Recycling of denim fabric wastes into high-performance composites using the needle-punching nonwoven fabrication route

At present, a large number of waste textiles are disposed through incineration and burial, which cause serious environmental pollution. Therefore, recycling textile wastes into high mechanical products with eco-friendly method is an urgent issue. Based on the above status quo, three kinds of 3D waste denim fiber needled felts/epoxy composites (3DWECs) with different areal densities of the mono-layer fiber web were designed and fabricated, and the effect of the areal density of the mono-layer fiber web on its mechanical properties was studied in this work. The cross-section morphologies of 3DWECs were also examined. Tensile, bending and compressive test results revealed that 2# 3DWECs (the planar density of mono-layer fiber webs was 557 g/m ² ) possessed better mechanical properties than 1# 3DWECs and 3# 3DWECs. Both the static and dynamic mechanical testing results showed that 3D waste denim fiber needled felts acting as the reinforcement played an essential role in the bearing function. Moreover, the peel tests indicated that the peel strengths of the 3DWECs were above the limits of the Chinese National Standard for particle board. The composites have the potential as a substitute for some particle boards.