a first plurality of fibers disposed in a first fiber web and a second plurality of fibers disposed in a second fiber web entangled with the first fiber web, wherein the plurality of fibers are selected from at least one of re-granulated polymer fibers and shredded product fibers, wherein the re-granulated polymer fibers are extruded from granulation or fragmentation byproducts derived from a polymer-containing source, and the shredded product fibers are direct byproducts of shredded fiber-containing products, wherein the first fiber web at least partially forms a first side of the nonwoven textile and comprises the re-granulated polymer fibers, and wherein the second fiber web at least partially forms a second side of the nonwoven textile opposite to the first side and comprises the shredded product fibers.

2. The garment article of claim 1, wherein the first surface of the nonwoven textile forms the outermost surface of the garment article.

3. The clothing article according to claim 1, wherein the first plurality of fibers comprises a first color, and wherein the fibers of the second plurality of fibers comprise a second color different from the first color.

4. The garment article according to claim 3, wherein the first color is dyed with a textile dye.

5. The clothing article according to claim 3 or 4, wherein the second plurality of fibers comprises a hue and a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

6. The clothing article of claim 1, wherein the plurality of fibers comprises about 25% to about 30% by weight of the nonwoven textile.

7. The garment article of claim 6, wherein the nonwoven textile comprises at least about 50% of the garment article by weight.

8. A clothing product comprising: A nonwoven textile comprising a first surface and an opposing second surface; the first surface forming the outermost surface of the garment article; and the second surface forming the innermost surface of the garment article, comprising at least about 50% by weight of fibers of the nonwoven textile comprising a first plurality of fibers and a second plurality of fibers, the first plurality of fibers having an average short fiber length ranging from 40 mm to 60 mm and a short fiber length standard deviation of 5 mm to 30 mm, the second plurality of fibers having a uniform short fiber length ranging from 40 mm to 60 mm, wherein the first plurality of fibers are arranged in a first fiber web and the second plurality of fibers are arranged in a second fiber web entangled with the first fiber web, wherein the first fiber web at least partially forms the first surface and comprises re-granulated polymer fibers extruded from a granulation or fragment by-product derived from a polymer-containing source, and wherein the second fiber web at least partially forms the second surface and comprises shredded article fibers, the shredded article fibers being a direct by-product of shredded fiber-containing articles.

9. The clothing article of claim 8, wherein the first plurality of fibers are derived from a shredded fiber source.

10. The clothing article of claim 9, wherein the second plurality of fibers comprises one or more of virgin extruded polyethylene terephthalate (PET) and re-extruded PET.

11. The clothing article of claim 10, wherein the second plurality of fibers comprises a first color dyed by a spinning solution.

12. The clothing article of claim 11, wherein the first plurality of fibers comprises a second color different from the first color.

13. The clothing article of claim 12, wherein the second color comprises a hue and a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

14. A method for manufacturing a nonwoven textile, the method comprising: The process involves forming a first plurality of fibers having an average short fiber length ranging from 40 mm to 60 mm and a short fiber length standard deviation ranging from 5 mm to 30 mm; forming a second plurality of fibers having a uniform short fiber length ranging from 40 mm to 60 mm; using the first plurality of fibers and the second plurality of fibers to form a first fiber web and a second fiber web; and entanglement of the first fiber web and the second fiber web to form the nonwoven textile, wherein the first fiber web at least partially forms a first face of the nonwoven textile and includes re-granulated polymer fibers extruded from granulation or fragment by-products derived from a polymer-containing source, and wherein the second fiber web at least partially forms a second face of the nonwoven textile opposite to the first face and includes shredded product fibers, the shredded product fibers being a direct by-product of shredded fiber-containing products.

15. The method of manufacturing a nonwoven textile according to claim 14, wherein the first plurality of fibers are formed by shredding the article.

16. The method of manufacturing a nonwoven textile according to claim 15, wherein the first plurality of fibers comprises one or more fiber blocks and one or more non-fiber materials.

17. The method of manufacturing nonwoven textiles according to claim 16, wherein the one or more non-fibrous materials include one or more inks and elastomer materials.

18. The method of manufacturing nonwoven textiles according to claim 14, wherein the second plurality of fibers are formed by re-extrusion granulation of polyethylene terephthalate (PET).

19. The method of manufacturing nonwoven textiles according to claim 18, wherein after re-extruding the granulated PET, the extruded fibers are cut into uniform lengths to form the second plurality of fibers.

