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US 2019/0153643 A1Published application
Nonwoven recyclable fabric and associated methods
AssigneePurlin, LLC
InventorsRichard Francis Ferrell, James Michael Posa, Deborah K. Lickfield, Joseph D. Wahlquist
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Abstract
A nonwoven recyclable fabric and associated methods are provided. The fabric is formed from 100% polyester, and may also include surface coatings such as hydrophilic coatings to promote heat transfer as well moisture vapor transmission rates and/or a silicone coating to promote fabric smoothness and reduce abrasiveness of the fabric.
Claims20
A nonwoven, recyclable fabric comprising:
- recyclable polyester fibers produced via melt extrusion from a first polyester polymer sourced from a plurality of polyester fiber products blended with a second polyester polymer consisting of a virgin polyester polymer in a ratio of about 1:99 to about 35:65 of first polyester polymer to the second polyester polymer;
- other polyester fibers having a different source than said recyclable polyester fibers;
- wherein a ratio of said recyclable polyester fibers to said other polyester fibers is about 25:75 to about 99:1 to form the nonwoven, recyclable polyester fabric;
- wherein said nonwoven recyclable fabric has a density of no less than about 0.15 g/cm3;
- wherein said nonwoven recyclable fabric has a thermal resistance value of less than about 0.025 K-m2/W per ASTM F1868-14;
- and
- wherein said nonwoven recyclable fabric has an abrasion resistance of greater than or equal to 750 cycles under the Wyzenbeek abrasion test method per ASTM D4157.
4 more elements
A method for forming a nonwoven recyclable fabric, the method comprising:
- procuring a plurality of used nonwoven fabric products, wherein each of the plurality of nonwoven fabric products is formed of one hundred percent polyester fibers;
- wherein said one hundred percent polyester fibers are used as a source of polymer for a melt extrusion process by producing recycled polyester flake or pellets which are then made into recycled polyester fibers via said melt extrusion process;
- forming a fiber web from said recycled polyester fibers;
- bonding and mechanically treating said fiber web to produce said nonwoven recyclable fabric, said nonwoven recyclable fabric having a density of no less than 0.15 g/cm3, a thermal resistance value of less than about 0.025 K-m2/W per ASTM F1868-14, and an abrasion resistance of greater than or equal to 750 cycles under the Wyzenbeek abrasion test method per ASTM D4157.
1 more element
Dependencies are inferred from the claim text.