PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to
be performed:
Textile recycling is the method of reusing or reprocessing of used clothing, fibrous material
and/or clothing scraps left from the manufacturing process. In municipal solid waste textile are
found mainly in the form of discarded clothing, although other sources include home furnishing
items, carpets, industrial textiles and nondurable goods such as kitchen fabric and towels.
Cotton and polyester fibers have long been dominant fibers in the textile industry. Low quality
greige fabrics or low value textile wastes predominantly consist of cotton and polyester fibers.
Saravanan (2011) explained that the scope of the waste from cotton industry extends its products
to upholstery cloth, cover cloths, blanket, towels, shirting, quilts, underwear, carpet, industrial
roller cloth, electric cabling, hosiery and in the manufacture of asbestos yarn, paper, linoleum and
regenerated fibres. It has been reported that, the total amount of waste generated in India is about
80,000 to 85,000 tons per annum and this obviously needs proper treatment apart from disposal
as landfill. Similarly Claudio (2007) reported that with the rise in production in the fashion
industry, demand for man-made fibers, especially polyester, has nearly doubled in the last 15
years.
Process of recycling or converting waste fabrics in fibers is follwed by many people in Amroha
district of Uttar Pradesh, India. Amroha district is known for their recycling units which convert
these waste fabrics into fibers by cutting, shredding and carding process which leads to a fiber
form of fabric, called as recycled fibers (Sharma, R and Goel, A. 2015). Cotton and polyester,
both the fibers have a high potential in the manufacturing of nonwovens fabrics that are quite
promising materials in the current market. Use of recovered fibrous waste is particularly
attractive as the processing characteristics of properly recovered fibers do not differ much from
those of original staple and cut filaments. Polyester is a synthetic fiber which is not biodegradable
and therefore need to be recycled from an eco friendly approach where as cotton is a
r >
biodegradable natural fiber and acceptable all over the world, still there are many properties of
cotton which confines its use in pure form, to overcome all these problems we blended cotton
with polyester fiber. This process of blending provides a very good combination of properties as
a textile material.
2
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Present invention gives a new approach of using that recycled cotton fiber (RCF) and recycled
polyester fibers (RPF), for the development of nonwoven fabrics. Nonwoven products are taking
place of many woven and knit materials because of their lower cost and lighter weight. Maity
and Singha (2012) also reported in their study that the high rate of growth in nonwovens has led
to a substantial increase in research aimed at establishing links between structure and desired
properties of nonwovens. Needle-punched nonwoven materials with the required combination of
functional properties are widely used in numerous technical applications, including, filters,
composites, protective clothing, packaging, geo-textiles, home furnishings, heat and noise
insulating, etc. Nonwoven fabric can be prepared by various methods like, thermal, mechanical
and chemical bounding. Needle punching is a mechanical bounding process of manufacturing
nonwoven fabric. Gramsch (2010) explained that needling machines are essential in the
production of nonwoven fabrics. Nonwovens are bonded mechanically by needling. The needles
punch vertically in and out of the material. The machine then transports the material and the
needles come down again. This process locks the fibers together. According to Ravishankar
(2013) the worldwide nonwoven industry has grown steadily at about 7.5% per annum in tonnage
in the last decade. A significant portion of worldwide nonwoven expansion is due to the rising
demand for these materials. As emerging economies like Asia expands, India and China are the
key players contributing to this growth.
Hence visualizing the ready availability of recycled cotton fiber and recycled polyester fibers and
their profusion, they were selected to be processed into nonwoven fabrics. A good quality
nonwoven fabric can be formulated by using needle punching technique. The said invention
proposes selection, testing, blending of recycled cotton and polyester fibers in various ratios for
preparation of needle punched nonwoven fabric. This invention emphasis the analysis of best
ratios for the preparation of blended nonwoven fabric by using recycled cotton fibers and
recycled polyester fibers.
