Nonwoven product containing regenerated textile material

Abstract

A nonwoven material containing a deconstructed material obtained from recycled textile waste is disclosed. The textile waste is deconstructed in such a way as to produce loose fibers and loose yarn segments. The combination of the loose fibers and the loose yarn segments can greatly enhance the properties of the nonwoven material.

Description

Background Art

[0001] Household and industrial wipes are often used to pick up and absorb polar and non-polar liquids. The wipes should be constructed to have sufficient absorbency to retain the liquid within the wipe structure. In addition, the wipes should also have good physical strength and abrasion resistance to withstand the tearing, stretching and abrasion forces often applied during use.

[0002] Traditional wiping products are made from woven and knitted fabrics. Such wipes have been used in all different types of industries, such as for industrial applications, food service applications, health and medical applications, and for general consumer use.

[0003] In the past, nonwoven wipes were also made from pulp fibers alone or in combination with synthetic fibers. For example, in the past, spunbond webs made from continuous filaments have been hydroentangled with pulp fibers to produce elastic wiping products. In many cases, these webs are used for one-time applications and then discarded. Although these wipes have good levels of strength and absorbency, these wipes require a considerable amount of polymers (especially fossil-based polymers) to construct the wipes.

[0004] In the past, attempts have also been made to incorporate recycled fibers into nonwoven materials. For example, U.S. Patent No. 6,037,282 (which is incorporated herein by reference) describes a nonwoven material containing recycled fibers mechanically chopped or torn from nonwoven waste or textile waste. The nonwoven material is made by a hydraulic entanglement process. The resulting material contains flocculates that remain uneven in the material. In some applications, these flocculates can cause undesirable strength reduction.

[0005] In view of the foregoing, there exists a need for an improved method and product for incorporating recycled textile fibers into nonwoven webs. Summary of the invention

[0006] Generally speaking, the present disclosure relates to nonwoven webs with excellent property balance containing recycled textile fibers. According to the present disclosure, textile fabrics and other materials are regenerated from recycled streams and deconstructed in a manner to produce nonwoven webs with excellent properties. In particular, the deconstruction of the textile material is carefully controlled to produce a fiber furnish containing not only loose individual fibers, but also loose yarn segments (wherein the individual fibers have not yet been released). It has been found that the combination of loose fibers and loose yarn segments produces nonwoven webs with unique and remarkable properties.

[0007] In one embodiment, the present disclosure relates to a nonwoven material, which includes loose fibers and loose yarn segments obtained from recycled textile materials. Loose fibers and loose yarn segments are blended together to form a nonwoven material. The loose fibers have an average fiber length greater than about 5mm. The loose yarn segments also have an average fiber length greater than about 5mm. For example, the loose fibers can have an average fiber length of about 6mm to about 18mm, including all increments of 0.5mm therebetween. The loose yarn segments can have an average length of about 6mm to about 25mm, including all increments of 0.5mm therebetween. The loose yarn segments can be generally present in the nonwoven web in an amount greater than about 1% by weight, such as in an amount of about 2% by weight to about 50% by weight, such as in an amount of about 5% by weight to about 30% by weight.

[0008] The loose fibers and loose yarn segments can be made of a variety of natural and synthetic materials. For example, the loose fibers and loose yarn segments can include polyester fibers. Alternatively, the loose fibers and loose yarn segments can include cellulose fibers (such as cotton fibers) or regenerated cellulose fibers (such as rayon fibers). In one aspect, the loose fibers and loose yarn segments can include a blend of polyester fibers and cotton fibers. For example, the loose fibers and loose yarn segments can contain polyester fibers in an amount of about 25% by weight to about 75% by weight, and can contain cotton fibers in an amount of about 25% by weight to about 75% by weight.

[0009] In one aspect, loose fibers and loose yarn segments can be combined with pulp fibers. For example, pulp fibers can be present in the nonwoven material in an amount of about 5 wt % to about 90 wt %, such as about 55 wt % to about 80 wt %. In one embodiment, loose fibers and loose yarn segments can account for about 10 wt % to about 50 wt % of the nonwoven material, such as about 15 wt % to about 40 wt %.

[0010] The nonwoven web can be formed using a variety of different processes and techniques. In one embodiment, the nonwoven web is a fluid-formed web, such as a foam-formed web. In one embodiment, the fluid-formed web can also be hydraulically entangled.

[0011] The loose fibers present in the nonwoven material can have relatively small size usually.For example, the loose fibers can have about 0.5 denier to about 5 deniers, such as about 0.5 denier to about 3 deniers, such as about 0.5 denier to about 1.5 deniers. The yarn segment can include textile yarn and can also have relatively small size.For example, the yarn segment can have about 5 deniers to about 15 deniers, such as about 5 deniers to about 12 deniers of yarn size.In one embodiment, nonwoven material can be produced when not containing any flocculation.Nonwoven material can have about 20gsm to about 500gsm usually, such as about 30gsm to about 250gsm basis weight.

[0012] The nonwoven material of the present disclosure can be used in many different applications. In one embodiment, the nonwoven material can be used to produce a wiping product. For example, the nonwoven material can be used to produce an industrial wipe. In one embodiment, the wiping product can be produced from the nonwoven material and then stacked together. In one embodiment, the nonwoven material is formed into a separate wiping product and then pre-saturated with a cleaning fluid.

[0013] Other features and aspects of the disclosure are discussed in greater detail below. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The disclosure that makes the present disclosure comprehensive and enabling is more particularly set forth in the remainder of the specification and with reference to the accompanying drawings, in which:

[0015] Figure 1 is a schematic diagram illustrating one embodiment of a process for deconstructing a textile material to form loose fibers and loose yarns for producing a nonwoven material according to the present disclosure;

[0016] Figures 2a and 2b illustrate loose fibers and loose yarns obtained from recycled textile materials;

[0017] Figure 3 is another view of loose fibers and loose yarns obtained from recycled textile materials;

[0018] Figure 4a and Figure 4b are Figure 3 , showing a magnified view of loose fibers and loose yarns;

[0019] Figure 5 is a cross-sectional view illustrating a yarn contained in a textile material;

[0020] Figure 6 is a perspective view of one embodiment of loose yarns that may be incorporated into a nonwoven material made according to the present disclosure;

[0021] Figure 7is a schematic diagram illustrating one embodiment for forming a nonwoven material according to the present disclosure;

[0022] Figure 8 is a schematic diagram of one embodiment of a process for forming a nonwoven material according to the present disclosure;

[0023] Fig. 9 yes Figure 8 a schematic diagram of an enlarged partial view of the illustrated schematic diagram;

[0024] Fig.10 is a plan view of one embodiment of a nonwoven material made according to the present disclosure;

[0025] Fig.11 is an enlarged portion of a nonwoven material made according to the present disclosure showing loose fibers and loose yarns; and

[0026] Fig.12 is a schematic diagram illustrating the void volume in a nonwoven material.

[0027] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.

[0028] definition

[0029] The term "loose fibers" refers to individual fibers obtained or extracted from recycled textile materials.

[0030] The term "loose yarn segments" are yarn segments having discrete lengths obtained or extracted from recycled textile materials.

