TECHNICAL FIELD

The present invention relates to a use of composite waste material. In particular, though not exclusively, this invention relates to a recycled composite textile and a method of manufacturing the recycled composite textile.

BACKGROUND

A composite textile waste material is produced in every phase of the textile manufacturing process such as spinning, weaving, dyeing, finishing, garment manufacturing, or even at consumer end. For example, around 30 percent of raw material gets scrapped during garment manufacturing. The composite textile waste material poses a huge problem, irrespective of whether it is produced during production stage, processing stage, or at end-of-life cycle of textile products. The composite textile waste material is often dumped into landfills as a measure of waste management. Once in the landfill, some composite textile waste materials will not decompose. In the landfills, the composite textile waste material typically releases harmful gases (for example, methane, CO2, and the like) into atmosphere. Further, they also release toxic substances into groundwater and surrounding soil, leading to fatal impacts on living beings in nearby areas. Aforesaid harmful impacts of dumping the composite textile waste material in the landfills can be minimized by recycling/reusing the composite textile waste material.

Conventionally, there are two main ways to recycle/ re-use the textile waste material, for example, a mechanical recycling method and a chemical recycling method. However, existing techniques for recycling/reusing the composite textile waste material have several problems associated therewith. For example, the mechanical recycling method involves shredding the composite textile waste material into a fibrous form. However, shredding may result in shortening (for example, in length) of the composite textile waste material (for example, fibres, yarns, and the like) as well as weakening (for example, in terms of strength) of the composite textile waste material leading to a decrease in the usability of a product to be manufactured using the composite textile waste material. Further, the chemical recycling method entails a chemical process that de-polymerizes the composite textile waste material into a sludge of polymers and fibres. However, the chemical recycling is not fully developed to be used on a commercial scale and is expensive.

Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the existing techniques to recycle/re-use the composite textile material.

SUMMARY OF THE INVENTION

A first aspect of the invention provides a recycled composite textile comprising: a backing material coated with a polymer; and a plurality of patches arranged on the polymer, wherein the plurality of patches are arranged as at least one layer in a manner that each patch is arranged directly on the polymer or on a binder applied on at least one other patch of another layer, and wherein the patches in a given layer are arranged in a non-overlapping or minimally overlapping manner.

The term "recycled composite textile" refers to a textile product of predefined dimensions. The recycled composite textile has two sides: a front side and a back side. The front side of the recycled composite textile comprises the backing material coated with the polymer and the plurality of patches arranged on the polymer. The recycled composite textile is used as a raw material in textile industry to manufacture a variety of products.

The term "backing material" refers a component that primarily serves to support other components of the recycled composite textile. The backing material forms, protects, and strengthens a back of the recycled composite textile. The backing material has two sides: a first side and a second side, wherein the aforesaid components of the recycled composite textile are provided on the first side of the backing material and the second side of the backing material forms the back side of the recycled composite textile. Optionally, the backing material is a flat sheet-like structure, that is in the form of a roll. In this regard, the backing material is unrolled before being used and the plurality of patches are arranged on it as described below. Alternatively, optionally, the backing material is in an un-rolled form. Optionally, the backing material have properties such as, bio sustainability, reusability, required strength to withstand weight of the plurality of patches, and the like.

Optionally, the backing material is implemented as at least one of: a paper, a textile, polymer. In one implementation, the backing material is implemented as the textile. Examples of the textile include, but are not limited to, cotton, recycled cotton, bioplastics, and bamboo. In other implementation, the backing material is implemented as the paper. In such an implementation, a plurality of layers of the paper could be used to make the backing material. A number of the plurality of layers of the paper that are required depends upon a required thickness of the backing material. For example, a higher number of the plurality of layers of the paper may be required to make the backing material with high thickness than the backing material with low thickness. In yet another implementation, the backing material is implemented as a polymer. The polymer could be a polyester. Advantageously, the technical effect of using different types of the backing material is that the aforesaid material is easy to procure and use, and is inexpensive. Moreover, aforesaid material imparts required strength and structural stability to the recycled composite textile.

Further, the backing material is coated with the polymer. Optionally, at least one of the two sides of the backing material is coated with the polymer. The coating of the polymer on the backing material helps to impart required texture, strength, and other prerequisite properties to the backing material. Optionally, the polymer acts as an adhesive for the plurality of patches to be applied on the backing material as described below. Optionally, the polymer is coated on the backing material as at least one layer. In this regard, a single layer or multiple layers of the polymer may be coated on the backing material. Optionally, the at least one layer of the polymer have a predefined thickness lying in a range of 0.10 millimetres to 2 millimetres. Examples of the polymer could be, but are not limited to, 0.25mm, 0.5mm, and 1.25mm.

