Textile Recycling

Abstract

A textile recycling method receives textile waste to be recycled, sorts the waste to separate cellulose-containing products from non-cellulose-containing products, and adjusts the size of at least a portion of the cellulose-containing products to generate a raw material. The raw material is treated in a cellulose solvent reactor having at least one ionic liquid. The ionic liquid dissolves the cellulose bonds between the molecules of the raw material to generate a spinning solution. Cellulose fibers dissolved in a cellulose-containing spinning solution solution are extruded in a cellulose coagulation bath to reorganize at least a portion of the cellulose fibers, and the reorganized fibers are wet-spun to generate a continuous cellulose thread that is commercially indistinguishable from a virgin fiber thread. Synthetic fiber materials are vacuum-extracted or mechanically extracted from the cellulose-containing solution and recycled to form a continuous synthetic fiber thread. The original color of the textile waste to be recycled can be retained or removed, and new colors can be added.

Description

Technical Field

[0001] The present disclosure relates generally to textile recycling. More particularly, but not limited to, the present disclosure relates to the recovery of, for example, cellulosic fiber components from manufactured materials by ionic liquids. Background Art

[0002] According to the U.S. Environmental Protection Agency (EPA), 25 billion pounds of textile waste is generated in the United States each year. Of this waste, only 15% is currently reused, and of that reused waste, approximately 14% is downcycled (such as used in mattresses, seat cushion fillings, etc.), and approximately 1% is chemically recycled. It is estimated that textile waste accounts for approximately eight percent (8%) of the total landfill waste.

[0003] It is well known that polyester / cotton blends account for a large proportion of textiles on the market. In 2019, the EPA has predicted that the demand for textile fibers will grow at a rate of three percent (3%) per year. The amount of textile waste that ends up in landfills is huge. Currently, the recycling process for cotton / polyester blends includes depolymerizing or dissolving one of the components. Some common industrial methods subject the polyester to alcoholysis, hydrolysis, or glycolysis reactions. Other common industrial methods degrade cellulose under acidic conditions. Dimethyl sulfoxide (DMSO) is currently a common solvent for dissolving polyester. However, DMSO is toxic to humans and other animals, this method requires high temperatures (e.g., over 150 degrees Celsius), and DMSO will also affect the properties of the remaining cellulose component.

[0004] A less toxic method currently used by the industry to recycle cotton / polyester blends is to place the material in hydrochloric acid. The hydrochloric acid hydrolyzes the cotton and produces a microcrystalline powder. The microcrystalline powder can then be separated from the polyester fibers, allowing the polyester fibers to be re-spun. In this process, a large portion of the cotton is wasted.

[0005] Certain aspects of the background art and related art that may be helpful in understanding the present disclosure are described in the following publications:

[0006] Published PCT patent application WO2018 / 115584A1, which describes a method for separating cellulose and polyester from a material mixture using a first portion of an ionic liquid based on a superbase;

[0007] Article entitled "Ionic liquids: a milestone on the road to green recycling of biocellulose", Rieland, JM and Love, BJ, Resources, Conservation & Recycling, 155, 104678. DOI: 10.1016 / j.resconrec.2019.104678 (2020);

[0008] Article entitled “Recycling Textiles: Use of Ionic Liquids in the Separation of Cotton-Polyester Blends”, Silva, R.D., Wang, X., and Byrne, N. RSC Adv., 4(55), 29094-29098. DOI: 10.1039 / c4ra04306e (2014);

[0009] Article entitled “Recycling of cotton fibers separated from waste blended fabrics”, Shuhua, W., Xiaoying, Y., Xiaogang, C., Wensheng, H., and Mei, Journal of Natural Fibers, 17(4), 520-531. DOI: 10.1080 / 15440478.2018.1503130 (2018);

[0010] Article entitled “Improving enzymatic degradation in textile dyes using ionic liquid surfactants”, Bento, RM, Almeida, MR, Bharmoria, P., Freire, MG, and Tavares, AP. Separation and Purification Technology, 235, 116191. DOI: 10.1016 / j.seppur.2019.116191 (2020);

[0011] Article entitled "Processing of cellulose using ionic liquids", Hermanutz, F., Vocht, MP, Panzier, N., and Buchmeiser, MR, Polymer Materials and Engineering, 304(2), 1800450. DOI: 10.1002 / mame.201800450 (2018);

[0012] “Upcycling of waste textiles into regenerated cellulose fibers: The impact of pretreatment methods”, Ma, Y., Rosson, L., Wang, X. and Byrne, N., Journal of the Textile Society, 111(5) 630-638. DOI: 10.1080 / 00405000.2019.1656355 (2019);

[0013] Article entitled "Evaluation of chemical recycling of post-consumer cellulosic textile waste based on cellulose degree of polymerization and molar mass distribution", Wedin, H., Lopes, M., Sixta, H. and Hummel, M., Journal of Textile Research, 89(23-24), 5067-5075. doi:10.1177 / 0040517519848159(2019);

[0014] Article titled “Circular Textiles: A Closed-Loop Process for Fiber-to-Fiber Wet Spinning from Recycled Cotton for Denim,” Ma, Y., Zeng, B., Wang, X., and Byrne, N., ACS Sustainable Chemistry & Engineering, DOI: 10.1021 / acssuschemeng.8b06166 (2019);

[0015] Article entitled "Cellulose regeneration and chemical recycling: Closing the "cellulose gap" using environmentally friendly solvents", Seoud, OAE, Kostag, M., Jedvert, K., and Malek, NI, Macromolecular Materials and Engineering, 305(4), 1900832. DOI: 10.1002 / mame.201900832(2020);

[0016] “Upcycling of cotton-polyester blended textile waste into novel man-made cellulosic fibers,” Haslinger, S., Hummel, M., Anghelescu-Hakala, A., Maattanen, M., and Sixta, H., Waste Management, 97, 88-96. DOI: 10.1016 / j.wasman.2019.07,040 (2019);

[0017] Select data published on the World Wide Web at www.epa.gov / facts-and-figures-about-matehals-waste-and-recycling / textiles-material-specific-data on October 30, 2019, and entitled “Textiles: Material Specific Data. EPA, Environmental Protection Agency”, and

[0018] Select data published on the World Wide Web website https: / / commons.wikimedia.org / wiki / File:Cellulose_strand.svg on September 1, 2022 and titled "Cellulose chain".

[0019] All the subject matter discussed in the background section is not necessarily prior art, nor should it be assumed that it is prior art simply because it is discussed in the background section. Therefore, problems existing in the prior art or problems related to these subjects discussed in the background section should not be considered prior art unless it is clearly stated to be prior art. Instead, the discussion of any subject matter in the background section should be considered as part of the inventor's method of solving the specific problem, which method itself may also be inventive. Summary of the invention

[0020] The following is a summary of the present disclosure, which provides an introductory understanding of some features and background. This summary is not intended to identify the key or important content of the present disclosure or to delimit the scope of the present disclosure. This summary introduces certain concepts of the present disclosure in a simplified form as a preface to a more detailed description later.

[0021] The apparatus, method, and system embodiments described in the present disclosure (ie, the teachings of the present disclosure) enable energy-efficient, environmentally friendly textile recycling.

[0022] In a first embodiment, a textile recycling method comprises: receiving a textile to be recycled; adjusting the size of at least a portion of the cellulose-containing product to generate a raw material; treating the raw material in a cellulose solvent reactor having at least one ionic liquid to generate a spinning solution, wherein the treatment comprises at least partially dissolving some or all of the intermolecular cellulose bonds in the raw material, thereby generating a cellulose-containing solution having cellulose fibers dissolved in at least one ionic liquid; extracting the spinning solution in a cellulose coagulation bath to reorganize at least a portion of the dissolved cellulose fibers; and wet spinning at least a portion of the reorganized cellulose fibers into continuous fiber strands.

[0023] In some cases of the first embodiment, the method also includes: vacuum extracting or mechanically filtering insoluble materials from the cellulose solvent reactor; separating synthetic fiber materials from the insoluble materials; and recycling the synthetic fiber materials into a continuous synthetic line.

[0024] In some cases of the first embodiment, the method also includes: adding at least one material to the raw material, the material being at least one of a dye, an inert identification chemical, a water repellent, and a flame retardant. Sometimes, the method also includes: adding at least one material to the cellulose coagulation bath, the material being at least one of a dye, an inert identification chemical, a water repellent, and a flame retardant, and sometimes the method includes: sorting the textiles to be recycled to separate the cellulose-containing products from the non-cellulose-containing products. In these and other embodiments, the method includes: sorting the textile to be recycled to separate a second type of cellulose-containing products, wherein the cellulose-containing products have a first type of cellulose fibers, and the second type of cellulose-containing products have a second type of cellulose fibers, and the first type of cellulose fibers are different from the second type of cellulose fibers; adjusting the size of at least a portion of the second type of cellulose-containing products to generate a second raw material; treating the second raw material in a second cellulose solvent reactor having at least one second ionic liquid to produce a second spinning solution, wherein the treating the second raw material includes at least partially dissolving some or all of the intermolecular cellulose bonds of the second raw material, thereby generating a second cellulose-containing solution having second cellulose fibers dissolved in at least one second ionic liquid; extracting the second spinning solution in a second cellulose coagulation bath to reorganize at least a portion of the dissolved second cellulose fibers; and wet spinning at least a portion of the reorganized cellulose fibers and at least a portion of the reorganized second cellulose fibers into a continuous cellulose mixed thread.

[0025] In some cases of the first embodiment, the method also includes: based on the sorting, directing the operation of at least one conveyor belt, gate, pump, valve, fan, motor, suction device, filter or timer. In these or other embodiments, the method also includes: based on the sorting, directing the operation of at least one electronically controllable circuit. Sometimes in some embodiments, the method includes: initializing a computing controller, which is used to direct the operation of the textile recycling method. In more cases, the cellulose solvent reactor is sometimes configured as a plurality of reaction vessels, and wherein processing the raw material includes receiving a portion of the raw material in each of the plurality of reaction vessels and generating a portion of the spinning solution in each of the plurality of reaction vessels.

[0026] In a second embodiment, a textile recycling system includes a textile pretreatment structure for receiving a textile to be recycled, wherein the textile to be recycled has at least a portion of a cellulose-containing product, and the textile pretreatment structure further adjusts the size of at least a portion of the cellulose-containing product to generate a raw material; a cellulose solvent reactor for receiving the raw material and at least one ionic liquid, and further making the raw material and at least one ionic liquid into a spinning solution by at least partially dissolving part or all of the intermolecular cellulose bonds in the raw material, thereby generating a cellulose-containing solution, wherein the cellulose fibers in the solution are dissolved in at least one ionic liquid; a cellulose coagulation bath for receiving the cellulose-containing solution, and further extracting the spinning solution by reorganizing at least a portion of the dissolved cellulose fibers; and a wet spinning spinneret subsystem for wet spinning at least a portion of the recombined cellulose fibers into a continuous cellulose thread.

[0027] In some cases of the second embodiment, the system includes a vacuum extraction or mechanical filtration subsystem for removing insoluble materials from the cellulose solvent reactor. In some cases, the system includes a controller for directing the operation of the cellulose solvent reactor. In these and other cases, the cellulose solvent reactor further includes: a plurality of reaction vessels for simultaneous operation, wherein each of the plurality of reaction vessels is used to receive a portion of the raw materials and is further used to generate a portion of the spinning solution. And sometimes in these cases, each of the plurality of reaction vessels is operated independently of the other reaction vessels in the plurality of reaction vessels.

[0028] In a third embodiment, a cellulose solvent reactor comprises: a container for containing a flowable raw material slurry formed by an ionic liquid and a cellulose-containing raw material; a control system for determining the cellulose concentration of the flowable raw material slurry; at least one sensor coupled to the control system for outputting electromagnetic energy to the container; at least one sensor coupled to the control system for providing data showing how much electromagnetic energy from the at least one sensor has passed through the flowable raw material slurry, and an output port formed in the container, the output port being used to provide a spinning solution to a coagulation bath, wherein the spinning solution is formed when part or all of the intermolecular cellulose bonds of the flowable raw material slurry are dissolved in the ionic liquid as cellulose fibers.

[0029] In some cases of the third embodiment, the cellulose solvent reactor further includes: a heating circuit for heating the flowable raw material slurry in the container. In some cases, the cellulose solvent reactor further includes: a stirring structure for stirring the flowable raw material slurry in the container. And in some other cases, the cellulose solvent reactor further includes: one or more reaction probes partially or completely arranged in the container, and the one or more reaction probes are used to generate at least one of pressure data, temperature data and conductivity data to indicate the cellulose concentration of the flowable raw material slurry. Sometimes, the cellulose solvent reactor further includes: a plurality of reaction vessels operating simultaneously, wherein each reaction vessel of the plurality of reaction vessels is used to receive a portion of the flowable raw material slurry and is further used to generate a portion of the spinning solution.

[0030] This brief summary describes some concepts in a simplified form that are described in more detail in the detailed description. This brief summary does not limit the scope of the claimed subject matter, but the scope of the claimed subject matter is determined by the text of the claims themselves. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Non-limiting and non-exhaustive embodiments are described with reference to the following figures, wherein like reference numerals in the various views refer to like parts unless otherwise specified. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements are selected, enlarged, and positioned to improve the readability of the drawings. For ease of identification in the drawings, specific shapes of the drawn elements have been selected. One or more embodiments are described below with reference to the drawings, wherein:

[0032] Figure 1 is a schematic diagram of the molecular structure of cellulose in one embodiment of a cellulose chain;

[0033] Figure 2A It is an implementation of the first unified textile recycling system;

[0034] Figure 2B It is another way to implement a unified textile recycling system;

[0035] Figure 2C is one embodiment of a first batch reactor in a unified textile recycling system; and

[0036] Figure 2D It is another embodiment of a batch reactor in a unified textile recycling system;

[0037] Figure 3 is an embodiment of a data flow diagram representing the workflow through a unified textile recycling system.

[0038] In this disclosure, for the sake of brevity, certain collections of related drawings may be referred to as single, multi-part drawings to facilitate a clearer understanding of the illustrated subject matter. For example, Figures 2A-2D May be referred to as Figure 2 individually or collectively. DETAILED DESCRIPTION

[0039] By referring to this specific embodiment and the accompanying drawings, the present disclosure can be more easily understood. The terms used herein are only used to describe specific embodiments and do not limit the claims unless a court or recognized institution with jurisdiction determines that these terms are restrictive. Unless explicitly defined in this disclosure, the terms used herein should be given the conventional meaning known in the relevant technical field.

[0040] In the following description, certain specific details are set forth in order to provide a thorough understanding of the various disclosed embodiments. However, those skilled in the relevant art will recognize that the embodiments can be implemented without one or more of these specific details, or using other methods, components, materials, etc. In other cases, certain logical and other structures associated with textile raw material recycling, such as barrels, pumps, spinnerets, conveyors, wired and wireless communication protocols, wired and wireless transceivers, radio equipment, communication ports, geo-location and optimization process mapping algorithms, etc., are not shown or described in detail to avoid unnecessarily obscuring a more detailed description of the embodiments. In these and other cases, well-known structures associated with computing systems, including client and server computing systems and networks, are not shown or described in detail to avoid unnecessarily obscuring a more detailed description of the embodiments.

[0041] The apparatus, method, and system embodiments described in the present disclosure (i.e., the teachings of the present disclosure) enable energy-efficient, environmentally friendly textile recycling. Textile waste is a global problem. Textile waste accounts for a large portion of landfill volume. The demand for textiles continues to increase, which places a demand on agriculture to produce more cotton. The industrial standard for spinning and dyeing cotton fibers is both dangerous and energy-intensive. Viscose wet spinning is a common industrial process that consumes large amounts of water, time, and energy.

[0042] Ionic liquids have been shown to dissolve organic matter such as cellulose fibers. Ionic liquids also show good promise in separating waste polymer-cellulose textile mixtures. When the cellulose concentration is high enough, ionic liquid cellulose solutions can be wet-spun to produce regenerated fibers. The remaining non-cellulose polymer fibers can also be re-spun and have properties comparable to virgin polyester fibers. The methods described in the present disclosure have shown the beneficial effects of retaining dyes, if necessary, or removing original pigments and producing neutral fibers, relieving industrial pressure in the dyeing process and saving time, water and energy.

[0043] With the U.S. Environmental Protection Agency (EPA) estimating that 25 billion pounds of textile waste is generated annually in the United States, and further estimating that only 15% of this waste is currently recycled, research into regenerating cellulose from textile waste is extremely important.

[0044] It is estimated that textile waste accounts for approximately eight percent (8%) of total landfill waste. It is well known that polyester / cotton blended textiles account for a large proportion of the market. The amount of polyester / cotton blended textile waste that ends up in landfills is huge. In addition, the increasing use of wood in the production of cellulose fibers in industry has put pressure on international forest land and landfill space. Utilizing recycled fibers from textile waste can meet future demand for textile production and reduce the total amount of textile waste.

[0045] Dyeing textiles requires a lot of energy and water. If the recycled fibers can retain their color, then the production of recycled fibers from textile waste can further reduce the energy consumption of textile production in the future.

[0046] The present disclosure describes a substantially or completely environmentally friendly textile recycling method that uses ionic liquids to dissolve the cotton component of certain textiles into a cotton solution. In some cases, the cotton solution contains more than one and a half percent (0.5%) cotton. In some cases, the cotton solution contains about one to two percent (1-2%) cotton. In other cases, the cotton solution contains more than two percent (2%) cotton. In other cases, the cotton solution contains less than five percent (5%), less than ten percent (10%), less than twenty-five percent (25%), less than fifty percent (50%) or less than one hundred percent (100%) of other percentages of cotton.