[0031] The term "yarn" refers to a group of fibers that are intentionally associated with each other. Yarn can be formed by fibers by twisting, spinning, laying, layering or otherwise grouping fibers together. Yarn can include multifilament yarns made of continuous filaments, stretch-break yarns made of stretch-break filaments, and textile yarns made of a close blend of staple fibers. A thread is a yarn. As used herein, yarn is different from and distinguished from flocculation. The term "flocculation" is generally considered to represent a random grouping of individual fibers, and may include areas with surface defects, kinks, frayed ends, etc., and is not produced by automated or artificial processes. The nonwoven material made according to the present disclosure may not have flocculation.

[0032] As used herein, the term "machine direction" refers to the direction of travel of the forming surface upon which the fibers are deposited during the formation of the nonwoven web.

[0033] As used herein, the term "lateral direction" refers to a direction perpendicular to the longitudinal direction defined above.

[0034] As used herein, the term "pulp" refers to fibers from natural sources such as woody and non-woody plants. Woody plants include, for example, deciduous and coniferous trees. Non-woody plants include, for example, cotton, flax, esparto grass, milkweed, straw, jute, hemp, and bagasse. Pulp fibers can include hardwood fibers, softwood fibers, and mixtures thereof.

[0035] As used herein, the term "average fiber length" refers to the average length of fibers, fiber bundles and / or fibrous materials determined by microscopic measurement. A sample of at least 20 randomly selected fibers is separated from a liquid suspension of fibers. The fibers are placed on a microscope slide that has been prepared to suspend the fibers in water. Coloring dyes are added to the suspended fibers to color the cellulose-containing fibers so that they can be distinguished or separated from synthetic fibers. The slide is placed under a Fisher Stereomaster II microscope--S19642 / S19643 series. 20 fibers in the sample are measured at 20X linear magnification using a 0-20 mil scale, and the average length, minimum and maximum lengths, and deviation or coefficient of variation are calculated. In some cases, the average fiber length will be calculated as the weighted average length of the fibers (e.g., fibers, fiber bundles, fibrous materials) as determined by a Kajaani fiber analyzer model FS-200, such as that available from Kajaani Oy Electronics, Kajaani, Finland. The samples are treated with an impregnation solution according to standard test procedures to ensure that no fiber bundles or fragments are present. Each sample is decomposed in hot water and diluted to approximately 0.001% suspension. When tested using the standard Kajaani fiber analysis test procedure, each test sample of approximately 50 ml to 100 ml is drawn from the diluted suspension. The weighted average fiber length can be an arithmetic mean, a length-weighted mean, or a weight-weighted mean, and can be represented by the following equation:

[0036]

[0037] in

[0038] k = maximum fiber length

[0039] x i =Fiber length

[0040] n i = Number of fibers of length xi

[0041] n = total number of fibers measured.

[0042] One characteristic of the average fiber length data measured by the Kajaani fiber analyzer is that it does not distinguish between different types of fibers. Therefore, the average length represents the average value based on the lengths of all different types (if any) of fibers in the sample.

[0043] As used herein, the term "staple fibers" refers to discontinuous fibers made from synthetic polymers such as polypropylene, polyester, post-consumer recycled (PCR) fibers, polyester, nylon, etc., and those that are non-hydrophilic can be treated to be hydrophilic. Staple fibers can be cut fibers, etc. Staple fibers can have a cross-section that is round, bicomponent, multicomponent, shaped, hollow, etc.

[0044] As used herein, the term "nonwoven web or material" refers to a web having a structure of individual fibers, yarns, or mixtures thereof that are interlayered but not arranged in an identifiable manner (such as in a knitted or woven fabric). Nonwoven materials include, for example, carded webs, wet-laid webs, air-laid webs, foam-formed webs, and the like. DETAILED DESCRIPTION

[0045] Those skilled in the art will appreciate that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0046] Generally speaking, the present disclosure relates to nonwoven materials incorporating textile materials of considerable amounts of recycling. The textile materials incorporated into the recycling in the nonwoven material can be in the form of loose fibers, loose yarn segments, and mixtures thereof. According to the present disclosure, the recycled textile materials are deconstructed in a manner to produce loose fibers and loose yarn segments, which have been found to be particularly suitable for producing nonwoven materials with many beneficial properties. The loose fibers and yarn segments incorporated into the recycling in the nonwoven material can also replace the original materials used in the past, such as polyester fibers. In this regard, the nonwoven webs made according to the present disclosure not only remove and utilize materials from waste streams, but also reduce dependence on fossil-based polymers. Therefore, the products made according to the present disclosure are sustainable and economically friendly.

[0047] In the past, various attempts have been made to incorporate recycled fibers into nonwoven materials. For example, U.S. Patent No. 6,037,282 (which is incorporated herein by reference) discloses a nonwoven material containing recycled fibers. In the above patent, the recycled fibers form flocculations in the material, which remain uneven. The presence of flocculations in the material may have various disadvantages. For example, when present in a certain amount, flocculations may lead to an undesirable reduction in material strength.

[0048] In order to remove the flocculates as much as possible, one possible method is to deconstruct the recycled textile material to the extent that only loose fibers are retained. For example, U.S. Patent No. 6,378,179 (which is incorporated herein by reference) discloses a method for loosening fibers from textile materials. However, producing completely loose fibers from recycled textile materials requires greater energy requirements and reduces production during the deconstruction process. In addition, the resulting fibers are not suitable for hydroentanglement processes due to their short size.

[0049] In this regard, the present disclosure relates to incorporating recycled textile materials into nonwoven materials, wherein the amount of deconstruction of the recycled textile materials is controlled and limited so that the resulting furnish includes not only loose fibers, but also loose yarn segments. It has been found that when incorporated into the resulting nonwoven product, the loose yarn segments provide various advantages and benefits. For example, the yarn segments can modify the surface texture of the nonwoven material, making it very suitable for use as a wiping product. The yarn segments are also considered to increase the void volume, thereby increasing absorbency. The yarn segments also do not adversely affect the strength properties of the nonwoven material, and in fact can increase the tensile strength in one or more directions.

[0050] refer to Figure 1 , shows an embodiment of a process for deconstructing recycled textile materials to obtain loose fibers and loose yarn segments. Initially, recycled textile materials or waste materials 101 are collected. According to the present disclosure, the recycled textile materials may include any textile materials that contain yarns and fibers that can be incorporated into the nonwoven webs according to the present disclosure. In one aspect, the recycled textile materials are fabric materials, such as woven fabrics, knitted fabrics, nonwoven fabrics, etc. Examples of recycled textile materials that can be used to produce nonwoven products according to the present disclosure include bedding materials, such as sheets, pillowcases, quilt covers, etc. The recycled textile materials may also include used towels and / or hotel supplies materials. Hotel supplies materials may include tablecloths or table covers, cloth napkins, decorative coverings, etc. The recycled textile materials may also include clothing items. For example, the recycled textile materials may include trousers, shirts, jeans, blouses, other clothing, and mixtures thereof. On the other hand, the recycled textile materials may include upholstery fabrics or any other suitable textile materials contained in the recycling stream, which may be deconstructed into fiber and yarn segments.