In an embodiment, a first side (namely, a top side) of the backing material is coated with the polymer, and the plurality of patches are arranged on the first side of the backing material. In other words, the polymer is sandwiched between the plurality of patches and first side of the backing material. In another embodiment, the first side and a second side (namely, a bottom side) of the backing material are coated with the polymer, and the plurality of patches are arranged on the first side of the backing material. Herein, the polymer sandwiched between the plurality of patches and the first side of the backing material serves as an adhesive for the plurality of patches and the polymer coated on the second side serves to improve prerequisite structural properties of the backing material.

In yet another embodiment, the first side and the second side of the backing material are coated with the polymer, and a first set of plurality of patches are arranged on the first side and a second set of plurality of patches are arranged on the second side of the backing material. In such case, the polymer is sandwiched between the first set of plurality of patches and first side of the backing material as well as the second set of plurality of patches and second side of the backing material. Beneficially, such recycled composite textile having plurality of patches arranged on either side of the backing bacterial coated with polymer can be used reversibly.

The patch refers to a piece of composite waste material. The piece of the composite waste material is processed to obtain the plurality of patches as described below before being applied to the polymer. The plurality of patches are arranged on the polymer in a form of at least one layer. In this regard, the plurality of patches are arranged in a single layer or in multiple layers, on the backing material that is polymer-coated. Optionally, the plurality of patches has a predefined weight. The predefined weight could lie in a range of 0.1 grams to 500 grams. Optionally, the plurality of patches has various shapes such as, but are not limited to, square, rectangle, circular, elliptical, and triangle. Optionally, the plurality of patches have various irregular shapes. More optionally, the plurality of patches has random size distribution depending upon their various sources. The term "random size distribution" refers to a distribution of the plurality of patches in the given layer irrespective of sizes of the plurality of patches. For example, a given patch may be small and another given patch could be comparatively large in the given layer.

A given patch is arranged directly on the polymer to form the at least one layer of the plurality of patches on the backing material. A technical effect of arranging a given patch directly on the polymer is that it ensures efficient binding of the patch to the backing material via the polymer, and eliminates a need for an additional adhesive to be applied to the patch previously or a layer of adhesive to bind the patch to the backing material. Alternatively, a given patch is arranged on the binder present on the patches of the another layer to obtain multiple layers of the plurality of patches as described in below paragraphs. Optionally, the plurality of patches are arranged on the polymer using at least one of: a person, a robot, a machine with a robotic arm.

Optionally, the binder is implemented as at least one of: the polymer, an epoxy powder, a fabric glue. Optionally, the epoxy powder is of low molecular weight. Advantageously, the technical effect of using one or more different kinds of the binder is that the plurality of patches gets adequately adhered on the binder leading to production of a stable and uniform recycled composite textile.

The patches in the given layer are arranged in a pre-determined manner. Such manner will ensure consistency of material performance and/or consistency of visual appearance, among other things. It will be appreciated that the patches are arranged such that any two patches don't overlap onto each other. Alternatively, the patches are arranged such that any two patches have minimum overlapping onto each other. The minimum overlapping could be along seam lines of the patches, around corners of the patches, or similar. Such an arrangement of the patches in the given layer is crucial to maintain uniformity and finish of the recycled composite textile which significantly enhances usability of the same. Nil or minimal overlapping ensures that the thickness of the recycled composite textile is consistent throughout.

The recycled composite textile has the plurality of patches arranged in a way that it offers several properties to the recycled composite textile which makes it suitable for various textile applications. The properties could be, but are not limited to, enhanced strength, structural stability, resistance against wear and tear, and the like. The plurality of patches used in the recycled composite textile are pieces of composite textile waste material which would have been otherwise subjected to landfilling as the measure of waste management, thereby leading to severe environmental pollution associated with the landfilling. Using such patches in the recycled composite textile considerably lowers such environmental pollution. The recycled composite textile considerably minimizes the composite textile waste material. Moreover, the recycled composite textile is a sustainable solution in the textile industry to be used as a raw material for manufacturing various products, as it saves considerable amount of energy sources such as electricity, water which would have been employed while manufacturing a product from scratch. The utilization of the recycled composite textile is easy and does not require much time, cost, and effort.