FIELD OF THE INVENTION
The present invention relates generally to recycled cotton fibers and recycled polyester fibers and
a nonwoven fabric comprising same. The invention also provides a method for the production of
fabric made of the recycled cotton and polyester'fibers in various ratios of blending. The prepared
nonwoven fabrics were analyzed on the basis of their physical properties to achieve the best one.
3
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PRIOR ART
Recycling is a way to process, the used materials (which is waste) into new products to prevent
waste of potentially useful materials. It reduces the consumption of fresh raw materials, energy
usage, air pollution, water pollution and land pollution. Recycling is a key component of modern
waste reduction and is the third component of the "Reduce, Reuse, Recycle and Recover" (4R's)
waste hierarchy. Textile waste recycling becomes more important phenomenon; bearing in mind
the limited availability of resources to produce natural fibers as well as fossil raw materials to make
synthetic fibers. Present invention highlights the novel approach of using recycled textile waste that
can be further converted in the form of fiber for the preparation of nonwoven fabrics.
In past, few studies have been conducted abroad by researchers to convert recycled fibers into
useful product forms. There are few patents in this line which mainly concentrate on processing
of recycled cotton and recycled polyester fibers and their conversion to different useful end
products. U.S. Patent No. 5331801 by Heifetz S. D. (1994) disclosed a method for manufacturing
yarns using recycled cotton waste and a new type of recycled cotton yarn. Various types of cotton
waste materials such as manufacturing by-products and post-consumer material are used in
• conjunction with virgin yarns to produce recycled yarns of sufficient quality to be used for
garment manufacture. However, the technology involved in this patent document is purely based
on yarn preparation and does not involve nonwoven. U.S. Patent No. 8398752 by. Brownstein J.
M. and Brownstein K. R. (2013) reveals a non-woven textile based filter media produced from
1 polyester fiber generated using recycled polyethylene terephthalate (PET) beverage bottles, and
that non-woven textile based filter media is used to make an air filter. China Patent No.
101173420 by Yuan C F. (2008) also explained the technique for producing nonwoven cloth by
using recycled polyester waste material with intrinsic viscosity of greater than 0.7 or more parts
mixed, then add 0.1 to 0.5% nucleating agent, and both are uniformly mixed, and finally by
feeding —* pre-drying —> thickening drying —• precrystaliization —• addition nucleating agent and
stirring —• —* second set screw melt extrusion melt filtration standard airflow drawing —>—>—•
spinning pendulum wire or directly into a network of pre-needled —• —> —• cut the main
acupuncture Roll edge —> —> —> product packaging production line production. Another U. S.
Patent No. 6753276 by Warlick, A. and Shuler, Q. (2004) developed a nonwoven fabric by
including a cohesively integrated web of hydrodynamically entangled short-staple or "waste
cotton" fibers. Milding etal. (200) also similarly explain in U. S. Patent No. 6037282, nonwoven
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material produced by hydroentangling a fiber web, comprising a certain proportion of recycled
fibers originating from nonwoven and/or textile waste. Gambhir, V. (2011) in WO Patent No
2011077446 Al provides a new way of manufacturing yarns i.e. yarns made of recycled cotton
paper. European Patent No. 2370623 by Coates et al. (2011) disclosed a method of forming a
nonwoven material, the method comprising: receiving fibrous material comprising thermoplastic
fibers; processing the fibrous material to produce short fibers; adding the short fibers to a
preformed web; and heating and optionally compressing the preformed web to form a nonwoven
material. A process for using recycled waste cotton material to produce a textile product is
provided by Lightman, E. D (2011) in Patent No. WO2011130276 Thus, a textile product can
be provided that includes yarn that can have at least three different categories of waste cotton
material that are from textile formation processes.
There have been different submissions to use recycled fibers for feasible ways. However, no
work has been found to be reported on the blending of recycled cotton fiber with recycled
polyester fiber for development of needle punched nonwoven fabric. This innovative idea of
blending recycled cotton with recycled polyester fibers for nonwoven textile production will not
only offer novel approach of non woven production but will also add an stream for waste
utilization.