[0051] like Figure 1As shown, once the recycled textile materials 101 are collected, these materials are then fed to a deconstruction process 102. During the deconstruction process 102, the recycled textile materials are deconstructed into loose fiber and yarn segments. For example, the recycled textile materials 101 can be cut, shredded or torn into smaller pieces and fed through a deconstruction device. The deconstruction process 102, for example, may include, but is not limited to, mechanical tearing, shredding, combing, and any other non-chemical means of converting the recycled textile materials 101 into deconstructed materials 103.

[0052] In one embodiment, a deconstruction equipment designed to deconstruct recycled textile materials may include a drum including spiked rollers. The recycled textile material is mechanically shredded and cut into small pieces and shredded with the help of spiked rollers to produce deconstructed material 103. An embodiment of a deconstruction equipment that can be used according to the present disclosure is disclosed in U.S. Patent 5,113,559, which is incorporated herein by reference. The '559 patent discloses a textile machine drum containing a cylinder. Attached to the cylinder are slats including tips or teeth. To deconstruct the textile material, the textile waste is fed to one or more continuous drums (or fed multiple times through a single drum), and the tips or needles deconstruct the material.

[0053] According to the present disclosure, the deconstruction equipment is designed to deconstruct the textile material in a limited and controlled amount, so that the resulting deconstructed material 103 contains loose fibers 103a combined with loose yarn segments 103b, such as Figure 1 As shown. More specifically, the deconstruction process 102 is specifically controlled to produce a deconstructed material 103 of desired specifications. For example, the settings and parameters of the deconstruction process 102 are controlled so as to produce a predetermined range of loose fibers 103a and loose yarns 103b. The parameters and settings are also controlled so as to produce a deconstructed material 103 in which the loose fibers 103a and the yarn segments 103b have a desired length or range of lengths. More specifically, the deconstruction process 102 can be controlled so as to produce a deconstructed material 103 that has a desired fiber length, yarn segment length, looseness, amount of kinks or curls, amount of twist, final quality, and if desired, service quality or smoothness.

[0054] refer to Figure 2A , Figure 2B , Figure 3 , Figure 4A and Figure 4B , shows a deconstructed material 103 that can be used to produce a nonwoven material according to the present disclosure. Figure 2A and Figure 2B For example, deconstructed material 103 is shown as including loose fibers 103a combined with loose yarn segments 103b. Figure 2B , showing the loose fibers 103a and the loose yarn segments 103b in more detail.

[0055] refer to Figure 3 , showing another embodiment of a deconstructed textile material 103 according to the present disclosure. The deconstructed material 103 is Figure 4A and Figure 4B As shown in more detail in Figure 4A and Figure 4B As shown, the deconstructed material 103 includes loose fibers 103a combined with loose yarn segments 103b.

[0056] Loose yarn segments 103b are more obvious in the above figure. Yarn segments 103b may also have an average fiber length longer than loose fibers, although this is not required. Loose yarn segments 103b represent yarns that have not yet been decomposed into fibers in recycled textile materials. The yarns can be, for example, spun yarns, stretch-break yarns, or multifilament yarns. For example, referring to Figure 5 , shows a cross section of yarn 103b before being deconstructed. Figure 6 As shown, the loose yarn segment 103b includes a specific configuration of individual fibers 104 that form void spaces 301.

[0057] It has been found that including yarn segment 103b can provide various advantages and benefits. For example, Figure 6 As shown in , the yarn segments 103b form a unique void space pattern that can provide capillary action when absorbing fluids such as liquids. In addition, the yarn segments 103b can enhance the overall strength of the resulting nonwoven material. The yarn segments 103b also change the surface characteristics of the nonwoven material. In particular, the yarn segments 103b can produce a material with a larger texture or topography that can enhance the abrasive properties of the nonwoven material when rubbed against a surface and / or can increase the absorption characteristics of the material, especially when used to remove grease and oil.

[0058] The yarn segments can be present in the nonwoven material in various forms. For example, the yarn segments can remain intact in the material and appear as textile yarn segments. Alternatively, the yarn segments can be in the form of scattered fibers that remain in a bundled form. In yet another embodiment, the yarn segments can be in the form of scattered fibers that are spread throughout the web. The yarn segments can be present in the material in all forms.

[0059] Generally speaking, any suitable textile fiber contained in the recycled textile material can be used to produce the nonwoven material according to the present disclosure. The fiber type included in the recycled textile material can include synthetic polymer fibers, synthetic cellulose fibers, natural fibers including natural cellulose fibers, etc. The synthetic polymer fibers that can be extracted from the recycled textile material include, for example, polyester fibers, nylon fibers, polyolefin fibers including polypropylene fibers and polyethylene fibers, etc. The synthetic polymer fibers can be monocomponent fibers or can be bicomponent fibers including a core-sheath configuration or a side-by-side configuration.

[0060] Any suitable regenerated cellulose fibers may also be extracted from recycled textile materials and incorporated into nonwoven products made according to the present disclosure. Regenerated cellulose fibers include all varieties of rayon and other fibers derived from viscose or chemically modified cellulose. For example, regenerated cellulose fibers may include lyocell fibers, modal fibers, etc.

[0061] Recycled textile materials may also contain natural fibers that are incorporated into nonwoven materials made according to the present disclosure. Natural fibers include cotton fibers and pulp fibers. Pulp fibers may include softwood fibers, hardwood fibers, and mixtures thereof.

[0062] In one embodiment, the textile material of the recovery deconstructed according to the present disclosure contains only polyester fibers. In an alternative embodiment, the deconstructed textile material of the present disclosure contains only cotton fibers. In other embodiments, the deconstructed textile material may contain a blend of fibers, such as a blend of polyester fibers and cellulose fibers (such as cotton fibers) and / or regenerated cellulose fibers (such as rayon). The fiber blend may be, for example, in an amount greater than about 10% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 30% by weight, such as in an amount greater than about 40% by weight, such as in an amount greater than about 50% by weight, such as in an amount greater than about 60% by weight, such as in an amount greater than about 70% by weight, and generally in an amount less than about 80% by weight, such as in an amount less than about 70% by weight, such as in an amount less than about 60% by weight, such as in an amount less than about 50% by weight containing polyester fibers. The cellulose fibers contained together with the polyester fibers may generally be present in the deconstructed textile material in the same amount as described above. For example, cellulosic fibers (such as cotton fibers) can be present in the deconstructed textile material in an amount greater than about 10 weight %, such as in an amount greater than about 20 weight %, such as in an amount greater than about 30 weight %, such as in an amount greater than about 40 weight %, such as in an amount greater than about 50 weight %, such as in an amount greater than about 60 weight %, such as in an amount greater than about 70 weight %, and typically in an amount less than about 80 weight %, such as in an amount less than about 70 weight %, such as in an amount less than about 60 weight %, such as in an amount less than about 50 weight %, such as in an amount less than about 40 weight %.

