Nonwoven recyclable fabric and associated methods

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. The polyester fibers forming the fabric are obtained from a mixture of monocomponent high melt polyester fibers and bicomponent high/low melt polyester fibers. The bicomponent fibers have a high melt polyester core, and a low melt polyester outer sheath. The fibers are hydroentangled with one another. After entanglement, the low melt outer sheaths are melted to form a low melt binder interspersed with the high melt polyester fibers and the remaining high melt polyester cores. The binder fuses to these fibers to provide desirable strength characteristics.

What is claimed is: 
     
         1 . A nonwoven, recyclable fabric for use as a linen, the fabric comprising:
 a plurality of high melt polyester fibers hydroentangled with one another; and   a low melt polyester binder interspersed with the plurality of high melt polyester fibers binding said plurality high melt polyester fibers to one another, the low melt polyester binder obtained by melting outer sheaths of a plurality of bicomponent polyester fibers, wherein each one of the plurality of bicomponent polyester fibers has a high melt polyester core and a low melt polyester outer sheath, said high melt polyester cores forming part of said plurality of high melt polyester fibers.   
     
     
         2 . The fabric of  claim 1 , wherein the plurality of high melt polyester fibers and the high melt polyester core of each one of the plurality of bicomponent polyester fibers have a melting point of at least about 270° C. 
     
     
         3 . The fabric of  claim 3 , wherein the low melt polyester outer sheath of each one of the plurality of bicomponent fibers has a melting point not greater than about 150° C. 
     
     
         5 . The fabric of  claim 1 , wherein the fabric has a density of greater than 0.15 gr/cm 3 . 
     
     
         6 . The fabric of  claim 1 , wherein the fabric is free of a chemical binder that is not polyester. 
     
     
         7 . The fabric of  claim 1 , wherein the fabric includes a hydrophilic coating. 
     
     
         8 . The fabric of  claim 7 , wherein the hydrophilic coating is silicone. 
     
     
         9 . A nonwoven recyclable product, the product comprising the fabric of  claim 1 . 
     
     
         10 . The product of  claim 9 , wherein the product is one of a bed sheet and a pillow case. 
     
     
         11 . The product of  claim 10 , wherein the product includes a color changing indicator, said color changing indicator exhibiting a color change after skin contact. 
     
     
         12 . The product of  claim 10 , wherein the product is a bed sheet and includes an embossed region adjacent an edge of said bed sheet. 
     
     
         13 . A method for forming a nonwoven recyclable fabric, the method comprising the steps of:
 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;   melting the plurality of used nonwoven fabric products to form a polyester liquid;   extruding the polyester liquid to form a bulk mass of monocomponent fibers;   adding bicomponent fibers to the bulk mass of monocomponent fibers to form a fiber mixture;   carding said fiber mixture to form a fiber web;   hydroentagling said fiber web to form a hydroentangled web;   drying said hydroentangled web in a drying oven; and   compacting said hydroentangled web to a predetermined thickness.   
     
     
         14 . The method of  claim 13 , further comprising winding said hydroentangled web onto a roll after the step of compacting. 
     
     
         15 . The method of  claim 13 , wherein the step of drying includes melting said outer sheaths of said bicomponent fibers in a drying oven to form a polyester binder interspersed throughout the hydroentangled web. 
     
     
         16 . The method of  claim 13 , wherein the step of compacting includes melting said outer sheaths of said bicomponent fibers in a compaction roller arrangement to form a polyester binder interspersed throughout the hydroentangled web. 
     
     
         17 . The method of  claim 13 , wherein the step of adding said bicomponent fibers includes adding said bicomponent fibers such that the fiber mixture comprises about 5% to about 10% by weight bicomponent fibers. 
     
     
         18 . The method of  claim 17 , wherein the step of adding the said bicomponent fibers includes adding said bicomponent fibers such that the fiber mixture comprises about 7% by weight bicomponent fibers. 
     
     
         19 . The method of  claim 13 , further comprising applying a hydrophilic coating at one of prior to or after the step of hydroentangling. 
     
     
         20 . The method of  claim 19 , wherein applying the hydrophilic coating includes applying a silicone coating. 
     
     
         21 . The method of  claim 20 , wherein applying the silicone coating includes applying said silicone coating such that it amounts to not greater than 10% by weight of said fabric. 
     
     
         22 . The method of  claim 13 , wherein the step of drying includes drying the hydroentangled web to less than about 7% moisture. 
     
     
         23 . The method of  claim 22 , wherein the step of drying includes drying the hydroentangled web to not greater than about 2% moisture. 
     
     
         24 . The method of  claim 13 , wherein the step of extruding is performed with the polyester liquid at a temperature above about 275° C. 
     
     
         25 . The method of  claim 24 , wherein the step of extruding is performed with the polyester liquid at a temperature of about 290° C.