In the present invention, blended nonwoven samples (three samples) using recycled cotton fibers
(RCF) and recycled polyester fiber (RPF) were prepared. Nonwoven samples were made by
using both recycled fibers; in different blend proportions i.e. 70:30 RCF/RPF, 50:50 RCF/RPF,
30:70 RCF/RPF. Webs were prepared by carding of fibers. This method was used to convert the
loose fibrous mat to a nonwoven structure. The developed nonwoven samples were subjected to
different tests to determine the characteristics, so as to establish the qualities of this fabric.
Objectives of the Invention:
• Major objective of the present invention is to develop a nonwoven fabric made-up of
recycled cotton fiber (RCF) and recycled polyester fiber (RPF) blend which gives a new
approach of recycled fiber application.
• Another object of the present invention is to test the various properties of'developed
nonwoven fabrics so as to analyze the best proportion therein.
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4. DESCRIPTION OF INVENTION
The following description illustrates preferred personification of the invention.
The present invention provides nonwoven fabric prepared with recycled cotton and recycled
polyester blended fibers with such a unique texture and properties which makes it suitable for
preparing the various household and commercial products out of it.'
According to review it was found that many inventions have been made before by using these
two fibers but no work was done by using them together in recycled form (shredded and carded
from fabncs) to produce blended needle punched nonwoven fabric. The nonwoven fabric of the
present invention has the comparable properties which helps to replace it with fresh nonwoven
fabric for various applications.
The invention also relates to the fabric production from this recycled cotton and recycled
polyester nonwoven fabric as an eco-friendly.and economically viable approach due to its waste
mmimization and utilization approach. The process of the production of the fabric from this
recycled cotton and recycled polyester fiber is simple and can be made on needle punch
nonwoven looms which are used for the preparation of other polyester nonwoven fabrics The
commercial production of the fabric of the recycled cotton and polyester nonwoven fabric of the
present invention is also very, viable as it does not require any complicated and costly machinery
In descnb.ng the inventions, various terms are used. As used herein, a "recycled fiber" is a form
of shredded textile materia, (i.e., cotton and polyester knitted and woven industrial and consumer
waste fabric).Sorting, cutting, and carding are various steps in processing which lead to the
development of recycled fiber.
"Needle punching" is another term used in the present invention refers to the mechanical
process of creating nonwoven fabric by interlocking carded web of fibers.
The recycled fiber of the present invention comprises a natural fiber in combination with the
synthetic fiber. The natural fiber here is recycled cotton which is blended with synthetic fiber i e
Polyester. The recycled cotton and recycled polyester fibers are blended in different ratios
(depicted in tabie ,) of 30:70, 50:50 and 70:30 i.e. in first ratio 30 percent recycled cotton and 70
percent recycled polyester then equal amount of each fiber 50 percent recycied cotton and 50
percent recycled polyester. Another ratio comprises 30 percent recycled polyester and 70 percent
recycled cotton used in the preparation of needle punched nonwoven fabric.
Table 1 Ratio of recycled cotton fibers (RCF) and Recycled polyester fiber (RPF) for
nonwovens
S.No
1.
2.
3.
Fiber content
Recycled cotton and recycled polyester
Recycled cotton and recycled polyester
Recycled cotton and recycled polyester
Ratios
50: 50%
70:30%
30:70%
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a) Raw material used for nonwoven fabric
For the present invention it was found that textile waste in recycling units can be categorized as
sorted and unsorted textile waste. Fibers drawn from sorted waste were selected on the basis of
availability, cleanliness and aesthetic appeal. Two recycled fibers, cotton and polyester were
selected for the preparation of nonwoven fabrics. Cotton and polyester both fibers are most
widely used fibers in clothing and other textile industry, may be this was the reason that most of
the textile waste comprised of these two fibers.
b) Physical Properties of Recycled Fibers
In the present investigation, selected fibers were tested in terms of fiber length, tenacity, crimp,
fineness, elongation, diameter, moisture content and microscopic appearance by using standard test
procedures. Testing was necessary as the fiber properties directely effect the properties of developed
nonwoven fabric. Before testing recycled cotton and recycled polyester, fibers were kept in standard
conditions for 24 hours i.e. 27°C temperature and 65 per cent RH. It was done to avoid deviation in
results. These tests were essential to determine the quality of fibers to be used for different purposes.