[0063] In one aspect, the textile material of the recovery selected for deconstruction according to the present disclosure can be selected so as to have the specific fiber type for specific application.For example, when being incorporated into nonwoven material and being used to absorb hydrophobic substances (such as oil and grease), the textile material of recovery can contain a larger amount of synthetic polymer fibers (such as polyester fibers).For example, the deconstructed textile material can be greater than the amount of about 70 % by weight, such as containing synthetic polymer fibers with an amount greater than about 80 % by weight.On the other hand, when nonwoven material of the present disclosure is used for absorbing water or otherwise needs to have hydrophilic properties, the deconstructed textile material can contain a larger amount of cellulose fibers.For example, the deconstructed textile material can be greater than the amount of about 50 % by weight, such as with an amount greater than about 60 % by weight, such as with an amount greater than about 70 % by weight, such as containing cellulose fibers with an amount greater than about 80 % by weight.

[0064] The length of the loose fibers released from the recycled textile material can vary according to specific applications and the starting materials used. In addition, the loose fibers can have a relatively wide fiber length distribution or a relatively narrow fiber length distribution. Generally speaking, the average fiber length of the loose fibers is greater than about 5mm, such as greater than about 6mm, such as greater than about 7mm, such as greater than about 8mm, such as greater than about 9mm, such as greater than about 10mm, such as greater than about 12mm, such as greater than about 14mm, such as greater than about 16mm. The average fiber length of the loose web is usually less than about 25mm, such as less than about 23mm, such as less than about 20mm, such as less than about 18mm, such as less than about 15mm, such as less than about 12mm, such as less than about 10mm. On the other hand, the fiber length distribution can be from about 1mm to about 60mm, such as from about 3mm to about 50mm.

[0065] The size of fiber also can change.In one embodiment, relatively thin fiber is used.For example, fiber can have less than about 15 deniers, such as less than about 12 deniers, such as less than about 10 deniers, such as less than about 8 deniers, such as less than about 7 deniers, such as less than about 6 deniers, such as less than about 5 deniers, such as less than about 4 deniers, such as less than about 3 deniers, such as even less than about 2 deniers.The size of fiber is usually greater than about 0.5 denier, such as greater than about 1 denier, such as greater than about 1.25 deniers, such as greater than about 1.5 deniers.In one aspect, can use size greater than about 2 deniers, such as greater than about 4 deniers, such as greater than about 6 deniers, such as greater than about 8 deniers, such as greater than about 10 deniers of larger fiber.

[0066] The yarn segments contained in the deconstructed textile material are generally made of the above-mentioned loose fibers. Therefore, the individual fibers contained in the yarn segments can have any size in the above-mentioned size for loose fibers.

[0067] The length of yarn segment also can change according to specific application.For example, yarn segment can have greater than about 5mm, such as greater than about 6mm, such as greater than about 7mm, such as greater than about 8mm, such as greater than about 9mm, such as greater than about 10mm, such as greater than about 12mm, such as greater than about 14mm, such as greater than about 16mm, such as greater than about 18mm, such as greater than about 20mm, such as greater than about 22mm, such as greater than about 24mm, such as greater than about 26mm average length.The average fiber length of yarn segment is usually less than about 80mm, such as less than about 70mm, such as less than about 60mm, such as less than about 50mm, such as less than about 40mm, such as less than about 30mm, such as less than about 25mm, such as less than about 20mm, such as less than about 18mm, such as less than about 16mm.In one aspect, the average length of yarn segment can be greater than the average length of loose fibers.Alternatively, the average length of loose fibers can be longer than the average length of yarn segment.

[0068] The length distribution of the yarn segments can vary greatly or be relatively narrow. In one embodiment, longer yarn segments are present in the yarn segment length distribution. For example, at least some of the yarn segments may have a length greater than about 15 mm, such as greater than about 20 mm, such as greater than about 25 mm, such as greater than about 30 mm, such as greater than about 35 mm, such as greater than about 40 mm, such as greater than about 50 mm, and generally less than about 80 mm, such as less than about 60 mm.

[0069] As described above, the loose yarn segments can be woven yarns, multifilament yarns, stretch-break yarns, etc. The size of the yarn is generally greater than about 5 deniers, such as greater than about 8 deniers, such as greater than about 10 deniers, such as greater than about 12 deniers, such as greater than about 14 deniers, such as greater than about 16 deniers, such as greater than about 18 deniers, such as greater than about 20 deniers. The size of the yarn is generally less than about 30 deniers, such as less than about 28 deniers, such as less than about 26 deniers, such as less than about 24 deniers, such as less than about 22 deniers, such as less than about 20 deniers, such as less than about 18 deniers, such as less than about 16 deniers, such as less than about 14 deniers, such as less than about 12 deniers, such as less than about 10 deniers.

[0070] The proportion of loose yarn segments in the deconstructed textile material can also be changed and controlled based on the deconstruction process. In one aspect, the loose yarn segments can be less than about 80% by weight, such as less than about 60% by weight, such as less than about 40% by weight, such as less than about 30% by weight, such as less than about 20% by weight, such as less than about 10% by weight. The loose yarn segments can be greater than about 1% by weight, such as greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 20% by weight, such as greater than about 30% by weight, such as greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 60% by weight, such as greater than about 70% by weight. The remaining deconstructed textile material may include loose fibers. For example, the loose fibers can be contained in the deconstructed textile material in an amount of about 1% by weight to about 99% by weight (including all increments of 1% by weight therebetween). For example, the loose fibers can be contained in the deconstructed textile material in an amount greater than about 10% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 30% by weight, such as in an amount greater than about 40% by weight, such as in an amount greater than about 50% by weight, such as in an amount greater than about 60% by weight, such as in an amount greater than about 70% by weight, such as in an amount greater than about 80% by weight, such as in an amount greater than about 90% by weight. The loose fibers can be contained in the deconstructed textile material generally in an amount less than about 95% by weight, such as in an amount less than about 90% by weight, such as in an amount less than about 80% by weight, such as in an amount less than about 70% by weight, such as in an amount less than about 60% by weight, such as in an amount less than about 50% by weight, such as in an amount less than about 40% by weight.

[0071] When forming a nonwoven material according to the present disclosure, the nonwoven material can be formed only by a deconstructed textile material containing loose fibers combined with loose yarn segments. Alternatively, when forming a nonwoven material, loose fibers and loose yarn segments can be combined with original fibers. Original fibers can be natural cellulose fibers, synthetic cellulose fibers, synthetic polymer fibers, etc. The nonwoven material can also contain a binder, such as a chemical binder and / or binder fibers. Chemical binders include latex binders. Binder fibers are fibers including a surface made of a low melting point polymer that softens and bonds to adjacent fibers when heated. In one embodiment, the binder fiber can be a bicomponent fiber. Binder fibers can be present in the nonwoven web in an amount of about 2% by weight to about 40% by weight (including all increments of 1% by weight therebetween).

[0072] In one embodiment, for example, loose fibers and loose yarn segments can be combined with cellulose fibers. Cellulose fibers that can be incorporated into the material include, but are not limited to, non-wood fibers such as cotton, abaca, kenaf, Indian grass, flax, thatch, straw, jute, bagasse, milkweed fibers, and pineapple leaf fibers; and wood or pulp fibers such as those obtained from hardwood and coniferous trees, including softwood fibers such as northern and southern softwood kraft fibers; hardwood fibers such as eucalyptus, maple, birch, and poplar. Pulp fibers can be prepared in high yield or low yield forms, and can be pulped by any known method (including kraft, sulfite, high yield pulping methods) and other known pulping methods. Fibers prepared by organic solvent pulping methods can also be used. For example, the above-mentioned cellulose fibers can have an average fiber length of less than about 8 mm, such as less than about 6 mm, such as less than about 4 mm. The average fiber length of cellulose fibers is generally greater than about 1 mm, such as greater than about 2 mm, such as greater than about 3 mm.

