Process for regenerating post-consumer and post-industrial fibers

Abstract

Processes for producing regenerated fibers from post-consumer and post-industrial waste are disclosed. The process generally involves obtaining a source of post-industrial and/or post-consumer scrap material comprising fibers, cutting the material into a desirable size in the range of from one square inch to thirty square inches, detangling the fibers, removing any finish from the fibers, if present, combing and/or picking the fibers to convert any threads into fibers, humidifying the fibers, and intimately blending the fibers. These regenerated fibers can be blended with other fibers, and intimately blended to provide a uniform blend of fibers. The fibers can then be subjected to a carding process to orient the fibers. The regenerated fibers can be used in any application that would otherwise use virgin fibers, including their use to form woven or non-woven materials.

1 . A process for preparing regenerated fibers, comprising the steps of:
 a) obtaining a source of post-industrial and/or post-consumer scrap material comprising fibers,   b) cutting the material into a size in the range of from one square inch to thirty square inches,   c) detangling the fibers,   d) removing any finish from the fibers, if present,   e) combing and/or picking the fibers to convert any threads into fibers,   f) humidifying the fibers, and   g) intimately blending the fibers.   
     
     
         2 . The process of  claim 1 , further comprising carding the intimately blended fibers. 
     
     
         3 . The process of  claim 1 , further comprising forming a non-woven fiber roll good comprising the regenerated. 
     
     
         4 . The process of  claim 3 , further comprising converting the non-woven fiber roll good into a hygiene product, medical product, filter, or geotextile. 
     
     
         5 . The process of  claim 1 , further comprising spinning the fibers into a thread or yarn. 
     
     
         6 . The process of  claim 5 , further comprising weaving the thread or yarn into a woven fabric. 
     
     
         7 . The process of  claim 6 , further comprising converting the woven fabric into a finished woven good. 
     
     
         8 . The process of  claim 1 , wherein the regenerated fibers are blended with other fibers before or after the intimate blending process. 
     
     
         9 . The process of  claim 8 , wherein such other fibers are selected from the group consisting of fibers derived from plant matter, fibers derived from animal hair, silk fibers, protein-based fibers, transformed natural fibers, wholly-synthetic (organic) fibers, glass fibers and metal fibers. 
     
     
         10 . The process of  claim 8 , wherein the ratio of regenerated fibers to other fibers is between about 2/98 and 99/1. 
     
     
         11 . The process of  claim 8 , wherein the other fibers are selected from the group consisting of Tencel, Rayon, Lyocel, Polyester, polypropylene (PP), nylon, and PLA fibers. 
     
     
         12 . The process of  claim 1 , further comprising applying a post-treatment to the fibers, wherein the post-treatment is selected from the group consisting of starch, glycol/glycerin, antimicrobial treatments, silicone, fluorinated anti-stain treatments, fire retardants, and cationic wet strength resins. 
     
     
         13 . The process of  claim 1 , further comprising applying a treatment to the fibers, wherein the fibers are treated with starch, glycol/glycerin, antimicrobial agents, silicones, and fluorinated stain-resisting agents. 
     
     
         14 . The process of  claim 1 , wherein the regenerated fibers are cellulosic fibers, further comprising treating the fibers with a cellulase enzyme. 
     
     
         15 . The process of  claim 1 , where the intimate blending step comprises the intimate blending of two or more batches of regenerated fibers. 
     
     
         16 . The process of  claim 1 , wherein the regenerated fibers are blended with thermoplastic fibers, where the thermoplastic fibers are present in a concentration of at least around 5% w/w. 
     
     
         17 . The process of  claim 1 , further comprising baling the regenerated fibers. 
     
     
         18 . The process of  claim 1 , further comprising twisting the regenerated fibers into a yarn. 
     
     
         19 . The process of  claim 1 , further comprising twisting the regenerated fibers into thread. 
     
     
         20 . The process of  claim 1 , further comprising including the regenerated fibers in a paper-making process. 
     
     
         21 . The process of  claim 1 , further comprising using the regenerated fibers to form a composite material. 
     
     
         22 . The process of  claim 1 , wherein the regenerated fibers comprise black fibers from black t-shirt waste streams. 
     
     
         23 . The process of  claim 23 , further comprising weaving the regenerated black fibers into marl yarns.