The results of the comparable physical properties of experimental fibers are presented in Table 2.
Table-2 Physical properties of experimental fibers
SI. No.
1
2
3
4
5
6
Properties
Length (mm)
Tenacity(g/denier)
Elongation (%)
Fiber fineness/ count (dtex)
Crimp No./ inch
Diameter(microns)
RCF
21.50
2.73
6.3
1.577
2/ inch
16.75
RPF
66.80
4.46
19.41
3.92
6/inch
24.29
RCF= Recycled Cotton Fiber, RPF= Recycled Polyester Fiber
Selected recycled fibers were evaluated according to their physical properties and Table-2
revealed that mean length of recycled cotton fiber was measured and observed as 21.50 mm
whereas in case of recycled polyester it is 66.80 mm. Recycled cotton fiber has the tenacity of
7
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24.6 g/tex (2.73g/d) where as tenacity of polyester fiber was noted as 4.46 g/ denier. Elongation
of recycled cotton fiber was noted as 6.30 per cent and for recycled polyester, elongation was
noted as 19.41 per cent Fineness of recycled cotton fiber was reported as 1.57 dtex and for
recycled polyester fiber was recorded as 3.92 dtex. Recycled cotton fiber had very few i.e. 2
crimps/inch whereas recycled polyester had 6 crimps/inch. Diameter of recycled cotton and
recycled polyester fiber was recorded as 16.75 ^m and 24.29 nm repeatedly.
c) Chemical analysis of recycled fibers
Recycled cotton and polyester fibers were evaluated for their chemical properties and the major
findings were that the average ash content for the test sample was 1.63 per cent for cotton and
0.06 per cent for polyester. Moisture regain of recycled cotton was 4.77 per cent and for recycled
polyester was recorded as 0.70 per cent. Table 3 reveals the effect of various chemicals i.e.,
sulphuric acid (98 per cent), sodium hydroxide (50 per cent), hydrochloric acid(38 per cent), glacial
acetic acid (99 per cent) , Nitric acid (69 per cent), Meta cresol on selected fibers at room
temperature (27°C) and on boiling for 30-60 seconds was evaluated for structural changes and
solubility. These tests also helped in confirming that the fibers were cotton and polyester. Recycled
cotton fiber shows good resistance toward alkalis compared to acid reagents. Recycled polyester fiber
dissolved in m-cresol at boiling temperature.
Table 3 Effect of acids and alkalies on selected fibers
Chemicals
Dil. HCL
Cone. HCL
Dil. HN03
Cone. HNO3
Dil. H2SO4
Cone. H2SO4
Glacial acetic acid
Meta-zrt$oDil.NaOH
Cone. NaOH
Effect of acids and alkalies on selected recycled fibers
Recycled Cotton Fiber
Room temp.