[0073] Other cellulosic fibers that may be incorporated into the material and in combination with the loose fibers and loose yarn segments include cotton fibers and / or any suitable regenerated cellulosic fibers, including rayon fibers, viscose fibers, cast fibers, lyocell fibers, and the like.

[0074] In yet another embodiment, the loose fibers and loose yarn segments can be combined with virgin synthetic polymer fibers. The synthetic polymer fibers can be polyester fibers, nylon fibers, polyolefin fibers, and the like.

[0075] In one embodiment, the deconstructed textile material containing loose fibers and loose yarn segments can be made of polyester fibers alone, can be made of cellulose fibers alone, or can be made of a blend of cellulose fibers and polyester fibers. The cellulose fibers can be cotton fibers or can be regenerated cellulose fibers (such as rayon fibers). When the deconstructed textile material contains a blend of different fibers, the polyester fibers can be present in an amount of about 25% by weight to about 75% by weight (including all increments of 1% therebetween), and the cellulose fibers can be present in the deconstructed textile material in an amount of about 25% by weight to about 75% by weight (including all increments of 1% therebetween). The above-mentioned deconstructed textile materials can then be used alone or in combination with virgin fibers. For example, the deconstructed textile material can be combined with pulp fibers, can be combined with other cellulose fibers, or can be combined with virgin polyester fibers.

[0076] When combined with pulp fiber (such as softwood fiber, hardwood fiber or their mixture), pulp fiber can be greater than about 40 % by weight, such as with greater than about 50 % by weight, such as with greater than about 60 % by weight, such as with greater than about 70 % by weight, and usually with less than about 90 % by weight, such as with less than about 80 % by weight, present in the resulting nonwoven material. The remainder of nonwoven material can be made by the deconstructed textile material containing loose fibers and loose yarn segments. For example, deconstructed textile material can be less than about 60 % by weight, such as with less than about 50 % by weight, such as with less than about 40 % by weight, and usually with greater than about 10 % by weight, such as with greater than about 20 % by weight, contained in the resulting nonwoven material. In one embodiment, when combined with pulp fibers, the deconstructed textile material may contain polyester fibers in an amount of about 50% by weight to about 80% by weight, such as in an amount of about 55% by weight to about 75% by weight, and may contain cellulosic fibers, particularly cotton fibers and / or regenerated cellulose fibers, in an amount of about 20% by weight to about 50% by weight, such as in an amount of about 25% by weight to about 45% by weight.

[0077] When combined with virgin polyester fibers, virgin cotton fibers, virgin regenerated cellulose fibers, or mixtures thereof, deconstructed textile materials containing loose fibers and loose yarn segments may be present in nonwoven materials typically in an amount of about 5% to about 95% by weight (including all increments of 1% therebetween). In one embodiment, the deconstructed textile material is present in a nonwoven material in an amount greater than about 40%, such as in an amount greater than about 60%, and typically in an amount less than about 85%, such as in an amount less than about 70%. Alternatively, the deconstructed textile material may be present in a relatively small amount, such as in an amount less than about 35% by weight, such as in an amount less than about 25% by weight, such as in an amount less than about 20% by weight, and typically in an amount greater than about 5% by weight, such as in an amount greater than about 10% by weight. The virgin polyester fiber, virgin cotton fiber or virgin regenerated cellulose fiber may have an average fiber length of about 15 mm to about 60 mm, such as about 25 mm to about 45 mm, and may have a size of about 0.5 denier to about 15 denier, such as about 1 denier to about 10 denier, such as about 1 denier to about 5 denier, such as about 1 denier to about 4 denier.

[0078] Once a fiber furnish containing at least a portion of loose fibers and loose yarn segments is selected according to the present disclosure, any suitable process may be used to form the fiber furnish into a nonwoven material or web. For example, the nonwoven material may be made by a carding process, or may be fluid-formed. The fluid-forming process includes a wet-laid web process, a foam-forming process, an air-laid web process, and a dry-laid web process. The nonwoven material may also be hydroentangled during the process. For example, hydroentanglement may be used together with any one of the above-mentioned fluid-forming process or the carding process.

[0079] See also Figure 7 , illustrates one embodiment of a schematic diagram showing a process for producing a nonwoven material according to the present disclosure. As shown, a recycled textile material 101 is deconstructed into a deconstructed material 103 containing loose fibers and loose yarn segments as described above. The deconstructed textile material 103 is optionally combined with virgin fibers 203 to form a fiber furnish 202.

[0080] Once the fiber furnish 202 is collected, various consolidation steps may be performed. For example, the fiber furnish may be consolidated by fiber pulping and blending, headbox formation, foam generation, or may be fed to a mixing tank and foam pulping process.

[0081] The fiber furnish 202 is then fed to a web forming process 204. The web forming process 204 may be a carding process or any of the above-described fluid forming processes. According to the web forming process 204, the formed nonwoven web may optionally be subjected to a hydroentanglement process 205. The hydroentanglement process may then be used to form a nonwoven material 210. Optionally, after the hydroentanglement process 205, before the nonwoven material 210 is collected, the nonwoven web may be fed to a drying process 206.

[0082] Any suitable drying process 206 can be used to dry the nonwoven material. For example, the drying process can include a through-air dryer, a heated drum, or a combination thereof.

[0083] In one specific embodiment, for exemplary purposes only, a foam forming process may be used in combination with a hydroentanglement step to form a fiber furnish into a nonwoven material.During foam forming, the fiber furnish is combined with a foam produced by mixing water with a blowing agent.

[0084] The foaming agent may, for example, comprise any suitable surfactant. In one embodiment, for example, the foaming agent may comprise sodium lauryl sulfate, also known as sodium laureth sulfate or sodium lauryl ether sulfate. In one embodiment, the foaming agent is a nonionic surfactant, which may comprise an alkyl polyglycoside. For example, the foaming agent may be a C8 alkyl polyglycoside, a C10 alkyl polyglycoside, or a mixture of a C8 and C10 alkyl polyglycoside.

[0085] Other foaming agents include sodium dodecyl sulfate or ammonium lauryl sulfate. In other embodiments, the foaming agent may include any suitable cationic and / or amphoteric surfactants. For example, other foaming agents include fatty acid amines, amides, amine oxides, fatty acid quaternary ammonium compounds, etc.

[0086] The blowing agent is typically combined with water in an amount greater than about 0.1 wt %, such as greater than about 1 wt %, such as greater than about 2 wt %, such as greater than about 3 wt %. One or more blowing agents are typically present in an amount less than about 50 wt %, such as less than about 10 wt %, such as less than about 8 wt %, such as less than about 4 wt %.

