Yarn manufactured from recycled mixed clothing fibers and a process of making yarn manufactured from recycled mixed clothing fibers. Upcycled yarn has approximately 70%-95% of fiber from separated used clothes fibers, whereby separated used clothes fibers have cotton, polyester, nylon, silk, rayon, spandex, synthetic fibers, wool, hemp, carbon fibers, and/or linen. The upcycled yarn also has approximately 5%-30% other fibers that can be recycled fibers and/or virgin fibers, whereby the recycled fiber is recycled polyester from recycled plastic bottles and other sources, recycled cotton, recycled nylon from fishing nets and other sources, and the virgin fiber is nylon, spandex, virgin polyester, hemp, carbon fiber, and/or organic cotton.

Yarn manufactured from recycled mixed clothing fibers and a process of making yarn manufactured from recycled mixed clothing fibers. Upcycled yarn has approximately 70%-95% of fiber from separated used clothes fibers, whereby separated used clothes fibers have cotton, polyester, nylon, silk, rayon, spandex, synthetic fibers, wool, hemp, carbon fibers, and/or linen. The upcycled yarn also has approximately 5%-30% other fibers that can be recycled fibers and/or virgin fibers, whereby the recycled fiber is recycled polyester from recycled plastic bottles and other sources, recycled cotton, recycled nylon from fishing nets and other sources, and the virgin fiber is nylon, spandex, virgin polyester, hemp, carbon fiber, and/or organic cotton.

Aspects of the present disclosure relate to a nonwoven textile that is sustainable and that sustainably manufactured. The subject matter may be sustainable in one or more respects. For example, the nonwoven textile may be manufactured from recycled materials. In other instances, the nonwoven textile is itself recyclable to produce additional or subsequent nonwoven articles. In addition, the manufacturing processes used to make the nonwoven textile may consume less energy than other manufacturing processes.

A method of manufacturing a cushioning material P includes a defibrating step of defibrating a cloth to produce fibers F in dry forming, a mixing step of mixing the fibers F with a bonding agent to produce a mixture, an accumulation step of accumulating the mixture in air to produce a web W, and a first forming step of pressurizing and heating the web W to form the web W.

An acoustic insulation web of fibrous material includes: a nonwoven batting including: a first layer including a first plurality of low-melt binder fibers forming a first predetermined percentage of the first layer; and a second layer bonded with the first layer and including a second plurality of low-melt binder fibers forming a second predetermined percentage of the second layer, the first predetermined percentage being greater than the second predetermined percentage such that the first layer is denser than the second layer.

An acoustic insulation web of fibrous material includes: a nonwoven batting including: a first layer including a first plurality of low-melt binder fibers forming a first predetermined percentage of the first layer; and a second layer bonded with the first layer and including a second plurality of low-melt binder fibers forming a second predetermined percentage of the second layer, the first predetermined percentage being greater than the second predetermined percentage such that the first layer is denser than the second layer.

A fiber structure manufacturing apparatus including: an accumulation portion that accumulates a material containing a resin and a fiber in air to generate a fiber web; a transport portion that transports the generated fiber web in a transport direction; and a heating and pressurizing portion that pressurizes the transported fiber web with a heated lower flat plate and an upper flat plate to melt the resin, in which a liquid absorbent having a first region where pressurization by the heating and pressurizing portion is performed the predetermined number of times and a second region where the pressurization is performed more than a predetermined number of times is formed by alternately repeating transport at a predetermined pitch shorter than a length of the flat plate in the transport direction by the transport portion and the pressurization.

A dual layer nonwoven acoustic insulating material having a more densified layer and a less densified layer that is comprised of shoddy fibers and other fibers.

A method for recycling a nonwoven fabric, including: a waste nonwoven fabric pulverization step of pulverizing a waste nonwoven fabric to obtain pulverized waste nonwoven fabric particles; a material mixing step of dispersing and mixing the pulverized nonwoven fabric particles and a filler in water to obtain a nonwoven fabric mixture; a raw material mixing step of adding a fixing agent for agglomeration of the pulverized waste nonwoven fabric particles and the filler to the nonwoven fabric mixture, followed by mixing, to form a raw material; a draining step of separating and removing water from the raw material to form a recycled nonwoven fabric sheet; a first lamination step of laminating the plurality of recycled nonwoven fabric sheets to form a laminate; and a compressing/dehydrating step of compressing and dehydrating the laminate.

A method for recycling a nonwoven fabric, including: a waste nonwoven fabric pulverization step of pulverizing a waste nonwoven fabric to obtain pulverized waste nonwoven fabric particles; a material mixing step of dispersing and mixing the pulverized nonwoven fabric particles and a filler in water to obtain a nonwoven fabric mixture; a raw material mixing step of adding a fixing agent for agglomeration of the pulverized waste nonwoven fabric particles and the filler to the nonwoven fabric mixture, followed by mixing, to form a raw material; a draining step of separating and removing water from the raw material to form a recycled nonwoven fabric sheet; a first lamination step of laminating the plurality of recycled nonwoven fabric sheets to form a laminate; and a compressing/dehydrating step of compressing and dehydrating the laminate.