Systems and methods for recycling end-of-use textiles into second generation textiles

Abstract

A process for making a textile from a feedstock comprising a quantity of post-consumer apparel, each item of apparel having a desired textile composition and devoid of non-textile materials, including shredding the feedstock to obtain textile shreds, providing the textile shreds as a component in at least a first layer of a plurality of stacked layers comprising at least a second layer of supporting material, and feeding the plurality of stacked layers through a needle-felting machine in a plurality of passes, including at least one pass in each of a plurality of different 90-degree offset orientations. The textile shreds, or a mixture of the textile shreds and new textile fibers comprising no more than 15%-20% new textile fibers, may be carded with a carding machine to form a batting. Products made by the process may include a 100% cotton mulch mat for agricultural use.

Dependencies are inferred from the claim text.