[0087] Once the blowing agent and water are combined, the mixture is blended or otherwise subjected to forces capable of forming foam.Foam generally refers to a porous matrix that is an aggregation of hollow cells or bubbles that may interconnect to form channels or capillaries.

[0088] Foam density can vary according to specific application and various factors, including the fiber furnish used. In one embodiment, for example, the foam density of the foam can be greater than about 200g / L, for example, greater than about 250g / L, for example, greater than about 300g / L. The foam density is generally less than about 600g / L, for example, less than about 500g / L, for example, less than about 400g / L, for example, less than about 350g / L. In one embodiment, for example, a foam density is generally less than about 350g / L, for example, less than about 340g / L, for example, less than about 330g / L of lower density foam is used. The air content of the foam will generally be greater than about 30%, for example, greater than about 40%, for example, greater than about 50%, for example, greater than about 60%. The air content is generally less than about 80% by volume, for example, less than about 70% by volume, for example, less than about 65% by volume.

[0089] To form a nonwoven web, the foam is combined with the selected fiber furnish and any adjuvants. The foamed suspension of fibers is then pumped into a tank and from the tank fed into a headbox. Figure 8 and Fig. 9 For example, one embodiment of a process for forming a web according to the present disclosure is shown. Fig. 9 As shown, the foamed fiber suspension may be fed into a tank 312 and then fed into a headbox 310. The foamed fiber suspension is discharged from the headbox 310 onto an endless moving forming fabric 326 supported and driven by rolls 328 to form the web 210. Fig. 9 As shown, the forming plate 314 can be positioned below the web 210 adjacent to the headbox 310. Once formed on the forming fabric 326, the foam-formed web can have a consistency of less than about 50%, such as less than about 20%, such as less than about 10%, such as less than about 5%. In fact, the forming consistency can be less than about 2, such as less than about 1.8, such as less than about 1.5. The forming consistency is generally greater than about 0.5, such as greater than about 0.8. The forming consistency represents the ability to produce a web according to the present disclosure while minimizing the amount of water required during forming.

[0090] Once the wet web is formed on the forming fabric 326, the web is transported downstream and dewatered. For example, the method may optionally include a plurality of vacuum devices 316, such as vacuum boxes and vacuum rolls. The vacuum boxes help remove moisture from the newly formed web 210.

[0091] like Fig. 9 As shown, the forming fabric 326 can also be placed in communication with a steam box 318 located above a pair of vacuum rolls 320. The steam box 318 can, for example, significantly increase dryness and reduce cross-machine direction moisture variation. The steam applied from the steam box 318 heats the moisture in the wet web 210, making it easier for the water in the web to drain, especially when combined with the vacuum rolls 320. Figure 8 In the embodiment shown, the newly formed web 210 is conveyed downstream from the forming fabric 326, subjected to hydroentanglement, and dried on a through-air dryer.

[0092] After the foam-formed web is produced, the web is subjected to one or more hydroentanglement steps. Fig. 9 In the illustrated embodiment, the web 210 is subjected to two different hydroentanglement steps. Fig. 9 In the embodiment of the present invention, the web 210 is hydroentangled on a first surface during a first hydroentanglement step and then hydroentangled on an opposite second surface during a second hydroentanglement step. Fig. 9 As shown, for example, the process may include a first hydroentanglement device 330 and a second hydroentanglement device 332. The hydroentanglement that occurs at each hydroentanglement station can be accomplished using conventional hydroentanglement equipment. Hydroentanglement of the foam-formed web can be performed using any suitable working fluid, such as water. The working fluid flows through a manifold that evenly distributes the fluid into a series of individual holes or orifices. For example, exemplary holes or orifices can have a diameter of about 0.003 inches to about 0.015 inches. For example, a manifold can include an orifice strip having a diameter of 0.007 inches. The manifold can contain about 20 to about 40 holes per inch and can include 1 to 3 rows of holes. Many other manifold configurations and combinations can be used. Fig. 9 In the illustrated embodiment, for example, hydroentanglement device 330 includes a plurality of ejectors 334, and hydroentanglement device 332 includes a plurality of ejectors 336. Ejectors 334 and 336 may be part of a manifold and may be in communication with a source of working fluid.

[0093] In the hydroentanglement process, the working fluid may be passed through the orifice at a pressure in the range of about 200 psig to about 3,500 psig. In the upper range of the pressure, it is contemplated that the web may be processed at a velocity of about 500 ft to about 2000 ft. The fluid impinges on the material or web which may be supported on a porous surface or wire or may be supported on a porous drum surface. Fig. 9In the illustrated embodiment, for example, hydroentanglement occurs on a first roller 338 and a second roller 340 .

[0094] When supported on a porous surface or wire during the hydroentanglement process, the wire may have a mesh size of about 40x40 to about 100x100. The wire or surface may also be a multi-layer sheet mesh having a mesh size of about 50x50 to about 200x200.

[0095] As described above, alternatively, during the hydroentanglement, the web 210 can be placed directly on the surface of the drum 338 and on the surface of the drum 340. Each drum can include a plurality of openings or vacuum channels for draining excess water. During the hydroentanglement process, these openings or vacuum channels can also form patterns in the web 210. For example, a pattern can be formed into one surface of the web at the first hydroentanglement station, and a pattern can be formed into the second opposite surface of the web at the second hydroentanglement station. The pattern formed in each surface of the web 210 can be very unique and can increase the aesthetic appeal of the nonwoven material made of the web. In addition, the pattern formed in the web can be three-dimensional, including mountains and valleys. This three-dimensional topography can further improve the various properties of the material.

[0096] In addition to improving the appearance of the web 210, one or more hydroentanglement stations can also significantly improve various physical properties of the web 210, such as the integrity of the web. For example, the columnar jets of working fluid that directly impact the surface of the web are used to entangle and entangle the fibers contained in the web, especially the loose yarn segments and loose fibers. The hydroentanglement process ultimately forms a coherent entangled matrix. The hydroentanglement step is further used to produce a substantially homogenous fiber mixture within the web. For example, the resulting hydroentangled web is "non-stratified" and does not contain distinguishable individual fiber layers through the thickness of the web.

[0097] Once the foam-formed web 210 has been hydroentangled one or more times, a non-compressive drying operation may be used to dry the web. Figure 8 As shown, a through-air dryer may be used to dry the foam-formed web.

[0098] refer to Figure 8 The foamed and hydroentangled web 210 is transferred from the drum 340 to the throughdrying fabric 344 by means of a vacuum transfer roll 346 or vacuum transfer shoe. If desired, the throughdrying fabric can be run at a slower speed than the web 210 to further enhance stretching. The transfer can be performed with vacuum assistance to ensure that the sheet is deformed to conform to the throughdrying fabric, thereby creating the desired bulk and appearance when desired.

[0099] exist Figure 8In the illustrated embodiment, the foam-formed web 210 is conveyed to a throughdrying fabric 344. Alternatively, the foam-formed web may be conveyed to a metal porous sleeve forming the circumference of the throughdryer 348. Using a metal sleeve instead of a fabric may provide various advantages. For example, the porous metal sleeve may further create porosity to increase the liquid absorption properties of the web.