[0047] Once the cotton content of the cotton solution is dissolved, these same environmentally friendly methods or different methods (such as mechanical separation, such as vacuum filtration, centrifugation, etc.) can filter out or otherwise recover some or all of the polyester fibers. The recovered polyester fibers can be re-spun.

[0048] In some cases, after removing (e.g., by filtering or other methods) some or all of the non-cellulose-containing components, the cotton solution can be further concentrated. In some cases, the cotton solution can be concentrated from raw fiber to contain fifteen to seventeen percent (15-17%) cotton. Alternatively, or in addition, the cotton solution can be concentrated from raw fiber to contain more than five percent (5%), more than ten percent (10%), more than twenty-five percent (25%), or even more than fifty percent (50%) cotton, which allows the cotton fibers to be re-spun as well. According to the inventors' observations, the regenerated cotton and polyester fibers produced in this manner are indistinguishable from virgin fibers.

[0049] Improved optimization of ionic liquid methods for textile recycling includes using N-methylmorpholine-N-oxide (NMMO), 1-allyl-3-methylimidazolium chloride (AMIM-CL) or 1-butyl-3-methylimidazolium acetate (BMIM-OAc) to dissolve cotton fibers in textile mixtures. In some cases, using one or more of these ionic liquids produces solutions with cellulose content of up to thirty-five percent (35%) or more.

[0050] The rheological properties of the highly concentrated cellulose solution allow it to be wet spun without further processing. A solution capable of being directly wet spun eliminates one or more steps to increase the concentration of the cellulose solution from raw fiber and allows all other wasted cotton fibers to be recovered without mixing in virgin fiber.

[0051] One of the reasons why ionic liquids are attractive for dissolving cellulose is that certain physical properties of ionic liquids can be tailored by selecting the ions and substituents on the cationic groups R. Thus, the water solubility of imidazolium, acetate oxide, and methoxide ionic liquids can be tailored to the selected needs of specific cellulose fibers according to the degree of polymerization.

[0052] Figure 1 is a schematic diagram of the cellulose molecular structure in one embodiment of a cellulose chain. Cellulose fibers are held together by hydrogen bonds. Synchrotron X-ray and neutron diffraction data show that there are intermolecular hydrogen bonds between the hydroxyl group on C6 in the cellulose molecule and the O atom on C3 of the adjacent cellulose chain. When these hydrogen bonds are broken, the cellulose fibers will separate and dissolve in the ionic liquid. This separation and dissolution is completed when the anions in the ionic liquid form hydrogen bonds with the hydroxyl groups in several adjacent fiber chains, causing the negatively charged anion-cellulose complexes to repel each other and separate. In this case, the cellulose fibers are not chemically decomposed; instead, the cations in the ionic liquid compete with the intermolecular binding sites of the cellulose fibers to form H bonds, and this disruption causes the cellulose fibers to dissolve in the ionic liquid. After separating the cellulose fibers from the original polyester-cotton blend to be recycled, the newly dissolved cellulose fibers can be easily re-spun using the ionic liquid / cellulose solution as the spinning stock.

[0053] It is noteworthy that the various mechanisms for dissolving cellulose fibers in ionic liquids described in the present disclosure are different from traditional chemical recycling. Chemical recycling of textiles involves the use of a catalyst to depolymerize one of the two polymers in a polyester-cotton blend. The embodiments described herein do not require any such catalyst and do not significantly depolymerize or affect the degree of polymerization of the cellulose. That is, the application of the teachings of the present disclosure to decompose and recycle cellulose fiber materials has an even smaller impact on the degree of polymerization than any natural depolymerization (e.g., by sunlight, physical friction, washing, etc.) that occurs during the daily use of textiles.

[0054] The inventors have learned that, in some cases, cotton and polyester fibers can be separated from each other on a commercial scale and by a unified process, and separated into fibers that are indistinguishable from the original fibers. For example, solutions of 1-allyl-3-methylimidazolium chloride (AMIM-CL) and 1-butyl-3-methylimidazolium acetate (BMIM-OAc) both have the property of dissolving cellulose, and both solutions have been thoroughly dried to a water content of less than 0.2%. The inventors have further learned that neither AMIM-CL nor BMIM-OAc dissolves polyester.

[0055] The efficacy of ionic liquids in separating cotton and polyester fibers has been tested by oven drying multiple yarn samples and preparing various yarn solutions in BMIM-OAc and AMIM-CL. Actual or other expected example temperatures for testing include "room temperature", temperatures between about ten degrees Celsius (10°C) and about one hundred and seventy-five degrees Celsius (175°C), temperatures of about eighty degrees Celsius (80°C), and other temperatures, including temperatures below ten degrees Celsius (10°C) and above one hundred and seventy-five degrees Celsius (175°C). Room temperature, as the term is used in this application, refers to the general ambient temperature of air in an industrial environment where textile recycling is performed, which can be heated or cooled.

[0056] Exemplary yarn solutions include yarn samples having a concentration of about two percent (2%), about four percent (4%), about six percent (6%), about eight percent (8%), and about ten percent (10%) by weight. Other concentrations, including concentrations less than two percent (2%) and greater than ten percent (10%), have also been tested or otherwise anticipated by the inventors. During testing and certain other ongoing analyses, yarn samples are retained in various ionic liquid solutions for a selected time. In some cases, the time in the solution is about 5 minutes (5min.) and about 10 hours (10hr.). In these and other cases, the time in the solution is more than about 30 minutes (30min.) or less than about 8 hours (8hr.). In at least one example case, the time in the solution is about six hours (6hr.), and in at least another example case, the time in the solution is less than two hours (2hr.). After a selected time in the solution, solids are removed from the subject solution by known methods, rinsed, and weighed, and the quality of at least a portion of the recycled fiber (such as recycled cotton) is characterized. Characterization methods included one or more of dynamic mechanical analysis (DMA), thermogravimetric analysis (TGA), and Fourier transform infrared spectroscopy (FTIR). Test results were compared to data from virgin fiber and no differences were found. Other testing and characterization methods were also considered.

[0057] In addition to the recycled cotton fibers, the recycled polyester fibers were characterized by various methods, including but not limited to differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), carbon nuclear magnetic resonance (NMR), and Fourier transform infrared spectroscopy (FTIR). The characterization results of the recycled polyester fibers were compared with the virgin fibers, and no differences were found. Therefore, the inventors have learned that, at least in some cases, AMIM-CL exhibits a higher yield of selective dissolution of cotton components in cotton / polyester blends than BMIM-OAc on a commercial scale and through a unified process, and that the use of AMIM-CL and BMIM-OAc ionic liquids in commercial processes can produce extremely high yields of recycled cellulose and polyester fibers.

[0058] The inventors have studied and learned from several other strategies to meet the growing demand for cellulose fibers in industry by regenerating dissolved cellulose in ionic liquids and alkaline solutions. For example, chemical recycling of poly-cotton blends has been studied. Such chemical recycling may provide an environmentally friendly way to fill the cellulose gap, but the inventors have not yet found that this method can provide commercial-scale recycling through a unified process. The chemical recycling mechanism for recycling cellulose fibers is through depolymerization and preferential dissolution. That is, although it is known that ionic liquids can successfully completely dissolve cellulose polymers with very different degrees of polymerization, other chemical methods can also be used to produce regenerated cellulose fibers. For example, other methods include chemically or physically dissolving cellulose fibers in an alkaline bath. In at least one case studied, viscose rayon can be produced by a chemical dissolution method in which cellulose fibers are regenerated from cellulose xanthate dissolved in an acid bath. In another case, Lyocell fibers are produced by completely physically dissolving cellulose fibers in N-methylmorpholine-N-oxide hydrate, after which the Lyocell fibers are regenerated in a water bath.

[0059] The inventors have also learned that in some cases, ionic liquids can be used to dissolve cotton fibers in denim on a commercial scale and through a unified process. New fibers can be generated by one or more known methods, such as wet spinning. Some of these unified methods for recycling denim can be performed in a manner that retains the original color of the fiber, and others of these unified methods can be performed in a manner that removes the original color to generate neutral fibers. In at least one exemplary use case, the buyer of the recycled fiber is the original manufacturer of the recycled product. In this way, the original manufacturer can use the recycled fiber with the original color without re-dyeing or other coloring treatment of the raw materials used to make new products. Of course, other use cases can also be considered.

[0060] At least one method of recycling denim uses dimethyl sulfoxide (DMSO) and an ionic liquid (such as AMIM-CL, BMIM-OAc or other ionic liquids) to dissolve the cellulosic fibers in the denim waste. Including DMSO as a co-solvent in the unified process can result in a solution with reduced viscosity, which can be used as a more advantageous or more versatile spinning solution (SD), which in some cases is the first component of the wet spinning process in textile production. In addition to reducing viscosity, or in the alternative, DMSO or other co-solvents can be used to increase viscosity, change the thermal characteristics of a selected reaction, or provide other still desirable rheological properties to the spinning solution. The spinning solution is a dissolved polymer solution that is formed before the solution is spun into filaments using a wet spinning process. In many cases, this unified method saves energy in the spinning process of the regenerated fibers.

[0061] In some cases, the recycled cotton fiber is pre-treated by cutting, tearing, chopping, pulverizing, grinding or other means. The pre-treatment may cause the material to become fragments, lumps, tufts, particles, fine powders or other forms. Most or all of the constituent elements (such as fragments, lumps, tufts, particles, etc.) of the pre-treated material may have a nominal size between about one hundred microns (100 μ) and about one centimeter (1 cm). In some cases, the constituent elements have a nominal size less than about 200 microns. In another case, it is expected that the constituent elements have a nominal size less than about 100 microns (100 μ) or greater than about 1 centimeter (1 cm).

[0062] In some cases, the pretreated material is immersed in an aqueous NaOH solution at a selected temperature, rinsed, for example, with deionized water, until a neutral pH is restored, and then dried using, for example, an oven, a radiant heating element, a forced air system, or other drying means. The selected temperature may be between about ten degrees Celsius (10° C.) and about one hundred and fifty degrees Celsius (150° C.). In some cases, the selected temperature is about ninety degrees Celsius (90° C.). In other cases, the selected temperature is less than about ten degrees Celsius (10° C.) or greater than about one hundred and fifty degrees Celsius (150° C.). In some cases, the selected temperature is room temperature.

[0063] After pretreatment, optionally including any or all of soaking, washing, pH balancing and drying, in some cases of a unified commercial recycling process, the treated fiber is dissolved in a solvent and ionic liquid solution at a selected temperature for a selected time. In at least one case, the solvent and ionic liquid solution is a 1:4 solution of DMSO and BMIM-OAc, the selected temperature is about 80 degrees Celsius (80°C), and the selected time is about 30 minutes (30 minutes). In other cases, the selected temperature can be between about 60 degrees Celsius (60°C) and about 100 degrees Celsius (100°C), however, temperatures below 60 degrees Celsius (60°C) and above 100 degrees Celsius (100°C) are expected. In these other cases, the selected time can be between about 5 minutes (5min.) and about 2 hours (2hr.), however, times below 5 minutes (5min.) and above 2 hours (2hr.) are also expected.

[0064] According to specific tests, studies and analyses of various pretreatment methods for producing spinning solutions, the inventors have learned that the recyclability of textile raw materials is affected by the rheological properties of the cellulose-containing solution (such as deformability, variability, fluidity, viscosity and other fluid parameters). The rheological properties of the cellulose-containing solution (such as the spinning solution) are found to be affected by temperature, polymer concentration, degree of polymerization, addition of co-solvents (such as DMSO, dimethylformamide (DMF), γ-butyrolactone (GBL), N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAc), etc.) and other factors. In some cases, the degree of polymerization of the fiber can be measured and recorded using an Ostwald viscometer. In some cases, the rheological properties of the fiber can be analyzed and recorded on a rheometer. In these and other cases, the mechanical properties of the recycled fiber can be analyzed using one or more of a load cell, a scanning electron microscope (SEM), a torsion meter, a dynamometer, a Coriolis flowmeter and other similar devices. It is also contemplated that other testing equipment may be used to determine one or more physical properties of the regenerated cellulose fibers. In tests performed by the inventors using various teachings of the present disclosure, the mechanical properties of the recycled fibers were commercially indistinguishable from comparable virgin fibers.

[0065] As taught in the present disclosure, cellulose dissolves in acetate and imidazolium ionic compounds. Advantageously, polyester is insoluble in acetate and imidazolium ionic liquids. Therefore, the inventors have learned that one or more of the ionic liquids in the group are suitable solvents for separating cellulose / synthetic blends by dissolving cellulose fibers. Further research has finally shown that a commercial-scale unified method can separate cotton and polyester fibers in high yields, and the generated fibers are commercially indistinguishable from virgin fibers. In some exemplary cases, the recovered cellulose fibers can be re-spun by wet spinning or other processes, and the cellulose / IL solution is a suitable spinning dopant that does not require further processing. Therefore, the teachings of the present disclosure provide a commercial-scale unified method that is efficient and effective for commercially viable industrial uses. The teachings also describe one or more optional features of the unified method. For example, if desired, regenerated cotton fibers can be produced in a manner that retains their original color, thereby making dyeing unnecessary and further improving the efficiency of the method described herein. Alternatively, the recycled polyester fibers can also be wet spun when suspended in an appropriate solvent that provides certain rheological properties that are selective for wet spinning.Other optional features of a commercial scale unified process for recycling textiles are also contemplated.

[0066] Figure 2Ais an embodiment of a first unified textile recycling system 100A. In the system 100A, a single workflow: 1) receiving textile raw materials at a system input, 2) treating the textile by one or more chemical and mechanical actions to recycle the textile into its component fibers, and 3) preparing one or more recycled fiber materials at a system output port. The recycled fiber materials are substantially the same in quality as virgin fibers (e.g., commercially indistinguishable). That is, the recycled fiber materials may be commercially indistinguishable from virgin fibers by one or more techniques generally accepted in the industry (e.g., load cells, scanning electron microscopes (SEMs), torque meters, dynamometers, Coriolis flow meters, and other devices for determining one or more physical properties of textile fibers).

[0067] In at least some cases, the first unified textile recycling system 100A is arranged to produce recycled fibers that retain certain characteristics of their pre-processed state (e.g., color, nominal fiber length, manufacturer identifier, etc.). In other cases, the system 100A is arranged to produce recycled fibers that appear as if they were formed commercially for the first time from newly harvested or otherwise generated raw materials (i.e., virgin fibers). In other cases, the system 100A is arranged to produce recycled fibers with explicitly introduced new characteristics, such as dyes or other color additives, certain fiber lengths, manufacturing identifiers, specific blends, one or more other such characteristics.

[0068] In the embodiment described in the present disclosure, system 100A is arranged to process cotton and cotton blended textiles. However, those skilled in the art will recognize that the system 100A is not limited thereto and can certainly process other materials. That is, by applying the teachings of the present disclosure, substantially all fabric waste (e.g., more than fifty percent (50%), more than seventy-five percent (75%), more than ninety percent (90%), more than ninety-five percent (95%) or more than other percentages greater than ninety-five percent that are considered as waste, dumped in landfills, burned or otherwise destroyed) can be processed according to the teachings of the present disclosure. In this way, the commercial application of the teachings described in the present disclosure can provide economic value in terms of reselling recycled fibers and avoiding landfill fees, significantly reducing global greenhouse gases generated in the natural or man-made destruction of the textile waste process, significantly reducing the use of available land (e.g., for farming or other raw material manufacturing, landfills, etc.), and significantly reducing the use of agricultural water.

[0069] exist Figure 2AIn the first unified textile recycling system 100A, a material receiving station 102 receives textiles to be recycled. The material receiving station can be a shipping platform, a garage, a door, a trash can, a basin, a cart, or any other suitable physical location or structure suitable for receiving textiles to be recycled. In an embodiment of the system 100A, textiles come from municipal collections 104a (e.g., recycling trucks, dump trucks, trucks, etc., generally directed by a city, government, or other entity), from textile mills and clothing factories 104b, from surplus clothing stores 104c or other similar institutions, and from brands, distributors, and retailers 104d. Of course, other sources of textiles to be recycled are also contemplated.

[0070] The received textiles can be individual garments, bulk textiles, pre-treated materials, or any single or mixed form of textiles. The received textiles can be washed or unwashed. The textiles can be sorted or unsorted. The textiles can be dry or wet. Optionally, the received textiles can be recycled in accordance with the teachings of the present disclosure. Any suitable form of pre-sorting, pre-cleaning, and pre-treatment can also be performed to improve the speed, efficiency, or other such characteristics of the systems, devices, and methods taught herein, but such pre-treatment is optional. In other words, according to Figure 2A The system of the embodiment of the system 100A can be arranged to assume or require some pre-treatment of the textile for recycling, but according to Figure 2A Other systems of system embodiment 100A are capable of without such limitations.

[0071] After the textiles are received at the material receiving station 102, some or all of the textiles to be recycled enter a first unified recycling workflow 106a. In at least some embodiments, the first unified recycling workflow 106a is a single workflow in which all textiles to be recycled undergo mechanical, chemical, or mechanical and chemical processing. The first unified recycling workflow 106a can be contained in a single location (e.g., a single factory, a single room, a single house, or the like). In other cases, some or all of the subsystems of the first unified recycling workflow 106a can be independent, different, remote, or otherwise not contained in a single location.