Optionally, the plurality of patches are implemented as at least two of: a knitted fibre patch, a woven fibre patch. In one example implementation, a mix of knitted fibre patches and woven fibre patches may be used as the plurality of patches to be applied in the given layer. In another example implementation, one layer may have the woven fibre patches and another layer may have the knitted fibre patches. The knitted fibre patch refers to a patch manufactured by knitting of a plurality of fibres. The woven fibre patch refers to a patch manufactured by waving of the plurality of fibres. An arrangement of textile fibres in the knitted fibre patch is different from an arrangement of textile fibres in the woven fibre patch. Advantageously, utilization of different kind of the patches significantly enhances strength, finish, and mechanical properties of the recycled composite textile. Moreover, usage of different kind of the patches allows for manufacturing various types of recycled composite textiles using the different kinds of patches and thus significantly reduces the problem of environment pollution which would have otherwise occurred owing to landfilling of the same. Optionally, the recycled composite textile has a width lying in a range of 1 meter to 1.5 meters and a length lying in a range of 25 meters to 50 meters. The width lies in a range of 1 meter to 1.1 meters, 1 meter to 1.2 meters, 1 meter to 1.3 meters, 1.1 meters to 1.4 meters, 1.1 meters to 1.5 meters, 1.2 meters to 1.5 meters. The length lies in a range of 25 meters to 35 meters, 25 meters to 45 meters, 25 meters to 50 meters, 30 meters to 35 meters, 30 meters to 45 meters, 30 meters to 50 meters, 40 meters to 45 meters, 40 meters to 50 meters. Advantageously, aforesaid dimensions (the length and the width) of the recycled composite meets with a standard size requirement of raw materials required in a textile industry to manufacture various textile products. Owing to the above, the recycled composite textile is efficiently used in industries using standard textile equipment. Utilization of the recycled composite textile does not require re-designing of existing textile equipment.

A second aspect of the present invention provides a method of manufacturing a recycled composite textile, the method comprising : laying a backing material on a flat surface; applying a polymer on the backing material; arranging a plurality of patches on the polymer, wherein the plurality of patches are arranged as at least one layer in a manner that each patch is arranged directly on the polymer or on a binder applied on at least one other patch of another layer, and wherein patches in a given layer are arranged in a non-overlapping or minimally overlapping manner; and pressing the plurality of patches arranged as the at least one layer to obtain the recycled composite textile.

In this regard, the backing material is laid on the flat surface to subsequently apply the polymer and the plurality of patches with ease. The flat surface could be a surface of a conveyor belt, a surface of a machine, a surface of a table, or similar. Optionally, the step of laying the backing material on the flat surface is performed using at least one of: a person, a robot, a machine with a robotic arm. Optionally, prior to laying the backing material, the backing material is unrolled so as to lay it on the flat surface by spreading it fully on the flat surface. Optionally, the backing material is unrolled using an unrolling machine.

Further, the polymer is applied on the backing material. The polymer imparts required texture, strength and other prerequisite properties to the backing material. Optionally, the polymer acts as an adhesive for the plurality of patches to be applied on the backing material as described below. Optionally, the step of applying the polymer on the backing material is performed using at least one of: a spray, a brush, a spreading tool, a coating device. Optionally, the spreading tool is at least one of: a roller, a spreading wheel, a spreader stick. More optionally, the coating device is at least one of: a screen coating device, a film coating device, a strip coating device. Aforesaid forms of application of the polymer result in adequate and even coating of the polymer to obtain a required thickness of the polymer.

Post applying the polymer on the backing material, the plurality of patches are arranged on the polymer. Herein, the arrangement of the plurality of patches on the polymer is optionally random, and is already described above. In some implementations, the plurality of patches are arranged as a single layer whereas in other implementations, the plurality of patches are arranged as a plurality of layers (i.e., multiple layers). Advantageously, the aforesaid arrangement of the plurality of patches imparts uniformity and stability to the recycled composite textile.

Lastly, when the plurality of patches arranged as the at least one layer, they are subjected to the step of pressing. Optionally, the step of pressing the patches in the given layer is performed by a pressing machine. Examples of the pressing machine could be, but are not limited to, heat press, steam press, and hand press. The plurality of patches are pressed to uniformly arrange the patches in the given layer. Optionally, the step of pressing is performed at a pressure lying in a range of 1 bar to 27 bar. Advantageously, the method of manufacturing the recycled composite textile is easy to perform, does not require large and expensive equipment and can be efficiently performed at a small scale as well.

