System and method for reconstituting fibers from recyclable waste material

Abstract

A system is provided for structurally reconstituting fibers from recycled waste fabric material, including cotton denim waste, wherein the reconstituted fibers are incorporated into a hydroentangled or needle punched product without binders or additives. A tearing line includes the application of steam and enzymes at a rate sufficient to remove surface additives from the fibers. The process completely opens the fibers and eliminates fraying, twisting and nonconformities. A fiber finishing process provides fibers which are substantially uniform with respect to a desired characteristic such as length, weight, type, or a desired blend thereof. The finishing process also provides a fiber web characterized by a uniform directional orientation of fibers, making the fibers more amenable to hydroentanglement. The resulting nonwoven product is characterized by high strength, fiber integrity and high uniformity and can be cross lapped to thereby provide greatly increased strength and absorbency.

We claim:  
     
         1 . A cross-lapped hydroentangled material made by the process comprising: 
 cutting fabric scrap material including cotton denim waste to a desired size;    conveying the cut material through a series of rotary pin cylinders for successively cutting the material to form a first web of constituent fibers; each cylinder comprising a plurality of cutting pins disposed about a circumference of said cylinder, such that a cutting angle of the pins of each cylinder can be varied independently to increase or decrease cutting action depending upon the strength and thickness of the fibers, whereby successive cutting action of the cylinders opens the fibers;    applying steam and enzymes at a temperature and rate sufficient to further open and cleanse the fibers of surface additives and bacteria, yet not saturate the web, such that unopened fibers are kept to a range of less than 10% and preferably to a range of about 0% to 1%;    forcing said opened and cleaned fibers through a web-laying machine at a desired angle to produce a second web of fibers characterized by substantially unidirectional fiber orientation and uniform fiber density    hydroentangling or needle punching the web of unidirectional fibers to produce a hydroentangled material capable of being cross lapped to provide greatly increased strength and absorbency.    
     
     
         2 . A hydroentangled product made according to  claim 1  further comprising: laminating and coating the resulting hydroentangled material with a polyurethane laminate barrier, for providing a barrier to blood -borne pathogens.  
     
     
         3 . A hydroentangled material made according to the process of  claim 1  further comprising providing three or more independently controlled cutting pin cylinders C 1 , C 2 , Cn for successively opening the scrap fibers, wherein the speed of cylinders C 1 , C 2 , Cn, can be varied to obtain different cutting results with respect to different types of fabrics.  
     
     
         4 . A needle punched product made according to the process of  claim 1  wherein the second web of unidirectionally oriented fibers is conveyed to a needle punching machine.  
     
     
         5 . A process for reconstituting fibers from recycled scrap fabric or waste material, including 100 percent cotton denim waste comprising: 
 conveying the scrap on a conveyor along a direction of travel to a series of Piret cutters;    cutting the material with the Piret cutters to cause a preferential fiber orientation in the lengthwise direction parallel to the direction of travel;.    sequentially cutting the preferentially oriented fibers to a desired length in a tearing line using a series of rotary screen cutters, which are arranged orthogonally with respect to the direction of travel,    adding steam and enzymes at a sufficient rate and quantity in the tearing line to open, untwist and clean fibers without breaking;    cutting the opened, untwisted fibers substantially across their diameter in a second tearing line;    forming a web of substantially uniform density comprising the opened fibers; and    hydroentangling the web to provide a hydroentangled product characterized by uniform structure and consistent disbursement of fibers.