[0072] The textile to be recycled comprises in some cases undesirable textile material, non-textile material, or undesirable textile and non-textile material.These undesirable textiles may be less in number, or undesirable commercially for any reason.The undesirable non-textile may have other values ​​due to its inherent structure, recyclability or other reasons.The example and non-exhaustive list of undesirable material comprise zipper, buckle, buckle, button, rivet, wire, support, hook and button subsystem, elastic material, paper, rubber, gum, adhesive, fire retardant, waterproof chemical, insect repellent chemical, pathogen destructive chemical, dirt, food, plastic, coin or similar material.In some cases, some materials are undesirable, and in other cases, some materials may be desired.As taught in the present disclosure, at least some embodiments of the first unified recovery workflow 106a are sufficiently stable, to selectively process any undesirable material that enters workflow together with the desired textile to be recycled.

[0073] The first unified recycling workflow 106a is used to separate and recycle selected desired fibers. Generally speaking, there are three types of fibers: 1) plant-based, which can be represented by one or more of the terms cellulose, cellulosic, etc.; 2) synthetic, which can be referred to as fossil fuel-based, artificial, or the like; and 3) animal, which can be referred to as protein-based or the like. Exemplary cellulose fibers include, but are not limited to, cotton, flax, rayon, hemp, jute, lyocell, bamboo, reed, etc. Exemplary synthetic fibers include, but are not limited to, polyester, nylon, acrylic, polyolefin, etc. Exemplary animal fibers include, but are not limited to, sheep wool, goat wool, cashmere, alpaca wool, mohair, rabbit hair, camel hair, silk, leather, etc.

[0074] After the textiles to be recycled enter the first unified recycling workflow 106a, the textiles to be recycled 108 can be transported to one or more locations for any suitable reason by a conveying mechanism (such as a conveyor belt, a roller, an elevator, a gate, a piston, a magnet, a robotic arm, suction, and any other means of moving objects). For example, optionally, the textiles to be recycled 108 can be sorted. In at least one case, the sorting is performed manually. In other cases, the sorting can be performed by weighing. In an example case, for example, Figure 2A In one embodiment of the system 100A, the textiles 108 to be recycled are optically sorted.

[0075] The optical sorting subsystem 110 can include one or more cameras of any suitable type, one or more optical filters, and any other suitable optical, temperature, or other sensing technology for distinguishing or assisting in distinguishing one type of textile from another type of textile. Thus, the optical sorting subsystem 110 can include sensors that detect electromagnetic signals in the human visual spectrum, the human non-visual spectrum, or any other portion. In at least one instance, the optical sorting subsystem 110 includes one or more human visual spectrum optical cameras and corresponding machine learning (e.g., artificial intelligence, image recognition, etc.) software, and in at least another instance, the optical sorting subsystem 110 includes an infrared-based camera, probe, or other sensor implemented by cooperating executable software.

[0076] The infrared camera can include one or more of a forward-looking infrared (FLIR) camera, a Fourier transform infrared (FTIR) camera, or other cameras based on infrared technology. In these and other cases, spectroscopic techniques can be used to determine the molecular composition of the textiles 108 to be recycled. These spectroscopic techniques can be used to generate one or more digital tags representing some or all of the textiles 108 to be recycled. For example, the optical sorting subsystem 110 can be used to create a first digital tag representing a cotton material, a second different digital tag representing a polyester material, a third digital tag representing a specific blend of cotton and polyester, a fourth digital tag representing a certain leather material, a fifth digital tag representing a certain paper material, and the like. The specific tags generated representing each of the textiles 108 to be recycled can be used to guide the conveying mechanism to move the items.

[0077] exist Figure 2A In an embodiment of the first unified textile recycling system 100A, the optical sorting subsystem 110 directs non-cellulosic material 112 to a non-cellulosic material treatment 114. The non-cellulosic material 112 can include pure synthetics, protein-based materials, non-textiles, and other such materials. The non-cellulosic material treatment 114 can be composted or used in traditional post-consumer fiber products (such as cardboard). In addition, or alternatively, the non-cellulosic material 112 can be chemically recycled (such as pure polyester) or recycled in other known ways.

[0078] While the optical sorting subsystem 110 is moving or otherwise processing the non-cellulose material 112, or at some other time, the optical sorting subsystem 110 directs the cellulose-based material 116 (e.g., pure cellulose or a cellulose mixture) to the cellulose solvent reactor 122. Optionally, a size adjustment subsystem 118 can be used to prepare the cellulose-based material 116 to increase the solubility of cellulose.

[0079] Where the sizing subsystem 118 is used, the subsystem can pre-treat the cellulose-based material 116 by cutting, tearing, shredding, grinding or performing other similar operations as described in the present disclosure. In at least one example of the system 100A embodiment, the pre-treating produces material having a nominal size of about 1 square centimeter (1 sq.cm) or less. Such pre-treating can also have the effect of partially or completely separating the cellulose-based material 116 into material to be dissolved (such as cellulose) and other materials, such as buttons, buckles, zippers, clasps, rings, rivets, wires, foams, rubber materials, elastic materials, etc. In some cases, the sizing subsystem 118 can include zero or more magnets, electrostatic or other charged surfaces, air moving devices or other subsystems for separating desired materials from undesired materials.

[0080] The pre-treated material from the sizing subsystem 118, or the cellulose-based material 116 itself if the optional sizing subsystem 118 is not included, is fed into the cellulose solvent reactor 122 as feedstock 120. The feedstock 120 will contain cellulose-based fibers. The feedstock 120 may also contain synthetic fibers, animal fibers, and non-fibrous materials (such as silicates, silicate salts, metal materials, oils, water, etc.).

[0081] The cellulose solvent reactor 122 includes at least one liquid reservoir for receiving the raw material 120 and dissolving the cellulose-based fibers in the raw material 120. The dissolution of the cellulose-based fibers is an ionic liquid process performed according to the teachings of the present disclosure. In particular, when the raw material 120 is immersed in a solution of one or more selected ionic liquids, the hydrogen bonds in the molecular structure of the cellulose chain are destroyed, and the cellulose fibers are separated and dissolved in the ionic liquid. It is worth noting that the cellulose fibers are not chemically decomposed, but the fibers are dissolved in the ionic liquid. Of course, the non-cellulose materials are not dissolved.

[0082] The cellulose solvent reactor 122 can include one or more storage tanks of a suitable number. Optionally, the cellulose solvent reactor 122 can include a temperature control subsystem, a stirring subsystem, a pressure subsystem, a flushing subsystem, one or more inlet ports, one or more outlet ports, one or more water sources, one or more ionic liquid sources, a filtering device, a metering device, one or more pumps and any other suitable control subsystems and equipment. As described in the present disclosure, a variety of ionic liquids have been tested, and specific test results have been approved by the inventors. The time required for dissolving a specific raw material 120 batch, the efficiency of the dissolution process, the energy required for executing the batch process and other such improvements may be affected by factors such as temperature, pressure, batch size, storage tank size, dissolution time, the selected ionic liquid or liquid combination.

[0083] exist Figure 2A In an embodiment of the first unified textile recycling system 100A, in the cellulose solvent reactor 122, after a selected period of time and selected treatment, the cellulose-containing solution 124 is transported to the cellulose coagulation bath 126; the second solution 134a is transported to the second solution storage tank 136a, and the insoluble material 140a is transported to the insoluble material container 142a.

[0084] The cellulose-containing solution 124 includes now dissolved cellulose fibers that can be easily re-spun using the ionic liquid / cellulose solution as a spinning solution. The cellulose coagulation bath 126 includes a liquid, such as water, deionized water, or other liquid. When the cellulose-containing solution 124 enters the cellulose coagulation bath 126, the cellulose fibers begin to coagulate (e.g., coagulate, coagulate, precipitate, grow, "fall off" or the like). The coagulated fibers are drawn out of the cellulose coagulation bath 126 and enter the wet spinning spinneret subsystem 128 and are extruded from the spinneret as one or more continuous threads. Together, or individually, the coagulation bath 126 and the wet spinning spinneret subsystem 128 can include a single or multi-hole spinneret, a temperature controller, one or more liquid inlets, one or more liquid outlets, a traction device (e.g., any suitable number of zero or more rollers, godet spindles, etc.), a washing device (e.g., a storage tank, a container, a tensioner, etc.), a drying device, a dyeing device, a coating or other treatment device (e.g., a flame retardant, a waterproofing agent, etc.), a finishing device (e.g., a coating, a packaging, a trimming, a waxing, etc.), a winding device (e.g., an industrial spool, an industrial spool winder, etc.), and other such textile processing equipment. The coagulation bath 126, the wet spinning spinneret subsystem 128, or some of the coagulation bath 126 and the wet spinning spinneret subsystem 128 are optional.

[0085] The coagulation bath 126 and the wet spinning spinneret subsystem 128 cooperate to produce recycled cellulose fibers that are commercially indistinguishable from virgin cellulose fibers (e.g., cellulose fibers produced using raw materials for the first time). Figure 2A In one embodiment of the system 100A, the recycled cellulose fibers are spun into threads or yarns (eg, filaments) and wound onto a first industry standard spool 130. In other embodiments, the recycled cellulose fibers can be arranged into different commercially desirable forms.

[0086] The coagulation bath 126 and the wet spinning spinneret subsystem 128 will include part or all of the ionic liquid, which is used to dissolve the cellulose part in the raw material 120 in the cellulose solvent reactor 122. This ionic liquid is non-volatile and will not be exhausted or consumed during the dissolution process. After removing the fiber and other solid materials from the cellulose-containing solution, the ionic liquid can flow back to the cellulose solvent reactor 122 or another container through the ionic liquid recovery loop 134a. In some cases, the ionic liquid recovery loop 132 can include one or more heating elements, vents and other structures to evaporate water or other substances in the ionic liquid. In this closed-loop first unified recovery workflow 106a, the reaction and recycling of the cellulose fiber are recovered to reduce harm to health and the environment, using ambient temperature or other commercial low temperatures, and operating in a low-cost and energy-efficient form.

[0087] In some cases, the second solution 134a can include synthetic fibers, animal fibers or other materials in part or in whole. The second solution can include synthetic fibers or other fibers suspended in the ionic liquid of the cellulose solvent reactor 122, in the original state. These synthetic fibers or other fibers are vacuum extracted or mechanically filtered from the cellulose solvent reactor 122, or removed from the cellulose solvent reactor 122 by other known methods. These synthetic fibers or other fibers are processed in a known manner and spun onto a second industrial standard spool 130B. At least in some cases, the recovered cellulose material from the first wet spinning spinneret subsystem 128 can be optionally combined with the recovered synthetic material from the second solution storage tank 136a.

[0088] In some cases, the second solution may include cellulose fibers, rather than synthetic fibers or animal fibers, which are different from the fibers in the cellulose-containing solution 124. The fibers in the second solution 134a have undissolved bonds in the cellulose solvent reactor 122. In this case, the cellulose solvent reactor 122 can be a first reactor with a first or mixed ionic liquid, and the second solution storage tank 136a can be a second reactor with a second or mixed ionic liquid. Therefore, according to the expectation of the present disclosure, the first unified recovery workflow 106a can have two or more stages of cellulose solvent reactors in some cases, wherein each reactor has a selected ionic liquid that is recovered for different types of cellulose fibers. In this case, the second solution storage tank 136a can further include a coagulation bath system and a wet spinneret subsystem along the coagulation bath 126 and wet spinneret subsystem 128 lines, and the generated line can be wound on a second industrial standard spool 130B. In this case, the ionic liquid in the pure ionic liquid or the mixed 138 can be recovered and returned to the cellulose solvent reactor 122 by the ionic liquid recovery loop 132.

[0089] As described in the present disclosure, cellulose-based fibers and synthetic fibers can be recycled and spun onto the same or separate industry-standard spools or some other method. Each fiber type can be spun into a wide range of threads, yarns, etc. (e.g., filaments) including, but not limited to, pure cotton, pure polyester, and other pure materials, as well as various new hybrid fibers not currently produced in the industry. In some cases, the original colors in the cellulose-based materials can be retained; in other cases, new colors can be added, and in other cases, all colors can be removed to give the recycled materials a completely natural color state.

[0090] exist Figure 2A In the implementation of the first unified textile recycling system 100A, insoluble material 140a is transported to an insoluble material container 142a. The insoluble material 140a can include synthetic fibers, animal fibers, zippers, buckles, clasps, buttons, rivets, wires, supports, hook and loop subsystems, rubber bands, paper, rubber, gum, adhesives, flame retardants, waterproof chemicals, insect repellent chemicals, pathogen-destructive chemicals, dirt, food, plastics, coins or similar materials. These materials can be separated and recovered, recycled or processed in other known ways. Such processing can include chemical treatment, high temperature processing (such as incineration, melting, etc.), reuse (such as processing into insulation materials, cardboard, cushion fillings, foams, etc.). The processed material 144 can be appropriately sent to industry or other off-site processing.

[0091] In at least some cases of the implementation of spinning of the system 100A of FIG. 2 , the operation of the first unified recovery workflow 106a is optionally, partially or completely, controlled by a specific controller 146. The optional controller 146 can include a microcontroller 148, one or more sensors 150, a network circuit 152, and other circuits to avoid ambiguity. Figure 2A The circuits are not shown. An exemplary non-exhaustive list of these other circuits includes: a program memory with processor executable software of the microcontroller 148, a data memory, a power supply circuit, a user interface circuit, a timing circuit, etc.

[0092] The one or more sensors 150 can have any suitable form, size, features, functions, and underlying technology. For example, in some cases, the sensors 150 include accelerometers, optical detectors, infrared sensors, pressure sensors, gas sensors, smoke sensors, color sensors, liquid sensors, flow sensors, temperature sensors, timers, load sensors, gyroscopes, proximity sensors, ultrasonic sensors, and any other suitable sensors that can provide useful information to the controller 146. Optionally, one or more sensors 150 are communicatively coupled to the sorting subsystem 110, the conveying system, the sizing system 118, the cellulose solvent reactor 122, the cellulose coagulation bath 126, the wet spinning spinneret subsystem 128, the industry standard spools 130a-130c ( Figure 2A , 2B ), the ionic liquid recovery circuit 132, the second solution storage tank 136a, the insoluble material container 136b ( Figure 2B ), the insoluble material containers 142a, 142b and any other specific loops of the first unified recovery workflow 106a.

[0093] Optionally, the controller 146 can communicate via a computing network 154 with one or more computing servers 156, one or more databases 158 (e.g., any suitable local or remote single or distributed data repository), and other computing devices such as mobile computing devices, wearable computing devices, vehicle-mounted computing devices, etc.

[0094] Figure 2B is another embodiment of a unified textile recycling system 100B arranged around a second unified recycling workflow 106b. Figure 2B The contents and operations of the system 100B are similar to Figure 2A The illustration and description of the system 100A are substantially the same. Therefore, for the sake of brevity, the previously identified and described structures and behaviors will not be repeated.

[0095] exist Figure 2B In the embodiment of the present invention, all cellulose-based materials in the cellulose-based materials 116 are dissolved in the cellulose solvent reactor 122 and enter the cellulose coagulation bath 126 through the cellulose-containing solution 124. All remaining materials enter the insoluble material container 142b as insoluble materials 140b.

[0096] In an embodiment of the system 100B, the insoluble material 134b is a synthetic material that is chemically recycled in the insoluble material container 142b. Threads, yarns, or some other form of synthetic fibers (such as filaments) are wound on industry standard bobbins or other commercially desirable structures. At least in some cases, the recycled cellulosic material from the first wet spinning spinneret subsystem 128 can be desirably combined with the recycled synthetic material from the insoluble material container 142b.

[0097] Figure 2C is the first batch reactor 222a in the embodiment of the third unified recovery workflow 106c. The third workflow 106c can optionally include one or more structures, subsystems, processes, etc., which are also found in the embodiments of the first and second unified recovery workflows 106a, 106b. However, in order to avoid unnecessary cluttering of the drawings, Figure 2C For example, the third unified recycling workflow 106c embodiment can include a material receiving station 102, control resources (e.g., controller 146, microcontroller 148, sensor 150, network circuit 152, computing network 154, computing server 156, database 158, etc.), spools 130a, 130b, 130c, and other structures, but Figure 2C These other structures are not shown in .

[0098] The workflow 106c includes a premix wetting structure 202, a batch reactor 122a, a transducer 204, various sensors 206a, 206b, reaction probes 208a-208n, one or more heating circuits 210, a stirring structure 212, a precipitation container 214, a filter 216, a pump 218, connecting pipes, support circuits, conveyor belts, robots and any other suitable mechanical, electrical and electromechanical structures known to those skilled in the art.

[0099] An exemplary embodiment of the third unified recycling workflow 106c is now described. Those skilled in the art will recognize that the various operations described herein can be performed in series, in parallel, or in a different order than described. In addition, the various operations can be performed once, twice, or any suitable number of times, and these or other operations can be optional or can not be performed at all.

[0100] In an exemplary embodiment, raw material 120a and wetting agent 220 are introduced into premixed wetting structure 202. In some cases, raw material 120a and wetting agent 220 are introduced into premixed wetting structure 202. Figure 2A , 2B The same as described raw material 120. In other cases, Figure 2C The raw materials 120a shown in the can include raw materials, cut materials, scraps, combed materials, clean materials, unclean materials, ground materials, uncut or unground materials, sorted materials, unsorted materials or any other suitable materials. In some cases, the raw materials 120a are all cotton materials, and in some cases, the raw materials 120a are blends of cotton and synthetic fibers or other fibers, such as polyester, nylon, acrylic, polyolefins, etc. Other fibers, such as animal fibers, may also be included. At least in some cases, all of the raw materials 120a shown can come from a single source (e.g., a cutting plant (end position and end loss), and it exceeds 18% of the original material bolts, a blue jeans manufacturer, a uniform manufacturer, a military department uniform replenishment, an industrial clothing supplier, a restaurant supplier, etc.). The raw materials 120a can be pre-processed by a grinder, a hopper, a spiral, a cutter, a pulverizer or any other suitable pre-processing structure.