[0100] Alternatively, the foam-forming web 210 may be conveyed on a throughdrying fabric 344 at the circumference of the throughdryer 348. The throughdrying fabric may contain tall, long press knuckles. For example, the throughdrying fabric may have from about 5 to about 300 press knuckles per square inch that are raised at least about 0.005 inches above the plane of the fabric. During the drying process, the web may further be macroscopically aligned to conform to the surface of the throughdrying fabric. However, flat surfaces may also be used in the present disclosure.

[0101] The side of the web that contacts the throughdrying fabric is often referred to as the "fabric side" of the nonwoven web. As described above, the fabric side of the nonwoven web can have a shape that conforms to the surface of the throughdrying fabric after the fabric is dried in the throughdryer. On the other hand, the opposite side of the nonwoven web is often referred to as the "air side." In the normal throughdrying process, the air side of the web is usually smoother than the fabric side.

[0102] The vacuum level for web transfer can be from about 3 to about 15 inches of Hg (75 to about 380 mm Hg), preferably about 5 inches (125 mm) of Hg. The vacuum shoe or roll (negative pressure) can be supplemented or replaced by using positive pressure from the opposite side of the web to blow the web onto the next fabric, in addition to or instead of using vacuum to suck onto the next fabric.

[0103] The web is finally dried by throughdryer 348 to a consistency of about 94% or higher and then transferred to carrier fabric 350. Carrier fabric 350 and optional carrier fabric 356 are used to transport the dried base sheet 352 to reel 354. An optional pressure turning roll 358 can be used to facilitate the transfer of the web from carrier fabric 350 to fabric 356. Suitable carrier fabrics for this purpose are Albany International 84M or 94M and Asten 959 or 937, which are relatively smooth fabrics with fine patterns. Although not shown, reel calendering or subsequent off-line calendering can be used to improve the smoothness and softness of the base sheet.

[0104] In one embodiment, the resulting foam-formed web 352 is a textured web that has been dried in a three-dimensional state. The texture in the web may be formed as a result of the hydroentanglement station, as a result of the manner in which the web is dried using the throughdryer 348, or may be the result of both processes. For example, the web 352 may be dried while still including a pattern formed in the web.

[0105] The basis weight of the web manufactured according to the present disclosure can vary depending on the final product. For example, the process can be used to produce tissues, industrial wipes, food service wipes, etc. Generally speaking, the basis weight of the product can vary from about 15gsm to about 500gsm. For example, the basis weight can be greater than about 30gsm, such as greater than about 40gsm, such as greater than about 45gsm, such as greater than about 50gsm, such as greater than about 55gsm, such as greater than about 60gsm, such as greater than about 65gsm, and usually less than about 400gsm, such as less than about 200gsm, such as less than about 150gsm, such as less than about 120gsm.

[0106] The method of the present disclosure can also produce a web having good bulk properties. For example, the bulk density can generally be greater than about 3cc / g, such as greater than about 5cc / g, such as greater than about 8cc / g, such as greater than about 10cc / g, such as greater than about 12cc / g, and generally less than about 20cc / g, such as less than about 15cc / g.

[0107] Sheet "bulk" is calculated as the quotient of the dry tissue paper sheet thickness expressed in microns divided by the dry basis weight expressed in grams per square meter. The resulting sheet bulk is expressed in cubic centimeters per gram. More specifically, thickness is measured as the total thickness of a stack of ten representative sheets, with each sheet in the stack placed with the same side facing up, and the total thickness of the stack divided by ten. Thickness is measured according to Instruction 3 for stacked sheets in TAPPI Test Method T411 om-89 "Thickness (caliper) of Paper, Paperboard, and Combined Board". The micrometer used to implement T411 om-89 was an Emveco 200-A Tissue Thickness Tester obtained from Emveco, Inc., Newberg, Oreg. The micrometer load is 2.00 kPa (132 g / in2), the presser foot area is 2500 mm2, the presser foot diameter is 56.42 mm, the dwell time is 3 seconds, and the descent rate is 0.8 mm / s. In one embodiment, the thickness can be measured when the web is wet. In fact, the nonwoven material made according to the present disclosure has excellent wet elastic properties.

[0108] refer to Fig.10 and Fig.11, shows one embodiment of a nonwoven material 210 manufactured according to the present disclosure. Fig.10 As shown, in one embodiment, loose yarn segments 103b may be visible when viewing the top surface of the web. Fig.11 103a and 103b. As shown, the two fiber types are blended together to form a consolidated structure. As described above, the nonwoven material 210 may also contain virgin fibers (such as cotton fibers), synthetic polymer fibers, regenerated cellulose fibers, and smaller pulp fibers.

[0109] like Fig.10 As illustrated, loose yarn segments 103b are distributed in the entire fiber matrix formed by loose fibers 103a. Generally speaking, the distribution of loose yarn segments 103b in the entire nonwoven sheet 210 can be about 0.5% to about 99% (including all increments of 0.5% therebetween) per square meter based on area. The amount of loose yarn segments 103b distributed in the entire nonwoven material 210 can have different effects on the physical properties of the resulting material. In various embodiments, the distribution of loose yarn segments 103b and nonwoven material 210 per square meter can be greater than about 10% based on total surface area, such as greater than about 15%, such as greater than about 20%, such as greater than about 25%, such as greater than about 30%, and generally less than about 45%, such as less than about 40%, such as less than about 30%.

[0110] The nonwoven materials made according to the present disclosure can be used in many different types of applications. For example, the nonwoven materials can be used to make absorbent components in absorbent articles such as diapers, feminine hygiene products, adult incontinence products, pull-on pants, etc. The nonwoven materials can also be used to produce all types of wiping products, such as consumer wipes, industrial wipes, pre-moistened wipes, mop heads, towels, etc.

[0111] In one embodiment, nonwoven material can be cut into the independent sheet material that is very suitable for being used as industrial wipe.Wipe can have any suitable size and shape.In one embodiment, wipe can have about 8cm to about 100cm, such as about 10cm to about 50cm, such as about 20cm to about 25cm width.The length of wipe can be about 10cm to about 200cm, such as about 20cm to about 100cm, such as about 35cm to about 45cm.

[0112] If desired, the wipes can also be pre-moistened with liquid (such as water, solvent, waterless hand soap or any other suitable liquid). The liquid can contain preservatives, flame retardants, industrial cleaners, surfactants, emollients, wetting agents, etc. The liquid can be applied by any suitable method known in the art (such as spraying, dipping, soaking, impregnation, brushing, etc.). The amount of liquid added to the wipes can vary according to the properties of the composite fabric, the type of container for storing the wipes, the properties of the liquid, and the desired end use of the wipes. Generally speaking, based on the dry weight of the wipes, each wipe contains a liquid greater than about 150% by weight, about 150 to about 1500% by weight in some embodiments, and about 300 to about 1200% by weight in some embodiments.

[0113] The wipes can be packaged in a variety of forms, materials, and / or containers, including but not limited to rolls, boxes, tubs, flexible packaging materials, etc. Some examples of suitable containers include rigid tubs, film bags, and the like.

[0114] As described above, the loose yarn segments 103b contained within the nonwoven material 210 can contribute to various performance characteristics and enhanced properties. For example, the loose yarn segments 103b can increase absorbency, increase strength, increase wicking rate, increase capillary flow, increase void volume, and change porosity in a very beneficial way.