Optionally, the method further comprises cutting the recycled composite textile to have a width lying in a range of 1 meter to 1.5 meters and a length lying in a range of 25 meters to 50 meters. The width lies in a range of 1 meter to 1.1 meters, 1 meter to 1.2 meters, 1 meter to 1.3 meters, 1.1 meters to 1.4 meters, 1.1 meters to 1.5 meters, 1.2 meters to 1.5 meters. The length lies in a range of 25 meters to 35 meters, 25 meters to 45 meters, 25 meters to 50 meters, 30 meters to 35 meters, 30 meters to 45 meters, 30 meters to 50 meters, 40 meters to 45 meters, 40 meters to 50 meters. Optionally, the step of cutting the recycled composite textile is performed by at least one of: a blade, a knife, a cutter, a machine having a cutting element. Alternatively, optionally, the step of cutting the recycled composite textile is performed manually by a person. Advantageously, the technical effect of manufacturing the recycled composite textile to have the aforesaid size is that it can be effectively used as a standard raw material for varying applications. Moreover, usage of the recycled composite textile does not require any changes to the textile machines, as it can be easily used with standard textile machines. Various applications of the recycled composite textile include, but are not limited to, garment manufacturing, soft furnishing material manufacturing, appliance covers manufacturing, and handicraft manufacturing. The soft furnishing material could be at least one of: upholstery material, rugs, carpets, curtains, cushion covers.

Optionally, the at least one layer comprises the plurality of layers, and wherein the method further comprises: building the plurality of layers in a stack-wise manner to obtain a required thickness of the recycled composite textile, wherein when building a next layer on top of the given layer, the method comprises applying a binder on the patches in the given layer; and arranging patches of the next layer on the binder applied to the patches of the given layer; and heat pressing the plurality of layers that are stacked, at a temperature lying in a range of 45 to 200 degrees Celsius .

In this regard, the at least one layer includes the plurality of layers comprising the plurality of patches. The plurality of layers are arranged in the stack-wise manner. Herein, the term "stack-wise manner" refers to an arrangement of the plurality of layers having one layer arranged on top of another layer in the form of a vertical stack of layers. A number of layers in the plurality of layers depend upon required thickness of the recycled composite textile. For example, the number of layers may be more in the recycled composite textile having more thickness than the recycled composite textile having less thickness. The number of layers in the plurality of layers could lie in a range of 1-15. Optionally, the number of layers also depend upon required strength and usability of the recycled composite textile. In order to arrange the next layer on top of the given layer, the binder is applied on the patches of the given layer. The binder has adhesive properties which effectively enable it to join the patches of the next layer with the patches of the given layer which is already applied on the (polymer-coated) backing material. A total number of times that the binder is applied when building the plurality of layers is optionally Z- 1, wherein Z is the number of layers in the plurality of layers. As an example, the recycled composite textile may have 3 layers of the plurality of patches, the 3 layers being referred to as a first layer, a second layer and a third layer. The first layer may be applied on the polymer-coated backing material. In this example, the binder may be applied on the first layer and a set of patches may be arranged on the binder to form the second layer on top of the first layer. Similarly, the binder may be applied on the second layer and another set of patches may be arranged on the binder to form the third layer on top of the second layer. The patches in the given layer are applied in a random manner. Lastly, the plurality of layers are subjected to a step of heat pressing. The step of heat pressing is performed at the temperature lying in a range of 45 to 200 degrees Celsius. Optionally, the step of heat pressing the plurality of layers is performed using at least one heat pressing machine. The step of heat pressing is performed to activate the binder applied on the patches of the given layer. Activation of the binder results in activation of chemical properties of the binder resulting in adequate adhesion of the patches of the next layer with the patches of the given layer. Optionally, the step of heat pressing is performed after arranging patches constituting the plurality of layers in the stack-wise manner to adequately adhere the plurality of layers with each other. Optionally, the step of heat pressing is performed for a predefined time duration lying in a range of 0.1 seconds to 30 seconds units. Advantageously, the technical effect of the plurality of layers is that the plurality of layers imparts a required strength, stability and thickness to the recycled composite textile which results in significant enhancement in usability of the same.

Optionally, the step of arranging the plurality of patches comprises: depositing the patches that are to be arranged in the given layer over a target area of the given layer; and distributing the patches randomly on the polymer or on the binder applied on at least one other patch of another layer on top of which the given layer is to be formed.

In this regard, the term "target area" refers to a required area of the given layer to be deposited with the patches. The given layer could be any one of the layers of the recycled composite textile. Optionally, the step of depositing the patches in the given layer is performed by at least one of: the person, the robot, the machine with a robotic arm. Further, the patches deposited in the given layer are distributed randomly.