[0101] Wetting agent 220 is optional. When using wetting agent 220, wetting agent 220 comprises any one or more suitable materials, and these materials can reduce the surface tension of specific target liquid, thereby increase the diffusion of shown target liquid on the solid that shown target liquid contacts. In many cases, shown target liquid is water, and selecting described wetting agent is in order to reduce the surface tension of water or water-based solution with appropriate amount. Cyclohexanone is a kind of material that can form wetting agent 220. Other suitable wetting agents can comprise the cationic compound derived from imidazoline. Other suitable wetting agents can be selected from and be used for other textile processing operations, such as dyeing, cleaning, stripping etc., surfactant or detergent. In these cases, wetting agent 220 can comprise sulfonated oil, soap, soybean lecithin, mercaptan, mercaptan acetal, acylhydrazine or other materials. Other suitable wetting agents 220 can also be considered to be used.

[0102] The premix wetting structure 202 can be any suitable size and structure. In some cases, the premix wetting structure 202 is an open tank, and in some cases, the premix wetting structure 202 is a closed or partially closed tank. In some cases, the premix wetting structure 202 is a pressurized container.

[0103] In at least one instance, the premix wet structure 202 is at least 100 gallons, and in at least another instance, the premix wet structure 202 is greater than 500 gallons.

[0104] The premixed wet structure 202 can be made of metal, plastic, composite material, glass, fiberglass, or one or more other substances.

[0105] The premix wetting structure 202 can include any appropriate number of sensors (e.g., volume sensors, weight sensors, temperature sensors, pressure sensors, valves, ports, etc.), and these sensors described herein can be used by the control system to start the unified recycling workflow, monitor the unified recycling workflow, control the unified recycling workflow, etc. The premix wetting structure 202 can further include a stirring mechanism, such as a rotating drum, a circulator, or a stirrer, whose shape, size, and operating characteristics can be arbitrarily selected.

[0106] The raw material 120a can include only solid materials (e.g., one or more textile-based materials) or solid materials suspended in a liquid, pulp, slurry, or other flowable component. In some cases, the raw material 120a and one or more liquids (e.g., water, a wetting agent 220, or some other liquid) are mixed in the premix wetting structure 202 to produce a flowable raw material 222. In at least one case, the premix wetting structure 202 is arranged to mechanically agitate the ground slurry and the wetting agent 220 to produce the flowable raw material 222 in a slurry state.

[0107] A flowable feedstock 222 is introduced into the first batch reactor 122a. The flowable feedstock 222 can include a target textile, such as cotton, and a wetting agent 220, which is added to overcome the surface tension of the ionic liquid in the first batch reactor 122a. At least in some cases, the size, shape, and other parts or all of the first batch reactor 122a are designed in accordance with Figure 2A-2B The circuit of the cellulose solvent reactor 122 is formed.

[0108] In the first batch reactor 122a, the flowable feedstock 222 is immersed in the ionic liquid solvent discussed herein. The mixed solution in the first batch reactor 122a can be heated, mixed (e.g., stirred, agitated, disturbed, perturbed, suspended, beaten, agitated, shaken, twitched, mixed, whisked or the like) and monitored until the desired cellulose concentration level is reached.

[0109] Whether the cellulose concentration has reached the desired level can be determined by any suitable means. Figure 2C In the third unified recycling workflow 106c embodiment, various sensors are controlled by a control system, such as Figure 2A , 2B The control resource can be controlled, monitored, or controlled and monitored. The sensor can be selected to include one or more of the sensor 204, sensors 206a, 206b and reaction probes 208a, 208b, 208c, 208n.

[0110] In at least one embodiment, the sensor 204 includes one or more light sources, such as a laser or a tunable laser. In this case, the sensor 204 can be configured and controlled to emit photons (e.g., pulses, streams, or some other configuration of photons). In at least one case, the sensor 204 is arranged to emit photon pulses at fixed intervals and different wavelengths, and these photons pass through the flowable feedstock 222 immersed in the ionic liquid solvent in the first batch reactor 122a.

[0111] To measure the concentration of cellulose dissolved in the ionic liquid solvent, the photons or other electromagnetic energy emitted by the sensor 204 are detected by any appropriate number and form of sensors 206a, 206b. Those skilled in the art will recognize that the location, structure and operation of any appropriate number of sensors 204, as well as the location, structure and operation of any appropriate number of sensors 206a, 206b, can be controlled and used by the control system. In this way, based on the data provided by one or more sensors 206a, 206b, the control system is used to determine the cellulose concentration of the flowable raw material 222 in the batch reactor 122a. The electromagnetic energy may be visible light, invisible light, sound or other electromagnetic energy. In at least one case, the sensor 204 is a tunable laser that is used to periodically emit photon pulses at different wavelengths through the ionic liquid and textile pulp in the batch reactor 122a. In this case and other cases, sensors 206a and 206b are high quantum efficiency photon detectors capable of measuring the amount of photons that have passed through the slurry, and further in this case, the control system integrates the light detection and the change in phase shift to determine the amount of cellulose in the slurry solution. Based on this detection, the operation of the third unified recovery workflow 106c can be controlled by the system, such as Figure 2A , 2B The control resources in said control include control, monitoring, or control and monitoring.

[0112] Where the first batch reactor 122a includes an optional heating loop 210, the loop is used to control the rate of dissolution of cellulose in the ionic liquid. For example, the inventors have learned that the rate of dissolution of cellulose in an ionic liquid is related to the amount of energy introduced into the slurry.

[0113] In some cases, instead of or in addition to the first batch reactor 122a including a heating loop 210, the first batch reactor 122a can also include a stirring structure 212. When such a structure is included, the optional stirring structure 212 can be used to keep the slurry in the first batch reactor 122a stirred and constantly moving. This stirring can be achieved by releasing a pressurized non-reactive gas into the slurry. The non-reactive gas can be dehumidified air, nitrogen, carbon dioxide or other gas from the atmosphere. In addition to normal atmospheric gases, almost any used gas can be recovered, liquefied, and re-stored for reuse. According to the inventor's observation, neither the ionic liquid solvent nor the ionic liquid cellulose solution will produce waste gas or cause harm to the surrounding environment. The non-reactive gas can be compressed to an atmospheric pressure or other pressure. The non-reactive gas can be released as a stream of small bubbles. In this regard, the stirring structure can include a tube or other structure, which has any suitable number, size and aperture configuration.

[0114] In some cases, the agitation structure 212 is located adjacent to the heater circuit 210, and the two structures cooperate with each other. That is, the release of bubbles can be enhanced or otherwise controlled by adding or removing heat prior to releasing the non-reactive gas.

[0115] In some cases, one or more reaction probes 208a, 208b, 208c, 208n can be arranged in the first batch reactor 122a. These probes can be used to measure various properties of the slurry in the batch reactor. By measuring these properties, the solubility of the cellulose-based fibers in the ionic liquid can be increased, reduced or maintained at the expected or other acceptable thermodynamic level. When the optional reaction probes 208a-208n are included, any appropriate number and configuration of probes can be deployed. In some cases, the reaction probes 208a-208n are used to measure temperature, in some cases, the reaction probes 208a-208n are used to measure the conductivity of the slurry, and in other cases, the reaction probes 208a-208n are used to measure another one or more properties of the slurry.

[0116] One or more of the heating circuit 210, the stirring structure 212 and the reaction probes 208a-208n can be controlled by the system, such as Figure 2A , 2B The control resources in said control, control, monitoring, or control and monitoring.

[0117] At appropriate times, a selected volume of cellulose-containing solution 124, which contains now dissolved cellulose fibers (i.e., spinning solution), is withdrawn or otherwise recovered from the first batch reactor 122a. The cellulose-containing solution 124 is processed as described in the present disclosure with respect to Figure 2A , 2B described.

[0118] In addition, when appropriate, the ionic liquid containing the insoluble material 140c is withdrawn from the first batch reactor 122a or otherwise recovered to the precipitation vessel 214. The precipitation vessel can be a water tank, a storage tank or other type of container. The insoluble material can be the insoluble material 140a ( Figure 2A ) or insoluble material 140b( Figure 2B ). The solid material in the insoluble material 140c can be removed from the precipitation container 214 by vacuum extraction, pressure filtration or other methods.

[0119] Once the solid material in the insoluble material 140c solution is removed, the "defatted" ionic liquid solution 226 is poured into a filter 216. The filter 216 can be a rotating baffle filter, a membrane filter, an electrostatic filter, or other type of filter. The filter 216 can include an automatic backwashing baffle, gate, or other structure. The filter 216 is generally used to filter out or otherwise remove any remaining particulate matter in the defatted ionic liquid solution 226, thereby generating a refined ionic liquid solution 228. The filter 216, the defatted ionic solution 226, and the refined ionic liquid solution 228 can form a Figure 2A , 2B Part or all of the ionic liquid recovery loop.

[0120] Optionally, the third unified recovery workflow 106c can include a pump 218 and an ionic liquid feed / return path 230. The pump 218 can include one or more fixed speed, variable speed, fixed volume, variable volume, or any other type of pump. The pump 218 and the ionic liquid feed / return path 230 are generally used to keep the material (e.g., flowable feedstock 222, slurry, ionic liquid, etc.) moving in the third unified recovery workflow 106c. Any suitable number of the pumps 218 and valves (not shown), gates (not shown), ports (not shown), etc. can be controlled by a control system, such as Figure 2A , 2B The control resources may be controlled, monitored, or controlled and monitored.

[0121] Figure 2DThe fourth unified recovery workflow 106d may optionally include one or more structures, subsystems, processes, etc. of the first, second and third unified recovery workflows 106a, 106b, 106c. However, in order to avoid unnecessary cluttering of the drawings, Figure 2D For example, the fourth unified recycling workflow 106d embodiment can include a material receiving station 102, control resources (e.g., controller 146, microcontroller 148, sensor 150, network circuit 152, computing network 154, computing server 156, database 158, etc.), spools 130a, 130b, 130c, and other structures, but Figure 2D These other structures are not shown in .

[0122] The workflow 106d includes a pretreatment structure 240, a premixing and wetting structure 202, a distribution switch 244, a second batch reactor 122b including one or more reaction vessels 246a, 246b, 246n, a cellulose coagulation bath, a wet spinning spinneret subsystem 128, an extraction filter 250, a recovery filter 252, an ionic liquid purification structure 254, and an ionic liquid container 256. Some structures of the workflow 106d can be optional. The workflow 106d can also include any suitable connecting pipelines, supporting circuits, conveyor belts, conveyors, robots, and any other suitable mechanical, electrical, and electromechanical structures known to those skilled in the art.

[0123] An exemplary embodiment of the fourth unified recycling workflow 106d is now described. Those skilled in the art will recognize that the various operations described herein can be performed in series, in parallel, or in a different order than described. In addition, the various operations can be performed once, twice, or any suitable number of times, and these or other operations can be optional or can not be performed at all.

[0124] The processing in the fourth unified recycling workflow 106d begins in the textile pretreatment structure 240. The pretreatment can include any suitable operations to produce the raw material 120b. Figure 2A , 2B The raw materials 120 and Figure 2C The raw material 120a is similar.

[0125] Raw material 120b is introduced into optional premix wetting structure 202. When premix wetting structure 202 is included in the workflow 106d, it is Figure 2CIn at least some cases, the wetting agent 220a is injected into the premixed wetting structure 202. This introduction can include a liquid handling pump 242. The liquid handling pump 242 can be arranged as a reflux valve, or other ways including a reflux valve or the characteristics of a reflux valve. The wetting agent 220a can be Figure 2C The wetting agent 220 can be the same wetting agent or different wetting agents.

[0126] The flowable raw material 222 is made from the raw material 120b. As described herein, the flowable raw material 222 is produced in the form of a slurry or some other composition that can flow or otherwise be delivered to the dispensing switch 244.

[0127] The distribution switch 244 can be arranged in any suitable manner to mechanically, electrically or electromechanically provide a portion of the flowable raw material 222 to the second batch reactor 122b. The distribution switch 244 can include valves, gates, pumps, conduits and any other such structures arranged in any suitable number, configuration, material and operating characteristics. The distribution switch 244 can provide a portion of the flowable raw material 222 in a sequential, serial, parallel, simultaneous, periodic, random, etc.

[0128] The power distribution switch 244 can include sensors, controllers, switches, actuators, and other control circuits, logic, and electrical structures. In at least some cases, the operation of the power distribution switch 244 can be controlled by a control resource (e.g., controller 146, microcontroller 148, sensor 150, network circuit 152, computing network 154, computing server 156, database 158, etc.), such as Figure 2A , 2B The control resources in.

[0129] The second batch reactor 122b is a multi-stage reactor. In the fourth unified recovery workflow 106d, the batch reactor 122b includes a first reaction vessel 246a, a second reaction vessel 246b and an nth reaction vessel 246n. One or more reaction vessels 246a-246n can be operated according to Figure 2A , 2B In addition, or as an alternative, one or more reaction vessels 246a-246n can be formed in accordance with Figure 2C The structure of the first batch reactor 122a is formed. In other cases, one or more reaction vessels 246a-246n can be formed using other configurations. In some cases, each reaction vessel 246a-246n is formed in the same manner, and in other cases, one or more reaction vessels 246a-246n are different from one or more other reaction vessels 246a-246n.

[0130] Reaction vessel 246a-246n can have any suitable shape, size, volume, material, construction and other characteristics. In a certain case, any reaction vessel described in the present disclosure (such as reaction vessel 246a-246n) can be spherical, hemispherical, elliptical, semi-elliptical or other similar symmetrical shapes. Forming such a container may be conducive to solving the known "lone angle" problem in liquid mixing, in which case the angle usually cannot obtain enough lamination or turbulent mixing force. At least in some embodiments, the internal volume of the reactor container has no angle (such as spherical, elliptical, etc.), while retaining the structure of square, rectangular or other regular shapes, and its external dimensions are planes or other ideal sizes, which are conducive to the stability, stacking, interlocking, etc. of the plane. In some cases, the volume of one or more reaction vessels 246a-246n is twenty-five (25) gallons or less. In other cases, the volume of one or more reaction vessels 246a-246n is greater than twenty-five (25) gallons. In some cases, the volume of one or more reaction vessels 246a-246n is about 500 gallons. In some cases, one or more of the reaction vessels 246a-246n has a volume greater than 500 gallons. In at least one case, the second batch reactor 122b has a plurality of reaction vessels 246a-246n having a total volume greater than 25,000 gallons.

[0131] In some cases, the reaction vessels 246a-246n can be arranged into modules or modular reactors that can be connected or disconnected at will. Each reactor can include sensors, monitors or other control circuits that allow manual or non-manual control machinery to control the output flow of the cellulose solution 124a from the second batch reactor 122b. As the inventors understand, the productivity of cellulose solution can increase or decrease within a certain range according to time, input system or energy intercepted from the system, the arrangement of raw materials, the selection of ionic liquids, the number of raw materials exposed in ionic liquids or the surface area exposed. According to this information, any suitable parameter can be used to operate any suitable number of reaction vessels 246a-246n to reach the volume, flow rate, concentration, etc. expected by the cellulose solution 124 in the second batch reactor 122b.

[0132] A solution pump 248 can be optionally included in the second batch reactor 122b, or coupled to the second batch reactor 122b. Such a pump 248 can be coupled to the structure of the pump 218 ( Figure 2C ) is similar. Such a pump 248 can be used to pump the pre-coagulated cellulose-containing solution 124 a into the coagulation bath 126 .

[0133] For a detailed description of the coagulation bath 126, see Figure 2A , 2B The coagulation bath tank 126 is used to receive the cellulose-containing solution 124a of the pre-coagulation bath, and provide the cellulose-containing solution 124b after the coagulation bath to the wet spinning spinneret subsystem 128. For a detailed description of the wet spinning spinneret subsystem 128, see Figure 2A , 2B The wet spinning spinneret subsystem 128 produces a cotton thread 262 (eg, a cotton thread that is substantially identical to thread produced from virgin cotton fibers).

[0134] In addition to the precipitated cellulose particles formed as the post-coagulation bath cellulose-containing solution 124 b, byproducts of the coagulation bath are an ionic liquid and an aqueous solution 260 . The ionic liquid and the aqueous solution 260 are processed in the extraction filter 250 .

[0135] In some cases, the extraction filter 250 is a reverse osmosis filter. In such a filter, water is separated or otherwise extracted from the ionic liquid by a low pressure, low energy or no energy reverse osmosis filter. Other extraction filter configurations are also contemplated. One output from the extraction filter 250 is water 266, which can be recycled, and another output from the extraction filter 250 is the ionic liquid 264, which is further processed and reused.

[0136] The ionic liquid 264 from the extraction filter 250 is further processed in the recovery filter 252. Solid materials or other materials of limited commercial value, if any, are processed materials 144 ( Figure 2A , 2B ). The further purified ionic liquid 268 passes through the ionic liquid purification structure 254. Some of the ionic liquid 230 is stored in the ionic liquid container 256; other ionic liquid 230 is removed from the ionic liquid container 256. The ionic liquid 230 is received in the distribution switch 244 to generate the flowable feedstock 222 slurry.

[0137] Figure 3 is a schematic diagram of a data flow 300, which shows that according to Figure 2A An embodiment of the system 100A or Figure 2B Embodiments of the system 100B can be implemented by implementing a workflow of embodiments of a unified textile recycling system. In many cases, some or all of the computing structures of the systems 100A, 100B, including the controller 146, the computing network 154, the computing server 156, and the database 158, cooperate to direct the operation of the unified recycling workflow 106a-106d ( Figures 2A-2D), in some cases, the controller 146 can be integrated with the unified recycling workflow 106a-106d. Alternatively, as shown by the dashed line of the controller 146, the controller 146 or at least some parts of the controller can be remote from the unified recycling workflow.