Fiber swell
Fiber dissolve
No effect
Swell slightly
Swell slightly
Fiber dissolve
Fiber dissolve
Swell slightly
No effect
No effect
Boiling
Swell fiber
Fiber dissolve
Swell slightly
Fiber dissolve
Fiber dissolve
Fiber dissolve
Fiber dissolve
Fiber dissolve
No effect
Swell slightly
Recycled Polyester Fiber
Room temp,
No effect
No effect
No effect
Light Yellow
No effect
No effect
No effect
Fiber swells
No effect
No effect
Boiling
No effect
Fiber swell
Light yellow
Light yellow
and fiber swell
No effect
fiber swell
No effect
Fiber dissolve
No effect
Swell slightly
00 8 d) Preparation of nonwoven fabric by recycled fiber:
Nonwoven fabrics were prepared in three ratios (70:30, 50:50 and 70:30) of recycled cotton
and recycled polyester fibers by using needle punching method. Machine used for the
preparation of nonwoven fabric was Zhentai nonwoven machine from China. Zhentai is a
professional machine with diversified functions and continuous line starting from opening,
feeding of fibers and ending with exit of final product of isotropic nature i.e. machine
direction and cross direction. Total six looms and one carder were attached in a single
production line. Machine parameters showed maximum width of fabric that can be
manufactured in the machine was three meter with the speed of six to seven meters/minute.
Triangle pointed needle having gauge size of 15X18X38 cm was used. Length of the needle
was 3 Vi inch. There were three needle boards attached in a loom for punching. Each board
contained 19900 needles in zigzag orientation. Looms were equipped with air pressure
pipes and oil pipes; 2-3 kg air pressure was permissible through rollers for punching. Oil
pipes passed oils for lubrication in machine barring and pistols for smooth running of
rollers.
The needle punch nonwoven blended recycled cotton and recycled polyester was prepared by
passing through the various steps are discussed below-
Blending
Recycled cotton and recycled polyester fibers were blended manually in three different ratios to
prepare web for nonwoven fabrics (Table 1). Blending ratios are of 30:70, 50:50 and 70:30 i.e. in
first ratio 30 percent recycled cotton and 70 percent recycled polyester then equal amount of each
fiber 50 percent recycled cotton and 50 percent recycled polyester. Another ratio comprises 30
percent recycled polyester and 70 percent recycled cotton.
Carding
Carding machine, Vijay Textiles (M/C AQQ1Q4) was employed in the present research work. It
consists of seven rollers covered with iron spikes of different length and thickness in each roller.
Fiber mass was placed evenly on lattice of carding machine. This machine works as to make web
of fibers and also it removes dust and other impurities. Carding machine helped in straightening
9
« . i 2 a t i o n of the fibers into thin web known as lap. To m a k e a good qua,ity non woven
fabnc, th.s is very essential to card fibers properly to prepare even web.
Web feeding
Layers of recycled cotton and recyCed polyester web were feed into the „eed,e
b > ™ s o f w e b feeder. Web feeder prevents the layers to get deformed.
Pre needling punching loom
The fiuffy , f flber thM fed ( h r o u g h a s e r i e s ^ ^ ^ ^
,n erlace vanous layers us,ng low needle density. „ was a preliminary 3 D interlacing to e„,a„g,e
fibers. Through this process the fluffy mass of fibers web ge, slightiy compact.
Needle punching
The pre punched layered web of b,e„ded fibers (each separately) was delivered by means of
conveyer e„ and toilers through two needle punching looms placed back to bac, Fabric passed
rom f,rs, loom to second loom where the web gets needle punched successive,, * ge, the 1
ens,.nonwoven fabric of recycied fibers. ,n this process of needle punching ,h! fiber web
Passed through there needle punching, looms, so tha, the more compressed nonwoven fabric can
Calendering
Calendering is a finishing process used on nonwoven where fabric is passed under ho, toilers at
h temperatures and pressures. The fabric runs through rollers that polish the surface and make
e fabnc smoother and more lustrous. High temperatures and pressure are used as w e , Fabric
that go through the calendering process feel thin „i„o A
r . , . , « Process teel thm, glossy and papery. For the present study 180°
Ceis.us temperature was kept for upper roiler and ,70° Celsius was kept for iower ro„er
L r b C r Ca,ende"8 Pr- ~ ^ " — ' * - - —,ed
e) Physical properties of blended nonwoven fabrics-
The physical properties of a„ the deve,oped fabrics were tested. Tests were carried o„, to eva,ua,e
br,c we,gh, (gm/m^,, fabric thickness (mm), bending ,eng«h, abrasion , „ , (per cent) ^
,eng, (gm/ ^ ) , e l o n g a t i o n ( p e r c e m ) o f ( h e p K p a r e d n o n w o y e n * e
apphcabrhty. The resu.ts are discussed characteristic wise as under.