20. A clothing article, comprising: A nonwoven textile comprising a first side and an opposing second side; the first side comprising the outermost side of the garment article; and the second side comprising the innermost side of the garment article, wherein at least about 50% by weight of the nonwoven textile comprises fibers selected from at least one of re-granulated polymer fibers and shredded product fibers, the re-granulated polymer fibers being extruded from a granulation byproduct derived from a product containing polyethylene terephthalate (PET), and the shredded product fibers being a shredded byproduct containing PET, and wherein the nonwoven textile comprises a first fiber web and a second fiber web entangled with the first fiber web, wherein the first fiber web substantially forms the first side and comprises the re-granulated polymer fibers, and wherein the second fiber web substantially forms the second side and comprises the shredded product fibers.

21. The clothing article of claim 20, wherein the nonwoven textile has a stiffness in the range of about 0.3 kgf to about 0.5 kgf.

22. The clothing article of claim 20, wherein the re-granulated polymer fiber comprises at least 5% by weight of a crystallinity modifier.

23. The garment article of claim 20, wherein the shredded article fibers comprise an average short fiber length ranging from 40 mm to 60 mm and a standard deviation of 5 mm to 30 mm.

24. The clothing article of claim 20, wherein the recycled polymer fiber comprises a first color, and wherein the shredded article fiber comprises a second color different from the first color.

25. The garment article of claim 24, wherein the shredded article fibers comprise a hue and a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

26. The clothing article of claim 20, wherein the nonwoven textile comprises more than 50% by weight of the clothing article.

27. A nonwoven textile having a first side and an opposing second side, the nonwoven textile comprising: A first fiber web and a second fiber web entangled with the first fiber web; The first fiber web substantially forms the first surface, and the first fiber web includes re-granulated polymer fibers having a first color, said re-granulated polymer fibers being extruded from granulation or fragment by-products derived from a polymer-containing source; Furthermore, the second fiber web substantially forms the second surface, the second fiber web comprising shredded product fibers having a second color different from the first color, the shredded product fibers being a direct byproduct of shredded fiber-containing products, wherein at least a portion of the shredded product fibers entangled with the regranulated polymer fibers and having the second color is visible on the first surface.

28. The nonwoven textile of claim 27, further comprising a third fiber web entangled with at least the second fiber web, wherein the third fiber web comprises re-granulated polymer fibers, and wherein the third fiber web is positioned between the first fiber web and the second fiber web.

29. The nonwoven textile of claim 27, wherein the first surface of the first fiber web comprises the outermost surface of the garment article.

30. The nonwoven textile of claim 29, wherein the first surface comprises at least 75% of the outermost surface of the garment article by surface area.

31. The nonwoven textile of claim 27, wherein the shredded product fibers comprise a hue and a plurality of chromaticities of the hue, a plurality of colors of the hue, or a combination thereof.

32. A nonwoven textile, comprising: A first fiber web and a second fiber web entangled with the first fiber web, both the first fiber web and the second fiber web comprising fibers selected from at least one of re-granulated polymer fibers and shredded product fibers, the re-granulated polymer fibers being extruded from a granulation by-product derived from PET-containing products, and the shredded product fibers being a shredded by-product derived from PET-containing products; And an elastomeric layer positioned between the first fiber web and the second fiber web, the elastomeric layer comprising a recycled thermoplastic elastomer, wherein the first fiber web at least partially forms a first side of the nonwoven textile and comprises the recycled granulated polymer fibers, and wherein the second fiber web at least partially forms a second side of the nonwoven textile opposite to the first side and comprises the shredded product fibers.

33. The nonwoven textile according to claim 32, wherein the nonwoven textile has a stiffness in the range of about 0.3 kgf to about 0.5 kgf.

34. The nonwoven textile of claim 32, wherein the re-granulated polymer fiber comprises at least 5% by weight of a crystallinity modifier.

35. The nonwoven textile of claim 32, wherein the shredded product fibers comprise an average short fiber length ranging from 40 mm to 60 mm and a standard deviation of 5 mm to 30 mm.

36. The nonwoven textile according to claim 32, wherein the nonwoven textile has about 45 M 2 K / W to approximately 95 M 2 Thermal resistance (Rct) in the K / W range.

37. The nonwoven textile of claim 36, wherein the nonwoven textile has a basic weight in the range of about 160 GSM to about 200 GSM.

38. The nonwoven textile of claim 32, wherein the nonwoven textile comprises at least about 50% by weight of the re-granulated polymer fiber, the shredded product fiber, or a combination thereof.

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