[0138] At 302, processing begins. The processing can include initialization of the controller 146 and initialization of one or more subsystems of the unified recycling workflow 106a-106d. For example, communication between subsystems can be tested; containers (such as chambers, tanks, reactors, containers, basins, boxes, etc.) can be washed, cleaned, filled or otherwise initialized; fans can be started or otherwise tested; heating elements can be started or otherwise tested; and sensors can be calibrated or initial data can be prepared in other ways. In some cases, one or more containers of the cellulose solvent reactor can be pre-loaded with a selected volume of a specific ionic liquid or mixed ionic liquid, and in these cases, zero or more other elements (such as water, acid, salt, dye, chemical identifier or other element) can also be added. If a chemical identifier is added, the chemical identifier can be arranged as a specific inert chemical chain, which can be used as a trademark to uniquely identify the manufacturer of the recycled textile. This process operates before 304.

[0139] At 304, textile waste is collected, transported or otherwise placed in a recycling center. The textile waste can come from municipalities, textile mills, clothing factories, surplus clothing stores, brand manufacturers, retailers, etc. The textile waste can be transported by recycling trucks, dump trucks, trucks, cars, bicycles, trains, ships or any other suitable means of transport. At the recycling center, the material can be weighed, can be manually sorted, stacked, piled up, layered or arranged according to any specific parameters (such as weight, physical size, color, type of article, cleanliness state, dryness state (such as humidity) or any other suitable parameters), so as to enter the unified recycling workflow in any suitable manner. Preparing the textile to be recycled in this way can improve the recycling process by reducing the dissolution time, reducing the energy required for recycling, increasing output, etc.

[0140] In some cases, the controller 146 can be communicatively coupled to any suitable number of sensors 150 (e.g., motion detectors, loading units, timers, conveyors, robots, material handlers, etc.) to facilitate receiving the textile waste. A human can operate a user input sensor to facilitate the receiving operation of the textile waste. This process is operated before 306.

[0141] At 306, the textile waste is sorted. At least in some cases, the textiles to be recycled are sorted and processed as different batches of cellulose materials, synthetic materials, protein materials, and mixed materials. The sorting can be performed by an optical sorting subsystem 110, a chemical sorting subsystem, a weighing sorting subsystem, or other types of sorting examples coupled to the controller 146. The processing can be fully or partially automatic. The processing can have manual input, or not. In at least one case, the sensor 150 of the optical sorting subsystem can be used to capture one or more images or other features of the textiles to be recycled using a specific type of camera (e.g., a forward-looking infrared (FLIR) camera, a Fourier transform infrared (FTIR) camera, or one or more of other infrared-based cameras). These cameras, which can also be referred to as one or more of the sensors 150, can independently or in cooperation with the controller 146 generate digital tags representing the subject textiles (e.g., optical digital tags, microscope-based digital tags, spectral-based digital tags, or other digital tags).

[0142] In at least one embodiment, the generated optical digital tag can be formed in any suitable manner, such as spectral data. The controller 146 can direct various computing operations to compare the generated optical digital tag with a series of optical digital tags stored in the database 158. The optical digital tags stored in the database 158 can represent different textiles or mixed textiles respectively. If a match is found (for example, the optical digital tag representing part or all of the recycled textiles is the same or substantially the same as the optical digital tag stored in the database 158), then one or more sensors 150 can be used to guide how to process the recycled textiles. For example, if the recycled textiles include cellulose-containing materials, the recycled textiles are fed into the cellulose solvent reactor 122. In another embodiment, if the recycled textiles include only non-cellulose materials 112, the recycled textiles will be directly used for non-cellulose material processing 114. Therefore, one or more sensors 150 of the optical sorting system can be used to control conveyors, gates, pumps, valves, fans, motors, suction, filters, timers, or any electronically controllable circuits.

[0143] In at least one other case, the sorting is based on a chemical analysis of the textiles to be recycled. The chemical sorting system can be communicatively coupled to the controller 146 and operate in accordance with the ideas of the optical sorting subsystem 110, which is based on chemical analysis rather than optical analysis. Such chemical analysis can be used to determine whether the textiles to be recycled include cellulose-containing materials, synthetic materials, protein-containing materials, or other types of materials. Similar to the optical sorting subsystem 110, the data from the chemical analysis can be used to generate a chemical digital tag, which is then compared with other chemical digital tags stored in the database 158. Further similar to the optical sorting subsystem 110, the results of this comparison can be used to guide one or more sensors in the unified recycling workflow 106a-106d. This guidance can determine the action taken on at least a portion of the textiles to be recycled.

[0144] In other cases, some of the textiles to be recycled include materials that have been treated with flame retardants, waterproof chemicals, pesticides, anti-biological pathogen chemicals, etc. (e.g., KEVLAR, GORE-TEX and GORE-TEX, etc.). Certain sensors 150 can be used to detect such substances. In some cases, textiles can be treated according to the teachings of the present disclosure while retaining specific chemical properties. In other cases, textiles to be recycled with these uncommon chemicals are treated using traditional processing methods.

[0145] Based on the sorting, one or more batches of textiles to be recycled 108 are advanced for further recycling. For example, in some cases, the controller 146 directs a conveyor, channel, gate, pump, valve, robot, or any other suitable structure to move the textiles to be recycled. In these or other cases, the controller 146 can cooperate with the human-machine interface sensor 150 to indicate the necessary actions and accept input from a person or machine to report the specific actions taken. This process operates before step 308.

[0146] At 308, the sorted material is optionally sized to form feedstock 120. For example, optionally, sizing subsystem 118 can be used to prepare the cellulose-based material 116 for any one or more of the following: increased cellulose solubility, faster cellulose dissolution rate, reduced cellulose dissolution energy consumption, larger cellulose dissolution batches, or other reasons. At least in some cases, the sizing can be referred to as pre-processing, preparation, batching, or other similar terms. Such pre-processing operations can be directed by controller 146 and cooperating sensors 150.

[0147] The controller 146 can also operate valves, actuators, sensors, etc. to move or otherwise position materials in the unified recycling workflow 106a-106d so that they can be placed in one or more reactors. For example, the pre-treated material from the size adjustment subsystem 118 is sent to the cellulose solvent reactor 122 as a raw material 120. The raw material 120 will contain cellulose-based fibers. In some cases, the raw material 120 will also contain at least one of synthetic fibers, animal fibers, and non-fibrous materials (such as silicates, silicate salts, metal raw materials, oils, water, etc.). This process is operated before step 310.

[0148] At 310, the raw material is added to a reaction chamber containing one or more selected ionic liquid solvents. The reaction chamber can be a cellulose solvent reactor 122 or other reaction chamber. In an embodiment described in the present disclosure, a reaction chamber (e.g., a cellulose solvent reactor 122) is arranged to contain one or more ionic liquids, and is further arranged to receive a material (e.g., a textile, cellulose, a blended fabric, etc.) on which the ionic liquid will act. In some cases, when the raw material 120 is added, the ionic liquid or liquid is already present in the reaction chamber. In some cases, when the ionic liquid or liquid is added, the raw material 120 is already present in the reaction chamber. In some other cases, the raw material 120 and the ionic liquid or liquid are added at about the same time. In order to perform these operations, the controller 146 can cooperate with a sensor 150, which includes a volume sensor, a weight sensor, a motion sensor, a motor, a pump, a valve, a port, a timer, a thermometer, a viscosity sensor, a pressure sensor, etc.

[0149] In some cases, the reaction chamber can have one, two, or any appropriate number of independent and different storage tanks (e.g., containers, chambers, wells, tanks, etc.). The independent and different storage tanks in the reaction chamber can cooperate with each other to sequentially process the raw material 120. For example, the raw material 120 can be placed in a first container under specific parameters (such as time, temperature, pressure, stirring, viscosity, etc.) managed by the controller 146, and the same raw material 120 or the remaining portion can be moved into a second container for additional processing, moved into a third container for more processing, and so on. Alternatively, under the guidance of the controller 146, the reaction chamber can have one or more independent and different storage tanks, the storage tanks having one or more inlet ports, outlet ports, pumps, valves, and other appropriate devices, so that sequential processing can be performed in the same storage tank with successively different sets of parameters. That is, in some cases, the reaction chamber can contain the raw material 120 and the first ionic liquid or ionic liquid mixture at the same time, and process them under a specific first set of parameters. Subsequently, the same raw material 120 or the remaining portion of the raw material is treated with a second ionic liquid or ionic liquid mixture, and processed under a specific second set of parameters.

[0150] The reaction chamber can be arranged as a reservoir (e.g., a bowl, basin, trough, well, container, or any other structure suitable for holding the desired amount of ionic liquid, feedstock, and other materials (if any)). In some cases, the volume of the reaction chamber can be between sixty-four fluid ounces (64 fl. oz.) and five gallons (5 gal.). In other cases, the volume of the reaction chamber can be between five gallons (5 gal.) and five thousand gallons (5000 gal.). In other cases, the volume of the reaction chamber may be less than sixty-four fluid ounces (64 fl. oz.). And in other cases, the volume of the reaction chamber can exceed five thousand gallons (5000 gal.).

[0151] In some cases, the feedstock 120 can be further pre-treated by various sensors 150 and other configurations of the controller 146 before being placed in the ionic liquid bath. For example, the feedstock 120 can be immersed in an aqueous NaOH solution one or more times at a selected temperature, stirred, washed with, for example, deionized water until a neutral pH is restored, and dried, for example, using an oven, a radiant heating element, a forced air system, or other drying means. In this case, the selected temperature can be between about ten degrees Celsius (10° C.) and about one hundred and fifty degrees Celsius (150° C.). In some cases, the selected temperature is about ninety degrees Celsius. In other cases, the selected temperature is less than about ten degrees Celsius (10° C.) or greater than about one hundred and fifty degrees Celsius (150° C.). In some cases, the selected temperature is room temperature.

[0152] After pretreatment, if any, optionally including any or all of soaking, washing, pH balancing and drying, the feedstock 120 is added to an ionic liquid solution. In some cases, the ionic liquid solution may include a single ionic liquid, in other cases, the ionic liquid may include two or more ionic liquids. In some cases, the ionic liquid solution may consist of only one or more ionic liquids, and in other cases, the ionic liquid solution may consist of one or more ionic liquids and other materials. In some cases, the ionic liquid solution selected for use in the reaction chamber is thoroughly dried to a water content of less than 0.2%.

[0153] The ionic liquid in one or more embodiments of the unified recycling workflow 106a-106d taught herein includes at least one of an imidazolium compound ionic liquid, an acetate oxide compound ionic liquid, and a methyl oxide compound ionic liquid. Ionic liquids are attractive for dissolving cellulose because certain physical properties of ionic liquids can be tailored by selecting ions and substituents on the R cationic groups to meet selected parameters and degree of polymerization of specific cellulose fibers.

[0154] In a certain case, the selected ionic liquid solution includes one or more of N-methylmorpholine-N-oxide (NMMO), 1-allyl-3-methylimidazolium chloride (AMIM-CL), 1-butyl-3-methylimidazolium acetate (BMIM-OAc), however, other ionic liquids can also be considered. The inventors have learned that NMMO, AMIM-CL and BMIM-OAc cannot dissolve polyester. The inventors have further learned that AMIM-CL can dissolve the cotton component in cotton / polyester blends at a higher yield than BMIM-OAc, and AMIM-CL and BMIM-OAc ionic liquids can produce recycled cellulose and polyester fibers at extremely high yields when used in the commercial process taught in this application. Therefore, in different embodiments, any ionic liquid solution containing NMMO, AMIM-CL and BMIM-OAc can be selected to dissolve cellulose-containing textiles and blends containing cellulose and synthetic fiber mixtures.

[0155] In one case, the solution in which cellulose is dissolved is composed of a solvent, such as dimethyl sulfoxide (DMSO), and an ionic liquid, such as NMMO, AMIM-CL, BMIM-OAc, or one or more of some other ionic liquids. As taught in the present disclosure, the addition of DMSO or other materials as co-solvents can change the rheological properties (such as viscosity, thermal response characteristics, cellulose-fiber yield, time response characteristics, etc.) of the solution after dissolving the cellulose, so that the obtained solution can be used as a spinning raw material for various purposes. At least in some cases, the viscosity can be controlled using ozone, hydrogen peroxide, dimethylformamide (DMF), γ-butyrolactone (GBL), N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAc) or other materials.

[0156] This process operates before 312.

[0157] At 312, the cellulose fibers are dissolved in the ionic liquid solution and the synthetic fibers are suspended in the ionic liquid solution. As with other operations of the unified recycling workflow 106a-106d, the controller 146 can transmit control signals to various sensors 150 and receive data from various sensors 150 to control the dissolution process. Such control can optionally include management and control of any suitable heating structures, cooling structures, agitators, valves, ports, gates, inlets, outlets, motion detectors, fluid sampling sensors, timers, power supplies, robots, etc.

[0158] In a certain case, the raw material 120 is dissolved in the ionic liquid solution at a selected temperature for a selected time. In at least one case, the solvent and ionic liquid solution are 1:4 DMSO and BMIM-OAc solutions, the selected temperature is about 80 degrees Celsius (80°C), and the selected time is about 30 minutes (30min.). In some cases, the selected temperature is between about ten degrees Celsius (10°C) and about one hundred and seventy-five degrees Celsius (175°C). In other cases, the selected temperature can be between about sixty degrees Celsius (60°C) and about one hundred degrees Celsius (100°C), however, temperatures below about sixty degrees Celsius (60°C) and above about one hundred degrees Celsius (100°C) are expected. In at least one case, the selected temperature is room temperature. In these and other cases, the selected time can be between about five minutes (5min.) and about two hours (2hr.), however, times below five minutes (5min.) and above two hours (2hr.) can also be expected. In some cases, the time in solution is between about 5 minutes (5 min.) and about 10 hours (10 hr.). In these and other cases, the time in solution is more than about 30 minutes (30 min.) or less than about 8 hours (8 hr.). In at least one example case, the time in solution is about six hours (6 hr.), and in at least another example case, the time in solution is less than two hours (2 hr.).

[0159] This process is performed before step 314.

[0160] At 314, the synthetic fibers suspended in the solution are removed and chemically recycled into "new" synthetic fiber strands, and the cotton fibers dissolved in the solution are removed and wet spun into "new" cellulose strands.

[0161] The synthetic fiber of example includes but is not limited to polyester, nylon, acrylic acid, polyolefin etc.In some cases, the synthetic fiber suspended in the solution of shown cellulose solvent reactor 122 is vacuum extracted under the instruction of controller 146.Other known methods can also be used to remove the suspended synthetic fiber shown in cellulose solvent reactor 122.In some cases, the synthetic fiber is filtered, rinsed with deionized water or processed with other known methods.In some cases, the previously suspended synthetic fiber is spun on the first industrial standard spool.In other cases, the synthetic fiber is combined with other fibers or filaments to produce mixed textiles.At least in some cases, the recovered cellulose material from the first wet spinning spinneret subsystem 128 can be optionally combined with the recovered synthetic material from the second solution storage tank 136a to produce a specific mixed fiber product.

[0162] Exemplary cellulose fibers include, but are not limited to, cotton, flax, rayon, hemp, jute, lyocell, bamboo, reed, and the like. After being acted upon by the ionic liquid solution in the cellulose solvent reactor 122, the cellulose fibers are dissolved to form a cellulose-containing solution 124. The cellulose-containing solution 124 can have any desired cellulose concentration. In some cases, the cellulose-containing solution 124 contains more than one and a half percent (0.5%) of cellulose fibers. In some cases, the cellulose-containing solution 124 contains one to two percent (1-2%) of cellulose fibers. In other cases, the cellulose-containing solution 124 contains more than two percent (2%) of cellulose fibers. In other cases, the cellulose-containing solution 124 contains less than five percent (5%), less than ten percent (10%), less than twenty-five percent (25%), less than fifty percent (50%), or less than one hundred percent (100%) of other percentages of cellulose fibers. In some cases, after removing (e.g., by filtering or other methods) some or all of the non-cellulose components (e.g., synthetics, proteins, insolubles, etc.), the cellulose-containing solution 124 can be further concentrated. In one case, the cellulose-containing solution 124 is concentrated to contain 15% to 17% (15-17%) cellulose fibers, if desired, using raw fiber. Alternatively, or in addition, the cellulose-containing solution 124 can be concentrated to contain more than five percent (5%), more than ten percent (10%), more than twenty-five percent (25%), and even more than fifty percent (50%) cellulose fibers, if desired, using raw fiber. These processes are performed under the guidance of the controller 146 and any suitable sensor 150.

[0163] The cellulose-containing solution 124 can be produced with rheological properties that make it suitable for wet spinning without further processing. Therefore, the cellulose-containing solution 124 can also be called a spinning solution.

[0164] According to the guidance of controller 146, the spinning solution is poured into, injected or otherwise placed in a cellulose coagulation bath 126, which includes a liquid, such as water, deionized water or other liquids. When the spinning solution enters the cellulose coagulation bath 126, the cellulose fibers begin to coagulate. Coagulated fiber is extracted from the cellulose coagulation bath 126, and enters a wet spinning spinneret subsystem 128, and is extruded from the spinneret as one or more continuous lines, yarns or other filaments. In some cases, the filaments are wound around an industrial standard bobbin. In some cases, two or more cellulose-based filaments are combined together to form a special mixed filament.