[0115] As about Figure 6 As explained, for example, the loose yarn segment 103b contains a group of individual fibers having a void volume and a pore structure different from the rest of the material. Generally speaking, each loose yarn segment 103b may contain about 10 individual fibers to about 500 individual fibers. For example, each loose yarn segment may contain greater than about 15 fibers, such as greater than about 20 fibers, such as greater than about 30 fibers, such as greater than about 40 fibers, such as greater than about 50 fibers, such as greater than about 60 fibers, such as greater than about 70 fibers, such as greater than about 80 fibers, such as greater than about 90 fibers, such as greater than about 100 fibers, such as greater than about 110 fibers, and less than about 170 fibers, such as less than about 150 fibers, such as less than about 130 fibers, such as less than about 110 fibers, such as less than about 90 fibers, such as less than about 70 fibers. In one aspect, the loose yarn segment may contain about 32 individual fibers to about 80 individual fibers composed together.

[0116] refer to Fig.12, for the purpose of explanation, a portion of the loose yarn segment is shown as containing three individual fibers 303. As shown, the three fibers 303 form unique void spaces or capillaries at the intersection of the fibers. These capillaries are particularly suitable for absorbing all different types of substances and fluids, such as water, oil, grease, solvents, cleaning solutions, etc. The small capillaries can be used to absorb pollutants and keep them in the nonwoven material, or can be used to absorb and release cleaning solutions or solvents.

[0117] The void volume (V void ) is a function of the number of individual fibers 303 contained in the fiber group and the denier of each individual fiber 303. Fig.12 As shown, the void volume between three tangentially oriented individual fibers 303 of equal denier can be determined using the following equation:

[0118] V VOID =L[A 1 -A 2 ]

[0119] A 1 =(1 / 2r)x(r√3)

[0120] A 2 =1 / 2πr 2

[0121] A 1 = the area of ​​the triangle 310 formed by the centers of the three fibers 303

[0122] r = radius of fiber 303

[0123] A 2 = Area of ​​the portion of fiber 303 intercepted by triangle 310 (307)

[0124] L = length of loose yarn 103B

[0125] As shown, the void volume of a loose yarn segment containing three individual fibers of equal denier is the area of ​​the equilateral triangle 310 formed by the centers of the three fibers 303 minus the three cross-sectional areas 307 that the individual fibers 303 intersect with the equilateral triangle 310, multiplied by the length of the loose yarn segment 103b. In embodiments where the loose yarn segment 103b contains more than three individual fibers, the above equation can be used to determine the void volume of each three tangential fibers, thereby forming a total void volume between the tangential fibers.

[0126] Depending on the fiber furnish used to form the nonwoven material, the void volume formed by the loose yarn segments can have different effects. As mentioned above, the nonwoven material can be combined with the original fibers including pulp fibers, synthetic polymer fibers, regenerated cellulose fibers, etc. In one embodiment, the void volume contained in the loose yarn segments can be greater than the void volume formed by the loose fibers. Alternatively, the void volume formed by the fibers in the nonwoven material can be greater than the void volume formed by the loose yarn segments. In one embodiment, the void volume formed by the loose yarn segments can have different pore structures and play different roles when absorbing fluid. For example, the void volume formed by the loose yarn segments can form capillary forces, which make the fluid remain in the fiber structure once it contacts the loose yarn segments. In this way, the loose yarn segments can greatly improve the absorption characteristics of the nonwoven material.

[0127] These and other modifications and variations of the present invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the present invention as more particularly described in the appended claims. In addition, it should be understood that the aspects of the various embodiments may be interchangeable in whole or in part. In addition, it will be appreciated by those of ordinary skill in the art that the foregoing description is merely illustrative and is not intended to limit the present invention as further described in such appended claims.

Claims

1. A nonwoven material comprising: Loose fibers and loose yarn segments, both of which are obtained from recycled textile materials, are blended together to form a nonwoven material, wherein the loose fibers have an average fiber length greater than about 5 mm, and the loose yarn segments also have an average fiber length greater than about 5 mm, and the nonwoven material optionally contains pulp fibers.

2. The nonwoven material of claim 1, wherein the loose fibers have an average fiber length of about 6 mm to about 18 mm.

3. The nonwoven material of any of the preceding claims, wherein the loose yarn segments have an average length of about 6 mm to about 25 mm.

4. The nonwoven material of any of the preceding claims, wherein the yarn segments are present in the nonwoven material in an amount of about 2 wt % to about 50 wt %, such as about 5 wt % to about 30 wt %, based on the total weight of the loose yarn segments and the loose fibers.

5. The nonwoven material of any of the preceding claims, wherein the loose fibers and the loose yarn segments comprise a polyester polymer.

6. The nonwoven material of any one of claims 1 to 4, wherein the loose fibers and the loose yarn segments comprise cellulosic fibers.

7. The nonwoven material of any of the preceding claims, wherein the loose fibers and the loose yarn segments comprise a blend of polyester fibers and cotton fibers.

8. The nonwoven material of claim 7, wherein the loose fibers and the loose yarn segments comprise from about 25% to about 75% by weight polyester fibers and from about 25% to about 75% by weight cotton fibers.

9. The nonwoven material of any of the preceding claims, wherein the nonwoven material comprises a fluid-formed web.

10. The nonwoven material of any of the preceding claims, wherein the nonwoven material comprises a foam-formed web.

11. The nonwoven material of any one of the preceding claims, wherein the nonwoven material contains pulp fibers.

12. The nonwoven material of claim 11, wherein the nonwoven material contains pulp fibers in an amount of about 55% to about 80% by weight.

13. The nonwoven material of any of the preceding claims, wherein the nonwoven material contains the bulk fibers and the yarn segments in an amount of about 10% to about 50% by weight, such as in an amount of about 15% to about 40% by weight.

14. The nonwoven material of any one of the preceding claims, wherein the yarn segments comprise textile yarns.

15. The nonwoven material of any one of the preceding claims, wherein the nonwoven material has been hydraulically entangled.

16. The nonwoven material of any one of the preceding claims, wherein the nonwoven material has a basis weight of about 20 gsm to about 400 gsm, such as about 30 gsm to about 250 gsm.

17. A nonwoven material as claimed in any one of the preceding claims, wherein the loose fibers and the fibers contained in the loose yarn segments have a size of about 0.5 denier to about 5 denier, such as about 0.5 denier to about 3 denier, such as about 0.5 denier to about 1.5 denier.

18. The nonwoven material of any of the preceding claims, wherein the yarn segments have a yarn size of about 5 denier to about 15 denier, such as about 5 denier to about 12 denier.

19. The nonwoven material of any one of the preceding claims, wherein the nonwoven material is free of floes.

20. An absorbent product made from the nonwoven material according to any one of the preceding claims.

21. The absorbent product of claim 20, wherein the absorbent product comprises an industrial wipe.

22. The absorbent product of claim 20 or 21, wherein the absorbent product comprises a plurality of individual wipes stacked together.

23. The absorbent product of claim 20, wherein the absorbent product comprises the nonwoven material pre-saturated with a cleaning solvent.

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