10
i. Fabric Weight: It is apparent from Table 4 that the fabric weight for blend of cotton and
polyester nonwoven fabric 30:70, 50:50, 70:30 was 188, 200, 190 g/m2 respectively.
ii. Fabric thickness: Thickness of blended nonwoven fabrics in all three ratios i.e. 30:70 (C:
P), 50:50, (C: P) 70:30 (C: P) was found to be 1:86 mm, 2.60 mm, 2.75 mm respectively.
iii. Bursting strength: Bursting strength was acquired as 7 kg/ cm in 30:70 cotton polyester
blend, 6.80 kg/cm2 in 50:50 cotton polyester ratios and 3.56 kg/ cm2 in 70:30 cotton polyester
blend.
iv. Abrasion resistance: Abrasion loss of the fabric prepared from recycled cotton & recycled
polyester blend having 30:70 (cotton: polyester), 50:50 (cotton: polyester), and 70:30
(cotton: polyester) ratio was recorded as 0.34 per cent, 0.52 per cent and 1.42 per cent
respectively.
Table 4 Physical properties of developed nonwoven fabric samples
Fabric Properties
Fabric weight g/m
Fabric Thickness mm
Busting strength kg/cm
Abrasion resistance
(percent weight loss)
Tensile strength
(kg/cm2)
Fabric elongation (%)
Bending Length (cm)
Fabric
Direction
-
-
-
~
MD
CD
MD
CD
MD
CD
Fabric Ratio
Nonwoven
30:70 (RC:RP)
188
1.86
7.00
1.42
16.84
23.6
36
30
4.10
6.90
50:50 (RC:RP)
200
2.60
6.8
0.52
14.60
21.49
35.00
32
4.50
5.3
70:30 (RC:RP)
190
2.75
3.56
0.34
3.60
7.80
44.11
37
3.50
5
RC: Recycled Cotton, RP: Recycled Polyester, MD: Machine Direction, CD: Cross Direction
v. Tensile strength: Table 4 depicts that blended nonwoven fabric samples of recycled cotton
with recycled polyester fiber were also tested for tensile strength and maximum tensile
strength was observed in blended nonwoven fabric prepared with 30:70 ratio of cotton and
polyester i.e. 16.84 kg/cm in machine direction and 23.60 kg/cm in cross direction followed
by 50:50 ratio of cotton and polyester i.e. 14.60 kg/cm2 in machine direction and 21.49 kg/cm2

5. WE CLAIM:
1. Having developed a novel needlepunched nonwoven fabric with the use of recycled cotton
and recycled polyester fibers and at the same time having requisite attributes viz; light
weight, thickness, tensile strength and abrasion resistance, ideally suited for various
applications as lining materials in the field of technical textiles.
2. in fabric of claim 1 above, we claim a ratio of blending recycled cotton fibers with recycled
polyester fibers which involves a ratio of 30:70 (RCF:RPF) for developing a fabric. ^
3. in the fabric of claim 1 above, we claim a fabric weight of 188 g/m2 with thickness of 1.86
mm,
4. in the fabric of claim 1 above, we claim bursting strength of 7 kg/cm 'abrasion loss of 1.42 per
cent, tensile strength of at least 16.84 kg/cm2 (Machine Direction) and 23.60 kg/cm2 (Cross
Direction).
5. in the fabric of claim 1 above, we claim elongation of 36 per cent in machine direction and
30. per cent in cross directions and bending length as 4.10 cm in machine direction and 6.90
in cross direction respectively.