[0165] In some embodiments, two or more independent and different types of cellulose-based fibers are formed in a single batch process. The two or more independent and different types of cellulose-based fibers can be formed by dissolving the raw material 120 through the first process, the second process, and any appropriate number of processes. Each different process can dissolve the raw material 120 under different conditions (e.g., different ionic liquids, different temperatures, different pressures, different durations, different agitations, different co-solvents, etc.), and the conditions are guided by the controller 146 and the cooperative sensor 150. In this case, the unified recovery workflow 106a-106d can have one or more cellulose solvent storage tanks, one or more cellulose coagulation baths, and one or more wet spinneret subsystems. The resulting line can be wound on the same or separate industry standard spools.

[0166] The recycling of synthetic and cellulosic fibers may also include actions related to the color of the resulting filaments. In some cases, the original color of the textile 108 to be recycled is retained; in other cases, new colors can be added; in other cases, all colors can be removed, for example by bleaching, leaving the recycled material with a completely natural color state. When new colors are required, they can be provided by dyeing.

[0167] This process is performed before step 316.

[0168] At 316, the controller 146 directs operations related to the protein fibers and insolubles. For example, the protein fibers are recovered, recycled, or disposed of, and any remaining insoluble materials are recovered and recycled or disposed of.

[0169] In some cases, materials heavier than liquid (such as zippers, buckles, buckles, buttons, rivets, wires, supports, hook and loop systems, coins, gems, ornaments, elastic materials, paper, rubber, chewing gum, adhesives, flame retardants, waterproofing agents, insect repellent chemicals, pathogen-destroying chemicals, dirt, food, water, air, etc.) will sink to the bottom of the cellulose solvent reactor 122, the cellulose coagulation bath 126, the second solution storage tank 136a, and the insoluble material container 136b. These materials can be removed by one or more magnets, filters, screens, sweepers or other devices, which can be manually operated or controlled and managed by the controller 146. These items can be recycled or processed in other known ways. For example, processing can include chemical treatment, high temperature treatment (such as incineration, melting, vitrification, etc.), reuse (such as processing into insulation materials, cardboard, fillers, foams, etc.), industrial reuse, or as a last resort, traditional landfill treatment. However, after research, the inventors believe that the amount of landfilled as a last resort is likely to be only a tiny fraction of the original waste volume, and that this waste is likely to involve materials that will not decay into greenhouse gases or nanoplastic particles.

[0170] In some cases, after the cellulose and synthetic fibers are removed, the protein fibers are separated from the remaining liquid. The protein fibers can be removed and recovered by a separate process. For example, the protein fibers can be filtered through a filter, collected on a membrane, vacuumed, centrifuged, or extracted in other known ways. In some cases, the collected protein fibers can be mechanically compressed into a wool felt pad. The pad can be carded and spun using conventional wool processes.

[0171] This process is performed before step 318.

[0172] At 318, the ionic liquid is recovered and reused in the reaction chamber. The ionic liquid used in the unified recovery workflow 106a-106d of the present disclosure is non-volatile, or will not be exhausted or consumed in the cellulose solvent reactor or in any other container of the unified recovery workflow 106a-106d. Some of the ionic liquid may also be removed when the raw material is processed and pushed from the cellulose reaction chamber to another container. After the fiber or other material is recovered, the ionic liquid can be returned to the cellulose solvent reactor or some other storage tank by means such as an ionic liquid recovery path. The recovery of the ionic liquid can include operating one or more heating elements, vents and other structures to evaporate water or other materials in the ionic liquid.

[0173] The operations performed in the data flow 300 are in progress. The process returns to 304.

[0174] After describing some embodiments, further describing certain terms used herein can help to more fully understand the contents believed to be inventive in the present disclosure.

[0175] In an embodiment of the present disclosure, one or more specific materials and fluids are arranged to flow in one or more chambers, receptacles, reactors, vessels, etc., and these structures can be controlled in part or in whole by an electronic control system. The various components and devices in the embodiments described herein can be interchangeably described as "coupled", "connected", "attached", etc. It should be recognized that once assembled, the system is arranged to be a unified recovery system consisting of two or more optionally subsystems. In this embodiment, the sealing degree of the joints formed by the material at the junction of two or more structures reaches a level acceptable to machinery, medicine, commerce or other industries.

[0176] Figure 3 The data flow diagram includes non-limiting processes that may be used in embodiments of the unified recycling workflow. In this regard, each process described can represent a module, segment, or portion of software code, including one or more executable instructions for implementing a specified logical function. It should also be noted that in some embodiments, the functions mentioned in the illustrated processes may appear in a different order, may include additional functions, may appear simultaneously, and / or may be omitted.

[0177] The drawings of the present disclosure illustrate portions of one or more non-limiting computing device embodiments, such as one or more components of the first and second unified textile recycling systems 100A, 100B. The computing devices shown can include operating hardware in conventional computing device devices, such as one or more processors, volatile and non-volatile memory, serial and parallel input / output (I / O) circuits that comply with various standards and protocols, wired and / or wireless networking circuits (such as communication transceivers), one or more user interface (III) modules, logic and other electronic circuits.

[0178] The processing devices or "processors" described herein include central processing units (CPUs), microcontrollers (MCUs), digital signal processors (DSPs), application specific integrated circuits (ASICs), peripheral interface controllers (PICs), state machines, etc. Therefore, the processors described herein include any device, system, or part thereof that controls at least one operation, and such devices can be implemented in hardware, firmware, or software, or a combination of at least two of them. Functions associated with any particular processor can be centralized or distributed, and can be local or remote. Processors can interchangeably refer to any type of electronic control circuit configured to execute programmed software instructions. The programming instructions shown can be high-level software instructions, compiled software instructions, assembly language software instructions, object code, binary code, microcode, etc. The programming instructions shown can exist in internal or external memory, or can be hard-coded as a state machine or a set of control signals. According to the methods and devices mentioned herein, one or more embodiments describe software executed by a processor, and when executed, the software performs one or more method actions.

[0179] This application discusses several embodiments that include or otherwise cooperate with one or more computing devices. It is recognized that the computing device is arranged to execute one or more algorithms to implement the various concepts taught herein. Each of the algorithms is understood to be a finite sequence of steps to solve a logical or mathematical problem or perform a task. Any or all algorithms taught by the present disclosure can be demonstrated by formulas, flow charts, data flow diagrams, the specification description, and other obvious ways in the present disclosure. Along these lines, the structure that executes the algorithm disclosed herein includes at least one processing device that executes at least one software instruction retrieved from at least one storage device. Depending on the circumstances, the structure can further include suitable input circuits known to those skilled in the art (e.g., keyboards, buttons, storage devices, communication circuits, touch screen inputs, and any other integrated circuit and peripheral circuit inputs (e.g., accelerometers, pH meters, capacitance or conductivity circuits, thermometers, light detection circuits, and other such sensors)), suitable output circuits known to those skilled in the art (e.g., displays, light sources, audio devices, tactile devices, control signals, switches, relays, etc.), and any additional circuits or other structures taught by the present disclosure. For this reason, if necessary, each call to a means or step function element in any claim will be explicitly stated.

[0180] As known to those skilled in the art, a computing device has one or more memories, and each memory includes any combination of volatile and non-volatile computer-readable media for reading and writing. Volatile computer-readable media include, for example, random access memory (RAM), etc. Non-volatile computer-readable media include, for example, read-only memory (ROM), magnetic media, such as hard disks, optical disks, flash memory devices, CD-ROMs, etc. In some cases, a specific memory is virtually or physically divided into different areas, such as a first memory, a second memory, a third memory, etc. In these cases, it is understood that different partitions of the memory can be in different devices, or embodied in a single memory. In some cases, the memory is a non-temporary computer medium for storing software instructions executed by a processor. Part or all of the storage content of the memory can include software instructions executed by a processing device to perform one or more specific actions.

[0181] The computing device described herein can further include operating software in a conventional computing device, such as an operating system or task loop, a software driver that guides operations through I / O circuits, network circuits, and other peripheral component circuits. In addition, the computing device can also include operating application software, such as network software for communicating with other computing devices, database software for building and maintaining databases, and task management software that is suitable for distributing communication and / or operating workloads between different processors. In some cases, the computing device is a single hardware machine that has at least some of the hardware and software listed herein, and in other cases, the computing device is a network collection of hardware and software machines that work together in a server group to perform the functions of one or more embodiments described herein. For the sake of brevity, certain aspects of the conventional hardware and software of the computing device are not shown in the accompanying drawings.

[0182] Among other things, the exemplary computing devices of the present disclosure (such as controller 146, computing network 154, computing server 156 and database 158) can be configured in any type of mobile or fixed computing device, such as a remote cloud computer, a computing server, a smart phone, a tablet computer, a laptop computer, a wearable device (such as glasses, jackets, shirts, pants, socks, shoes, other clothing, hats, helmets, other headwear, watches, bracelets, pendants, other jewelry), a vehicle-mounted device (such as a train, an airplane, a helicopter, an unmanned aerial vehicle, an unmanned underwater vehicle, an unmanned land vehicle, a car, a motorcycle, a bicycle, a scooter, a hoverboard, other personal or commercial transportation equipment), an industrial device (such as a factory robot device, a home use robot device, a retail robot device, an office environment robot device) or the like. Therefore, the computing device includes other components and circuits not shown, such as a display, a network interface, a memory, one or more central processors, a camera interface, an audio interface, and other input / output interfaces. In some cases, the exemplary computing device can also be configured in different types of low-power devices, such as mounted cameras, Internet of Things (IoT) devices, multimedia devices, motion detection devices, intrusion detection devices, security devices, crowd monitoring devices, or other devices.

[0183] When arranged as described herein, each computing device is capable of being transformed from a general-purpose, non-specific computing device into a combined device consisting of hardware and software configured for a specific and particular purpose, such as providing a determined technical solution. When arranged as described herein, to the extent that any inventive concept described herein is found by an adjudicating body to be contained in an abstract concept, an ordered combination of elements and limitations is expressly proposed to provide the necessary inventive concept by transforming the abstract concept into a tangible and concrete practical application of said abstract concept.

[0184] The embodiments described herein utilize computer technology to improve textile recycling technology, but there are still other technologies and tools that can be used to process textile waste. Therefore, the subject matter of the claims does not exclude the entire or even most of the field of textile recycling technology. The innovation described herein uses new and known structures and combines them with other structures and limitations in new and useful ways to create something more than has been known so far. The embodiments improve computing systems that cannot perform or provide the specific unified recycling workflow system functions described herein without being programmed or programmed differently. The embodiments described in the present disclosure improve known textile recycling processes and technologies. The computerized actions described in the embodiments are not purely traditional behaviors and are not well known. On the contrary, the actions are new actions in the industry. In addition, the combination of actions described in the embodiments provides new information, motivation and business results that do not exist when these actions are considered separately. There is currently no generally accepted definition of what constitutes an abstract concept. To the extent that the concepts discussed in this disclosure can be considered abstract, the claims propose significantly more specific, more practical and more tangible applications of the abstract concepts. And the claims also improve previously known computer-based systems for performing textile recycling operations.

[0185] Software can include a fully executable software program, a simple configuration data file, a link pointing in other directions, or any combination of known software types. When a computing device updates software, the update can be small or large. For example, in some cases, a computing device downloads a small configuration data file as part of the software, and in other cases, a computing device completely replaces most or all of the existing software on itself or other computing devices with the new version. In some cases, software, data, or both are encrypted, encoded, and / or compressed for reasons of security, privacy, data transfer speed, data cost, and the like.

[0186] If a database structure is present in the textile recycling system described herein, it can be formed in a single database or multiple databases. In some cases, a hardware or software repository is shared between various functions of one or more specific systems associated therewith. The database can be built as part of a local system or local area network. Alternatively, or in addition, the database can also be built remotely, such as in a distributed "cloud" computing system, which can be accessed via a wide area network or other network.

[0187] Input / output (I / O) circuits and user interface (III) modules include serial ports, parallel ports, universal serial bus (USB) ports, IEEE 802.11 transceivers and other transceivers that conform to protocols managed by one or more standards-setting bodies, displays, projectors, printers, keyboards, computer mice, microphones, micro-electromechanical devices such as accelerometers, etc.

[0188] In at least one embodiment, devices such as controller 146 can communicate with other devices via a computing network 154. The network can involve an Internet connection or some other type of local area network (LAN) or wide area network (WAN). Non-limiting examples of structures that can implement or form part of the network include, but are not limited to, Ethernet, twisted pair Ethernet, digital subscriber loop (DSL) equipment, wireless LAN, Wi-Fi, Worldwide Interoperability for Microwave Access (WiMax), etc.

[0189] In the present disclosure, memory can be used in one or another configuration. The memory can be configured to store data. Alternatively or in addition, the memory can be a non-volatile computer readable medium (CRM). The CRM is configured to store computing instructions executed by the processor of the controller 146. The computing instructions can be stored individually or as a group of instructions in a file. The file can include functions, services, libraries, etc. The file can include one or more computer programs, or may be part of a larger computer program. Alternatively or additionally, each file can include data or other computing support materials for performing the computing functions of the unified recycling workflow system.

[0190] Buttons, keyboards, computer mice, memory cards, serial ports, biosensor readers, touch screens, etc. can be used to operate the unified recovery workflow system to scientific workers individually or in cooperation. For example, the device can control the information input system. Displays, printers, memory cards, LED indicators, temperature sensors, audio devices (such as speakers, piezoelectric devices, etc.), vibrators, etc. all help to provide output information to the scientific workers operating the unified recovery workflow system. In some cases, the input and output devices are directly coupled to the controller 146 and are electronically coupled to a processor or other operating circuit. In another case, the input and output devices transmit information through one or more communication ports (such as RS-232, RS-485, infrared, USB, etc.).

[0191] As described herein, for the sake of brevity, the unified recycling workflow is described in some cases in the context of the male gender. It should be understood that the unified recycling workflow can be of any gender, and the terms "he," "his," and the like used herein should be interpreted broadly to include all known gender definitions. As required by the context in this disclosure, the singular refers to the plural and vice versa, unless the context otherwise requires; all pronouns shall refer to and include the individual, entity, firm, or company to which they relate; and the masculine refers to the feminine and vice versa.

[0192] As used herein and in the claims that follow, the terms "real-time" or "real time" do not imply instantaneous processing, transmission, reception, or otherwise as the case may be. Rather, the terms "real-time" and "real time" mean that an activity is performed in an acceptably short period of time (e.g., in microseconds, milliseconds, minutes, or hours) and that the activity is capable of being performed on an ongoing basis (e.g., sorting, dissolving cellulosic material, etc.). An example of a non-real-time activity is an activity that occurs over an extended period of time (e.g., days, weeks, months, or years), or an activity that occurs under the intervention or guidance of a unified recycling workflow or other activity.

[0193] In the absence of any specific description of its clear use in a particular context, in the present disclosure and any appended claims, the term "substantially" or "approximately" used as a modifier in any grammatical form (e.g., for modifying structure, size, measurement or some other feature) should be understood as that the characteristic can vary by up to 30%. For example, a cellulose solvent reactor can be described as being formed or otherwise oriented "substantially vertically", in which case a completely vertical reactor is oriented along a Z axis, which is orthogonal (i.e., 90 degrees or right angles) to the plane formed by the "X" axis and the "Y" axis. Unlike the precision of the term "vertical", the use of "substantially" to modify a feature allows a deviation of up to 30% for a "vertical" feature. Therefore, a cellulose solvent reactor with a "substantially vertical" orientation includes a cellulose solvent reactor with an orientation between 63 degrees and 117 degrees. However, a cellulose solvent reactor that is 45 degrees from the XY plane does not belong to a "substantially vertical" installation. As another example, the specific linear dimension of the cellulose solvent reactor is "between about three feet (3ft.) and five feet (5ft.)", including equipment with a linear dimension variation of up to 30%, thus, the specific linear dimension of the cellulose solvent reactor can be between one and a half feet (1.5ft.) and six and a half feet (6.5ft.).

[0194] Where a numerical range is provided, unless the context clearly dictates otherwise, each interval value between the upper and lower limits of the range (in units of one-tenth of the lower limit) and any other specified values ​​or interval values ​​within the range are included in the present invention. The upper and lower limits of these smaller ranges can be independently included in the smaller ranges and are also included in the present invention, subject to any explicitly excluded limitations in the ranges. When the specified range includes one or two limitations, the range that does not include one or both of the included limitations is also included in the present invention.

[0195] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as those generally understood by those of ordinary skill in the art to which the invention belongs. Although any methods and materials similar or equivalent to the methods and materials described herein can also be used in the practice or testing of the present invention, only a limited number of exemplary methods and materials are described herein.

[0196] In the present disclosure, when an element (e.g., component, circuit, device, apparatus, structure, layer, material, etc.) is referred to as being "on", "coupled to" or "connected to" another element, the elements can be directly on, directly coupled to, or directly connected to each other, or there can be intermediate elements. Conversely, when an element is referred to as being "directly on", "directly coupled to" or "directly connected to" another element, there are no intermediate elements.

[0197] The terms "include" and "comprising," and their derivatives and variations, in all their syntactic contexts, are to be construed as having an open, inclusive meaning (e.g., "including, but not limited to"). The term "or" is inclusive, meaning and / or. The phrases "associated with" and "related to," and their derivatives, can be construed as including, contained within, interconnected with, containing, contained within, connected to or with it, coupled to or with it, communicating with, cooperating with, interlaced, juxtaposed with, proximate to, bound to or with it, having, having attributes thereof, and the like.

[0198] References to "one embodiment" or "an embodiment" and variations thereof in this specification refer to specific features, structures, or characteristics associated with the embodiment, which are included in at least one embodiment. Therefore, the phrases "in one embodiment" or "in an embodiment" appearing throughout this specification do not necessarily refer to the same embodiment. In addition, in one or more embodiments, specific features, structures, or characteristics can be combined in any suitable manner.

[0199] In the present disclosure, the terms first, second, etc. can be used to describe various elements, but these elements are not limited by these terms unless the context clearly requires such limitation. These terms are only used to distinguish one element from another element. For example, a first machine can be called a second machine, and, similarly, a second machine can also be called a first machine without departing from the scope of the present inventive concept.

[0200] Unless the context and the like clearly dictate otherwise, the singular terms "a", "an", and "the" in this disclosure include plural references. The conjunction terms "and" and "or" are generally used in the broadest sense, including "and / or", unless the context and the like clearly dictate inclusivity or exclusivity as appropriate. In this document, the "and / or" consisting of "and" and "or" includes embodiments that include all the relevant elements, as well as at least one alternative embodiment that includes less than all the relevant elements.

[0201] In the present disclosure, a comma is used to connect lists, which can be called Oxford comma, Harvard comma, serial comma or other similar terms. Such a list is intended to connect words, clauses or sentences so that the content after the comma is also included in the list.

[0202] The titles and abstracts of the disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

[0203] An estimated 10 to 20 million metric tons of textile waste is generated in the United States each year. Globally, it is estimated that close to 100 million tons of textiles are discarded each year, and this number is expected to reach nearly 150 million tons per year by 2030. Currently, only a small portion of this textile waste is reused, mainly by shredding and using it as insulation or stuffing. It is estimated that less than one percent of textile waste is chemically recycled into new fibers. Instead, most textile waste today is dumped in expensive landfills. It is estimated that the cost of disposing of this waste in the United States is about $1 billion per year, while in Europe, where landfill costs are much higher than in the United States, it is estimated to be more than $8 billion. However, the proposed new EU regulations are expected to prevent the landfilling of any fabrics or the transfer of any waste to other countries.

[0204] Most of the textile waste dumped into landfills is made up of cotton, polyester, and cotton and polyester blends. Cotton quickly decays, turning into water and two damaging greenhouse gases, methane and carbon dioxide. In contrast, polyester does not decay, and it breaks down into microplastic particles that migrate into the surrounding ecosystem. Microplastics have been linked to changes in human hormones, they are suspected of affecting fertility, and contributing to childhood obesity, autoimmune diseases, and other cancers. In addition, countries such as China and Indonesia, which have traditionally received fabric waste from the United States and Europe, are currently reducing or ending this practice. A few countries, such as Chile, continue to receive textile waste, but the waste is not processed. Instead, the waste is simply dumped in the deserts of the Andes. Many environmental organizations condemn this practice.

[0205] The textile recycling system described in the present disclosure provides multiple technical effects and advances in the field of textile waste treatment. Technical effects and advantages include the ability to completely recycle cellulose and synthetic fabric waste into new fibers that are commercially indistinguishable from the original fibers. The teachings of the present disclosure solve the problem of textile waste by using ionic liquids and other chemical processes in a single closed-loop workflow to recycle textiles. Implementations of the systems, devices, and methods disclosed herein reduce energy consumption and improve environmental management by reducing greenhouse gases produced during landfill decomposition and reducing the need to farm and manufacture new textiles at a commercially acceptable price.

[0206] For example, in at least one embodiment, textile waste is collected and transported to a loading and unloading area of ​​a recycling center. The waste is then sorted into pure cotton, pure polyester, pure protein, and cotton blends by a novel, non-obvious optoelectronic method. In the case of cotton-polyester blends, the sorted material is chopped into small particles and added to a reaction chamber with one or more selected ionic liquid solvents. Once the cellulose fibers are dissolved and once the polyester fibers are suspended in the solution, the polyester fibers are removed by filtration and the cotton fibers are removed by wet spinning. The polyester filaments and cotton filaments are then wound on industry standard spools and prepared for sale. After removing the cotton and polyester fibers, the protein fibers are filtered out and recovered by a separate process, insoluble items (such as metal buckles, buttons, rivets, zippers, etc.) are extracted and recovered, and the ionic liquid is recovered and reused in the reaction chamber.

[0207] The disclosure sets forth details of various structural embodiments that can be used to implement the teachings of the disclosure. By utilizing the unified recycling workflow described herein, some example systems, devices, and methods are now disclosed.

[0208] Embodiment A-1 is a textile recycling method, comprising receiving textiles to be recycled; sorting the textiles to be recycled to separate cellulose-containing products from cellulose-free products; adjusting the size of at least part of the cellulose-containing products to generate raw materials; treating the raw materials in a cellulose solvent reactor having at least one ionic liquid to generate a spinning solution, wherein the treatment includes at least partially dissolving part or all of the intermolecular cellulose bonds of the raw materials, thereby generating a cellulose-containing solution having cellulose fibers dissolved in at least one ionic liquid; extruding the spinning solution in a cellulose coagulation bath to reorganize at least part of the dissolved cellulose fibers; and wet spinning at least part of the reorganized cellulose fibers into continuous cellulose filaments.

[0209] Embodiment A-2 can include the subject matter of Embodiment A-1, and may alternatively or additionally include the subject matter of any other embodiment herein, further comprising: vacuum extracting or mechanically filtering insoluble material from the cellulose solvent reactor; separating synthetic fiber material from the insoluble material; and recycling the synthetic fiber material into continuous synthetic filaments.

[0210] Embodiment A-3 can include the subject matter of any of Embodiments A-1 to A-2, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes initializing a computing controller for directing the operation of the textile recycling method.

[0211] Embodiment A-4 can include the subject matter of any one of Embodiments A-1 to A-3, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes pre-loading a selected volume of a specific ionic liquid in the cellulose solvent reactor.

[0212] Embodiment A-5 can include the subject matter of any of Embodiments A-1 to A-4, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes pre-loading a selected volume of a specific mixture of two or more ionic liquids in the cellulose solvent reactor.

[0213] Embodiment A-6 can include the subject matter of any one of Embodiments A-1 to A-5, and can alternatively or additionally include the subject matter of any other embodiment herein, wherein receiving the textiles to be recycled includes one or more of weighing, manually sorting according to weight, physical size, color, item type, cleanliness or dryness status, stacking, piling or layering.

[0214] Embodiment A-7 can include the subject matter of any one of Embodiments A-1 to A-6, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes generating at least one digital tag representing at least one attribute of at least some of the textiles to be recycled, comparing the at least one produced digital tag with the stored digital tag, and guiding the processing of at least some of the textiles to be recycled based on the comparison result.

[0215] Embodiment A-8 can include the subject matter of any of Embodiments A-1 to A-7, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, based on the sorting, directing the operation of at least one conveyor belt, gate, pump, valve, fan, motor, aspirator, filter or timer.

[0216] Embodiment A-9 can include the subject matter of any of Embodiments A-1 to A-8, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, based on said sorting, directing the operation of at least one electronically controllable circuit.

[0217] Embodiment A-10 can include the subject matter of any of Embodiments A-1 to A-9, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, based on the sorting, directing a recovery operation of the cellulose-containing material.

[0218] Embodiment A-10 can include the subject matter of any of Embodiments A-1 to A-10, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, based on said sorting, directing a recovery operation of synthetic-containing materials.

[0219] Embodiment A-12 can include the subject matter of any of Embodiments A-1 to A-11, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, based on said sorting, directing a recovery operation of protein-containing material.

[0220] Embodiment A-13 can include the subject matter of any one of Embodiments A-1 to A-12, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, based on the sorting, directing the recovery operation of insoluble materials.

[0221] Embodiment A-14 can include the subject matter of any one of Embodiments A-1 to A-13, and may alternatively or additionally include the subject matter of any other embodiment herein, and further include: based on the sorting, generating at least one of a first digital label representing cotton material, a second digital label representing polyester material, a third digital label representing a specific cotton and polyester blend, a fourth digital label representing a specific leather material, and a fifth digital label representing a specific paper material, and guiding a conveying machinery to move at least a portion of the textiles to be recycled.

[0222] Embodiment A-15 can include the subject matter of any one of Embodiments A-1 to A-14, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes storing a plurality of digital tags in a database, wherein each of the plurality of digital tags represents a material having a specific molecular structure.

[0223] Embodiment A-16 can include the subject matter of any one of Embodiments A-1 to A-15, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes storing a plurality of digital tags in a database, wherein each of the plurality of digital tags represents a material having a specific molecular structure, wherein the specific molecular structure includes at least one of pure cellulose, pure synthetic, pure protein, a blend of cellulose and at least one other material.

[0224] Embodiment A-17 can include the subject matter of any one of Embodiments A-1 to A-16, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes storing a plurality of digital tags in a database, wherein each of the plurality of digital tags represents a material having a specific molecular structure, wherein the specific molecular structure includes at least one pure cellulose fiber, a majority of the pure cellulose fibers having a selected minimum length.

[0225] Embodiment A-18 can include the subject matter of any of Embodiments A-1 to A-17, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes storing a plurality of digital tags in a database, wherein each of the plurality of digital tags represents a material having a specific color.

[0226] Embodiment A-19 can include the subject matter of any of Embodiments A-1 to A-18, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes receiving at least one ionic liquid into the cellulose solvent reactor through an inlet port.

[0227] Embodiment A-20 can include the subject matter of any of Embodiments A-1 to A-19, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes receiving a second ionic liquid into the cellulose solvent reactor.

[0228] Embodiment A-21 can include the subject matter of any one of Embodiments A-1 to A-20, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, passing said feedstock or a portion of said feedstock from a first storage tank of said cellulose solvent reactor into a second storage tank of said cellulose solvent reactor.

[0229] Embodiment A-22 can include the subject matter of any of Embodiments A-1 to A-21, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, stirring the cellulose solvent reactor or the material within the cellulose solvent reactor.

[0230] Embodiment A-23 can include the subject matter of any of Embodiments A-1 to A-22, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, stirring said cellulose solvent reactor or material within said cellulose solvent reactor for a determined period of time.

[0231] Embodiment A-24 can include the subject matter of any of Embodiments A-1 to A-23, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, heating the cellulose solvent reactor or material within the cellulose solvent reactor.

[0232] Embodiment A-25 can include the subject matter of any one of Embodiments A-1 to A-24, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, heating said cellulose solvent reactor or material within said cellulose solvent reactor to a determined temperature or temperature range.

[0233] Embodiment A-26 can include the subject matter of any of Embodiments A-1 to A-25, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, heating the cellulose solvent reactor or material within the cellulose solvent reactor for a determined period of time.

[0234] Embodiment A-27 can include the subject matter of any of Embodiments A-1 to A-26, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, pressurizing the cellulose solvent reactor.

[0235] Embodiment A-28 can include the subject matter of any of Embodiments A-1 to A-27, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, pressurizing the cellulose solvent reactor to a selected pressure or pressure range.

[0236] Embodiment A-29 can include the subject matter of any of Embodiments A-1 to A-28, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, pressurizing said cellulose solvent reactor for a determined period of time.

[0237] Embodiment A-30 can include the subject matter of any of Embodiments A-1 to A-29, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, controlling the viscosity of the fluid in the cellulose solvent reactor.

[0238] Embodiment A-31 can include the subject matter of any of Embodiments A-1 to A-30, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, controlling the viscosity of the fluid in the cellulose solvent reactor at least in part by adding a selected amount of ozone.

[0239] Embodiment A-32 can include the subject matter of any of Embodiments A-1 to A-31, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, controlling the viscosity of the fluid in the cellulose solvent reactor at least in part by adding a selected amount of hydrogen peroxide.

[0240] Embodiment A-33 can include the subject matter of any of Embodiments A-1 to A-32, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an aqueous NaOH solution at a selected temperature.

[0241] Embodiment A-34 may include the subject matter of any of Embodiments A-1 to A-33, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an aqueous NaOH solution at a selected temperature.

[0242] Embodiment A-35 can include the subject matter of any of Embodiments A-1 to A-34, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an aqueous NaOH solution at a temperature between about ten degrees Celsius (10°C) and about one hundred fifty degrees Celsius (150°C).

[0243] Embodiment A-36 can include the subject matter of any of Embodiments A-1 to A-35, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an aqueous NaOH solution at a temperature of about ninety degrees Celsius (90°C).

[0244] Embodiment A-37 can include the subject matter of any of Embodiments A-1 to A-36, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an aqueous NaOH solution at a temperature of less than about ten degrees Celsius (10°C).

[0245] Embodiment A-38 can include the subject matter of any of Embodiments A-1 to A-37, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an aqueous NaOH solution at a temperature greater than about one hundred fifty degrees Celsius (150°C).

[0246] Embodiment A-39 can include the subject matter of any of Embodiments A-1 to A-38, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an aqueous NaOH solution at room temperature.

[0247] Embodiment A-40 can include the subject matter of any one of Embodiments A-1 to A-39, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, washing said feedstock with deionized water until a neutral pH is reached.

[0248] Embodiment A-41 can include the subject matter of any of Embodiments A-1 to A-40, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, drying said feedstock using at least one of an oven, a radiant heating element, or a forced air system.

[0249] Embodiment A-42 can include the subject matter of any of Embodiments A-1 to A-41, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, immersing the feedstock in an ionic liquid solution including a single ionic liquid.

[0250] Embodiment A-43 can include the subject matter of any of Embodiments A-1 to A-42, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, immersing the feedstock in an ionic liquid solution including two or more ionic liquids.

[0251] Embodiment A-44 can include the subject matter of any of Embodiments A-1 to A-43, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, immersing the feedstock in an ionic liquid solution including only one or more ionic liquids.

[0252] Embodiment A-45 can include the subject matter of any of Embodiments A-1 to A-44, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the processing, immersing the feedstock in an ionic liquid solution including one or more ionic liquids and at least one other material.

[0253] Embodiment A-46 can include the subject matter of any one of Embodiments A-1 to A-45, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an ionic liquid solution comprising one or more of an imidazolium compound ionic liquid, an acetate oxide compound ionic liquid, and a methyl oxide compound ionic liquid.

[0254] Embodiment A-47 can include the subject matter of any one of Embodiments A-1 to A-46, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the treatment, immersing the feedstock in an ionic liquid solution, the ionic liquid comprising one or more of N-methylmorpholine-N-oxide (NMMO), 1-allyl-3-methylimidazolium chloride (AMIM-CL), and 1-butyl-3-methylimidazolium acetate (BMIM-OAc).

[0255] Embodiment A-48 can include the subject matter of any of Embodiments A-1 to A-47, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an ionic liquid solution comprising at least one ionic liquid and at least one solvent.

[0256] Embodiment A-49 can include the subject matter of any of Embodiments A-1 to A-48, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an ionic liquid solution comprising at least one ionic liquid and at least one co-solvent.

[0257] Embodiment A-50 can include the subject matter of any one of Embodiments A-1 to A-49, and can alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the treatment, immersing the feedstock in an ionic liquid solution, the ionic liquid solution comprising at least one ionic liquid and at least one co-solvent, the co-solvent being at least one of dimethyl sulfoxide (DMSO), ozone, hydrogen peroxide, dimethylformamide (DMF), γ-butyrolactone (GBL), N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAc), or other materials.

[0258] Embodiment A-51 can include the subject matter of any of Embodiments A-1 to A-50, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an ionic liquid solution having a temperature of about eighty degrees Celsius (80° C.).

[0259] Embodiment A-52 can include the subject matter of any of Embodiments A-1 to A-51, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an ionic liquid solution having a temperature between about ten degrees Celsius (10° C.) and about one hundred and seventy-five degrees Celsius (175° C.).

[0260] Embodiment A-53 can include the subject matter of any of Embodiments A-1 to A-52, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, soaking said feedstock in an ionic liquid solution having a temperature between about sixty degrees Celsius (60° C.) and about one hundred degrees Celsius (100° C.).

[0261] Embodiment A-54 can include the subject matter of any of Embodiments A-1 to A-53, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an ionic liquid solution having a temperature of less than about 60 degrees Celsius (60° C.).

[0262] Embodiment A-55 can include the subject matter of any of Embodiments A-1 to A-54, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing said feedstock in an ionic liquid solution at a temperature greater than about one hundred degrees Celsius (100° C.).

[0263] Embodiment A-56 can include the subject matter of any of Embodiments A-1 to A-55, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the treatment, immersing the feedstock in an ionic liquid solution for about thirty minutes (30 min.).

[0264] Embodiment A-57 may include the subject matter of any one of Embodiments A-1 to A-56, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the treatment, immersing the feedstock in an ionic liquid solution for about five minutes (5 min.) to about two hours (2 hr.).

[0265] Embodiment A-58 can include the subject matter of any of Embodiments A-1 to A-57, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the treatment, immersing the feedstock in an ionic liquid solution for less than 5 minutes (5 min.).

[0266] Embodiment A-59 can include the subject matter of any of Embodiments A-1 to A-58, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said treating, immersing said feedstock in an ionic liquid solution for more than two hours (2 hr.).

[0267] Embodiment A-60 can include the subject matter of any one of Embodiments A-1 to A-59, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the treatment, immersing the feedstock in an ionic liquid solution for about 5 minutes (5 min.) to about 10 hours (10 hr.).

[0268] Embodiment A-61 can include the subject matter of any one of Embodiments A-1 to A-60, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of the treatment, immersing the feedstock in an ionic liquid solution for greater than about 30 minutes (30 min) or less than about 8 hours (8 hr.).

[0269] Embodiment A-62 can include the subject matter of any of Embodiments A-1 to A-61, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said, immersing the feedstock in an ionic liquid solution for about 6 hours (6 hr.).

[0270] Embodiment A-63 can include the subject matter of any of Embodiments A-1 to A-62, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said treating, immersing said feedstock in an ionic liquid solution for less than about two hours (2 hr.).

[0271] Embodiment A-64 can include the subject matter of any of Embodiments A-1 to A-63, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes, as part of said processing, immersing the feedstock in an ionic liquid solution dried to a water content of less than 0.2%.

[0272] Embodiment A-65 can include the subject matter of any of Embodiments A-2 through A-64, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes filtering the synthetic fibers to remove undesirable matter.

[0273] Embodiment A-66 can include the subject matter of any of Embodiments A-2 through A-65, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes rinsing the synthetic fibers with deionized water.

[0274] Embodiment A-67 can include the subject matter of any of Embodiments A-2 to A-66, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes combining the continuous synthetic filaments with the continuous cellulosic filaments to produce a mixed filament product.

[0275] Embodiment A-68 can include the subject matter of any of Embodiments A-2 through A-67, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes winding the continuous synthetic filament onto a first industry standard spool.

[0276] Embodiment A-69 can include the subject matter of any of Embodiments A-1 through A-68, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes bleaching the cellulosic fibers.

[0277] Embodiment A-70 can include the subject matter of any of Embodiments A-1 through A-69, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes dyeing the cellulosic fibers.

[0278] Embodiment A-71 can include the subject matter of any of Embodiments A-1 to A-70, and alternatively or additionally include the subject matter of any other embodiment herein, and further includes recovering protein fiber from the feedstock.

[0279] Embodiment A-72 can include the subject matter of any of Embodiments A-1 to A-71, and alternatively or additionally include the subject matter of any other embodiment herein, and further comprises recovering protein fibers from the feedstock via at least one of a filter and a membrane.

[0280] Embodiment A-73 can include the subject matter of any one of Embodiments A-1 to A-72, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes collecting heavier-than-liquid material from the cellulose solvent reactor.

[0281] Embodiment A-74 can include the subject matter of any one of Embodiments A-1 to A-73, and may alternatively or additionally include the subject matter of any other embodiment herein, and further includes collecting heavier-than-liquid material from the cellulose solvent reactor using at least one of a magnet, a screen, and a sweeper.

[0282] Embodiment A-75 can include the subject matter of any of Embodiments A-1 through A-74, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the acts of the textile recycling method are performed at a single location.

[0283] Embodiment A-76 can include the subject matter of any of Embodiments A-1 to A-75, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the actions of the textile recycling method are performed at a single location, wherein the single location is one of a single factory, a single room, or a single residence.

[0284] Embodiment A-77 can include the subject matter of any of Embodiments A-1 to A-76, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is performed by an optical sorting subsystem.

[0285] Embodiment A-78 can include the subject matter of any of Embodiments A-1 to A-77, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is performed by an optical sorting subsystem having at least one forward-looking infrared (FLIR) camera.

[0286] Embodiment A-79 can include the subject matter of any of Embodiments A-1 to A-78, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is performed by an optical sorting subsystem having at least one Fourier transform infrared camera.

[0287] Embodiment A-80 can include the subject matter of any of Embodiments A-1 to A-79, and can alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is performed by an optical sorting subsystem having at least one infrared camera.

[0288] Embodiment A-81 can include the subject matter of any of Embodiments A-1 to A-80, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is performed by a chemical sorting subsystem.

[0289] Embodiment A-82 can include the subject matter of any of Embodiments A-1 to A-81, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is performed by a subsystem that measures the weight of at least a portion of the textiles to be recycled.

[0290] Embodiment A-83 can include the subject matter of any of Embodiments A-1 to A-82, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is used to generate at least one digital tag representing at least one characteristic of at least a portion of the textiles to be recycled.

[0291] Embodiment A-84 can include the subject matter of any of Embodiments A-1 to A-83, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is used to identify at least one batch of cellulosic material, synthetic material, protein material or mixed material in the textile to be recycled.

[0292] Embodiment A-85 can include the subject matter of any of Embodiments A-1 to A-84, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is used to identify at least one batch of cellulosic material and one batch of synthetic material, protein material or mixed material in the textile to be recycled.

[0293] Embodiment A-86 can include the subject matter of any of Embodiments A-1 to A-85, and can alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is used to identify at least one batch of material in the textiles to be recycled that has been treated with a flame retardant, a water repellent chemical, a pesticide, or an anti-biological pathogen chemical.

[0294] Embodiment A-87 can include the subject matter of any of Embodiments A-1 to A-86, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is used to advance at least one batch of the textile material to be recycled for processing in the cellulose solvent reactor.

[0295] Embodiment A-88 can include the subject matter of any of Embodiments A-1 to A-87, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sorting is used to advance at least one batch of the textile materials to be recycled for non-cellulosic material processing.

[0296] Embodiment A-89 can include the subject matter of any of Embodiments A-1 to A-88, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the sizing includes at least one of cutting, tearing, shredding, crushing, and grinding.

[0297] Embodiment A-90 can include the subject matter of any of Embodiments A-1 to A-89, and can alternatively or additionally include the subject matter of any other embodiment herein, wherein the sizing converts at least a portion of the textile to be recycled into at least one of fragments, clumps, clumps, particles, and fines.

[0298] Embodiment A-91 can include the subject matter of any of Embodiments A-1 to A-90, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sizing is used to produce a pretreated material having constituent elements, wherein most or all of the constituent elements of the pretreated material have a nominal size between about one hundred microns (100μ) and about one centimeter (1 cm).

[0299] Embodiment A-92 can include the subject matter of any of Embodiments A-1 to A-91, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sizing is used to produce a pretreated material having constituent elements, wherein most or all of the constituent elements of the pretreated material have a nominal size of less than about 200 microns.

[0300] Embodiment A-93 can include the subject matter of any of Embodiments A-1 to A-92, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sizing is used to produce a pretreated material having constituent elements, wherein most or all of the constituent elements of the pretreated material have a nominal size of less than about one hundred microns (100μ).

[0301] Embodiment A-94 can include the subject matter of any of Embodiments A-1 to A-93, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sizing is used to produce a pretreated material having constituent elements, wherein most or all of the constituent elements of the pretreated material have a nominal size greater than about one square centimeter (1sq.cm).

[0302] Embodiment A-95 can include the subject matter of any one of Embodiments A-1 to A-94, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein the sizing is used to produce a pretreated material having constituent elements, wherein most or all of the constituent elements of the pretreated material are cellulose-based materials that are partially or completely separated from other materials, wherein the other materials include one or more of buttons, buckles, zippers, buckles, rings, rivets, wires, foams, rubber materials, and elastic materials.

[0303] Embodiment A-96 can include the subject matter of any of Embodiments A-1 to A-95, and alternatively or additionally include the subject matter of any other embodiment herein, wherein at least part of the sizing is performed by a grinder.

[0304] Embodiment A-97 can include the subject matter of any of Embodiments A-1 through A-96, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein at least a portion of the resizing is performed by magnets.

[0305] Embodiment A-98 can include the subject matter of any of Embodiments A-1 to A-97, and alternatively or additionally include the subject matter of any other embodiment herein, wherein at least a portion of the resizing is performed by a charged surface.

[0306] Embodiment A-99 can include the subject matter of any of Embodiments A-1 through A-98, and may alternatively or additionally include the subject matter of any other embodiment herein, wherein at least a portion of the resizing is performed by an air moving device.

[0307] Embodiment A-100 can include the subject matter of any of Embodiments A-1 through A-99, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the volume of the reaction chamber is between sixty-four fluid ounces (64 fl. oz.) and five gallons (5 gal.).

[0308] Embodiment A-101 can include the subject matter of any of Embodiments A-1 through A-100, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the volume of the reaction chamber is between five gallons (5 gal.) and five hundred gallons (500 gal.).

[0309] Embodiment A-102 can include the subject matter of any of Embodiments A-1 through A-101, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the volume of the reaction chamber is less than sixty-four fluid ounces (64 fl. oz.).

[0310] Embodiment A-103 can include the subject matter of any of Embodiments A-1 through A-102, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the volume of the reaction chamber exceeds five hundred gallons (500 gal.).

[0311] Embodiment A-104 can include the subject matter of any of Embodiments A-2 through A-103, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the synthetic fiber material is at least one of polyester, nylon, acrylic, and polyolefin.

[0312] Embodiment A-105 can include the subject matter of any one of Embodiments A-1 to A-104, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the cellulose fiber is at least one of cotton, linen, rayon, hemp, jute, lyocell, bamboo, and reed fibers.

[0313] Embodiment A-106 can include the subject matter of any of Embodiments A-1 to A-105, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the cellulose-containing solution has a concentration of cellulose fibers greater than one-half percent (0.5%).

[0314] Embodiment A-107 can include the subject matter of any of Embodiments A-1 through A-106, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the cellulose-containing solution has a concentration of about one to two percent (1-2%) cellulose fibers.

[0315] Embodiment A-108 can include the subject matter of any of Embodiments A-1 through A-107, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the cellulose-containing solution has a concentration of cellulose fibers exceeding two percent (2%).

[0316] Embodiment A-109 can include the subject matter of any of Embodiments A-1 to A-108, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the cellulose-containing solution has a concentration of less than five percent (5%), less than ten percent (10%), less than twenty-five percent (25%), less than fifty percent (50%), or less than one hundred percent (100%) of some other percentage of cellulose fibers.

[0317] Embodiment A-110 can include the subject matter of any of Embodiments A-1 to A-109, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the cellulose-containing solution has a concentration of about fifteen to seventeen percent (15-17%) cellulose fibers.

[0318] Embodiment A-111 can include the subject matter of any of Embodiments A-1 to A-110, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the cellulose-containing solution has a concentration of cellulose fibers greater than five percent (5%), ten percent (10%), twenty-five percent (25%), or fifty percent (50%).

[0319] Embodiment A-112 can include the subject matter of any of Embodiments A-1 through A-111, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the coagulation bath includes water.

[0320] Embodiment A-113 can include the subject matter of any of Embodiments A-1 to A-112, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the coagulation bath comprises deionized water.

[0321] Embodiment A-114 can include the subject matter of any one of Embodiments A-1 to A-113, and can alternatively or additionally include the subject matter of any other embodiment herein, wherein the wet spinning forms at least a portion of the coagulated cellulose fibers into second continuous cellulose filaments that are different from the continuous cellulose filaments.

[0322] Embodiment A-115 can include the subject matter of any of Embodiments A-1 through A-114, and alternatively or additionally include the subject matter of any other embodiment herein, wherein the continuous cellulose strand is commercially indistinguishable from strands formed from virgin fibers.

[0323] The various embodiments described above can be combined to provide more embodiments. The various features of the embodiments described are optional, and the features of one embodiment can be appropriately combined with other embodiments. If necessary, various aspects of the embodiments described can also be modified to adopt concepts in various patents, applications and publications to provide more embodiments.

[0324] The various embodiments described above can be combined to provide further embodiments. If necessary, various aspects of the embodiments can be modified to adopt the concepts in the various patents, applications and publications to provide more embodiments.

[0325] In the description herein, specific details are listed in order to provide a thorough understanding of various example implementations. It should be understood that those skilled in the art will readily find various modifications to the embodiments, and the general principles defined herein can be applied to other implementations and applications without departing from the spirit and scope of the present disclosure.

[0326] In addition, in the following description, many details are listed for ease of explanation. However, it should be understood by those skilled in the art that the embodiments can be implemented without using these specific details. In other cases, well-known structures and processes are not shown or described to avoid blurring the description with unnecessary details. Therefore, the present disclosure is not intended to be limited to the embodiments shown, but to be given the widest scope consistent with the principles and features of the present disclosure. Therefore, according to the above detailed description, these and other changes can be made to the embodiments. In general, in the following claims, the terms used should not be interpreted as limiting the claims to the specific embodiments disclosed in the specification, but should be interpreted as including all possible embodiments and the full range of equivalents enjoyed by these claims. Therefore, the claims are not subject to the limitations disclosed.

[0327] U.S. Provisional Patent Application No. 63 / 239,274, filed on August 31, 2021, is incorporated herein by reference in its entirety.

Claims

1. A method for recycling textiles, comprising: receiving a textile to be recycled, the textile to be recycled having at least a portion of a cellulose-containing article; Sorting the textiles to be recycled to separate the cellulose-containing products from the non-cellulose-containing products; sorting the textiles to be recycled to separate a second type of cellulose-containing products, wherein the cellulose-containing products have a first type of cellulose fibers, and the second type of cellulose-containing products have a second type of cellulose fibers, the first type of cellulose fibers being different from the second type of cellulose fibers; adjusting the size of at least a portion of the cellulose-containing product to produce a first feedstock; adjusting the size of at least a portion of the second cellulose-containing product to produce a second feedstock; treating the first feedstock in a first cellulose solvent reactor having at least one first ionic liquid to produce a first spinning solution, wherein the treating comprises at least partially dissolving some or all of the intermolecular cellulose bonds in the first feedstock, thereby producing a first cellulose-containing solution having first cellulose fibers dissolved in at least one first ionic liquid; treating the second feedstock in a second cellulose solvent reactor having at least one second ionic liquid to produce a second spinning solution, wherein treating the second feedstock comprises at least partially dissolving some or all of the intermolecular cellulose bonds of the second feedstock to produce a second cellulose-containing solution having second cellulose fibers dissolved in the at least one second ionic liquid; extracting the first spinning solution in a first cellulose coagulation bath to reconstitute at least a portion of the dissolved first cellulose fibers; and extracting the second spinning solution in a second cellulose coagulation bath to reconstitute at least a portion of the dissolved second cellulose fibers; wet spinning at least a portion of the reconstituted first cellulose fibers into continuous cellulose strands; and At least a portion of the recombinant first cellulose fibers and at least a portion of the recombinant second cellulose fibers are wet spun into a continuous cellulose blend strand.

2. The method according to claim 1, further comprising: vacuum extracting or mechanically filtering insoluble material from the first cellulose solvent reactor; separating synthetic fiber material from said insoluble material; as well as The synthetic fiber material is recycled into a continuous synthetic thread.

3. The method according to claim 1, further comprising: At least one material is added to the first raw material, the material being at least one of a dye, an inert identification chemical, a water repellent, and a flame retardant.

4. The method according to claim 1, further comprising: At least one material is added to the first cellulose coagulation bath, the material being at least one of a dye, an inert identification chemical, a water repellent, and a flame retardant.

5. The method according to claim 1, further comprising: Based on the sorting, the operation of at least one conveyor belt, gate, pump, valve, fan, motor, suction device, filter or timer is directed.

6. The method according to claim 1, further comprising: Based on the sorting, operation of at least one electronically controllable circuit is directed.

7. The method according to claim 6, further comprising: A computing controller is initialized, the computing controller being used to direct the operation of the textile recycling method.

8. A method according to claim 1, wherein the first cellulose solvent reactor is configured as a plurality of reaction vessels, and wherein processing the first raw material includes receiving a portion of the first raw material in each of the plurality of reaction vessels and generating a portion of the first spinning solution in each of the plurality of reaction vessels.

9. The method according to claim 1, further comprising: After extracting at least a portion of the spinning dope, part or all of the at least one first ionic liquid is recovered.

10. A textile recycling system comprising: A textile pretreatment structure for receiving textiles to be recycled, wherein the textiles to be recycled have cellulose-containing products and non-cellulose-containing products; Sorting the textiles to be recycled to separate the cellulose-containing products from the non-cellulose-containing products; sorting the textiles to be recycled to separate the second type of cellulose-containing products, wherein the cellulose-containing products have a first type of cellulose fibers, and the second type of cellulose-containing products have a second type of cellulose fibers, the first type of cellulose fibers being different from the second type of cellulose fibers; adjusting the size of at least a portion of the cellulose-containing products to generate a first raw material; adjusting the size of at least a portion of the second type of cellulose-containing products to generate a second raw material; a first cellulose solvent reactor for receiving the first feedstock and at least one first ionic liquid, and further for generating a first spinning solution from the first feedstock and the at least one first ionic liquid, by at least partially dissolving some or all of the intermolecular cellulose bonds in the first feedstock to generate a first cellulose-containing solution having first cellulose fibers dissolved in the at least one first ionic liquid; a second cellulose solvent reactor for receiving the second feedstock and at least one second ionic liquid, and further for generating a second spinning solution from the second feedstock and the at least one second ionic liquid, by at least partially dissolving some or all of the intermolecular cellulose bonds in the second feedstock to generate a second cellulose-containing solution having second cellulose fibers dissolved in the at least one second ionic liquid; a first cellulose coagulation bath for receiving the first cellulose-containing solution and further for extracting the first spinning solution by reorganizing at least a portion of the dissolved cellulose fibers; as well as a second cellulose coagulation bath for receiving the second cellulose-containing solution and further for extracting the second spinning solution by reorganizing at least a portion of the dissolved cellulose fibers; as well as A wet spinning spinneret subsystem is used to wet-spin at least a portion of the recombinant first cellulose fibers and at least a portion of the recombinant second cellulose fibers into a continuous cellulose mixed line.

11. The system according to claim 10, further comprising: A vacuum extraction or mechanical filtration subsystem is used to remove insoluble materials from the first cellulose solvent reactor.

12. The system according to claim 10, further comprising: A controller is used to guide the operation of the first cellulose solvent reactor.

13. The system of claim 10, wherein the first cellulose solvent reactor further comprises: A plurality of reaction vessels for simultaneous operation, wherein each reaction vessel in the plurality of reaction vessels is used to receive a portion of the first raw material and is further used to generate a portion of the first spinning solution.

14. The system of claim 13, wherein each reaction vessel in the plurality of reaction vessels operates independently of the other reaction vessels in the plurality of reaction vessels.

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