Optionally, the method further comprises: inspecting for presence of gaps in the target area; and when it is determined that at least one gap is present in the target area, at least redistributing loose patches in the given layer to cover the at least one gap.

In this regard, the gaps can be formed among the plurality of patches in the target area while distributing the patches in the given layer. The presence of gaps can impact thickness and structural integrity of the recycled composite textile. Therefore, the gaps need to be eliminated from the target area. The presence of gaps is determined amongst the plurality of patches in the target area. Optionally, the step of inspecting for the presence of gaps in the target area is performed by at least one of: manually inspecting the target area using eyes of a person, inspecting the target area using a camera. Other solutions of inspecting the target area for presence of the gaps are also feasible such as, but not limited to, laser inspection, radiation detection and the like. Optionally, the step of redistributing the loose patches in the given layer is performed by at least one of: the person, the robot, the machine with a robotic arm. Optionally, when it is determined that the at least one gap is present in the target area, the method also comprises depositing new patches to cover the at least one gap. The new patches are deposited by at least one of: the person, the robot, the machine with a robotic arm. A given gap may be covered using a single patch or using multiple patches. Optionally, when it is determined that no gaps are present in the target area, it is determined that the target area has been manufactured properly. In this regard, the target area has a requisite quality. Advantageously, the at least one gap is covered in the target area to impart uniformity, enhanced strength, and required mechanical properties to the recycled composite textile.

Optionally, the method further comprises removing any extra patches that fully overlap with the patches in the given layer. The step of removing any extra patches is performed by at least one of: the blower, the air knife, and the like. An extra patch refers to a patch that fully overlaps one or more patches in the given layer. The extra patches are removed from the given layer owing to a fact that the extra patches interfere in obtaining uniformity in the patches of the given layer. Advantageously, the step of removing the extra patches helps in obtaining the recycled composite textile having uniformity, enhanced strength and an even finish.

Optionally, the method further comprises scanning the patches in the given layer upon their arrangement for at least inspecting for presence of defects in the given layer. Optionally, the step of scanning the patches in the given layer is performed by at least one of: laser scanning, interferometry. Alternatively, optionally, the step of scanning the patches in the given layer is performed manually by a person using his/her eyes. Optionally, the step of scanning the patches in the given layer is performed to ensure requisite quality of the recycled composite textile. The step of scanning the patches in the given layer is performed to inspect for presence of the defects in the given layer. The defects could be at least one of: gaps in the target area, extra patches that fully overlap with the patches in the given layer, torn/worn out patches in the given layer, un-adhered patches in the given layer. Optionally, the method further comprises scanning the patches in the given layer upon their arrangement for also counting the number of patches, measuring a width and a length of the given layer, or similar.

Optionally, the method further comprises infusing at least one resin on the patches in the given layer upon their arrangement. Optionally, the step of infusing the resin on the patches in the given layer is performed by at least one of: resin transfer moulding (RTM) technique, vacuum infusion (VI) technique, resin film infusion (R.FI) technique. Such techniques are well-known in the art. Advantageously, the technical effect of infusing the resin on the patches in the given layer is to impart required properties to the recycled composite textile, such as ease of manufacturing, enhanced strength, enhanced stability, resistance against wear and tear, good finish, and the like. Optionally, the method further comprises: obtaining composite waste material; sorting and separating the composite waste material into a plurality of pieces of the composite waste material; and removing resins from the plurality of pieces of the composite waste material to obtain the plurality of patches.

The term "composite waste material" refers to a material in which a reinforcement material is introduced or crosslinked with a matrix. The matrix could be one of: a resin, a polymer. The reinforcement material could be fibres. The composite waste material could be obtained from various sources, such as mills, factories, home, hospitals, markets, and other such facilities where composite materials are used. The composite waste material could be, but is not limited to, weaving waste material, knitting waste material, dyeing waste material, clothing waste material, and the like.

Optionally, the method further comprises drying the composite waste material. The composite waste material is dried when it is wet, since the composite waste material that is wet may interfere in subsequent sorting and separation. Optionally, the composite waste material that is wet is dried using at least one of: an air blower, a hot air generator, a heater, and the like. Optionally, the composite waste material that is wet is dried for a required time duration. The required time duration depends on an amount of wetness of the composite waste material, an extent of drying required, drying rate of equipment used for drying, and similar.

Optionally, the step of sorting and separating the composite waste material is performed by at least one of: the person, the robot, the machine with robotic arm. This step can be performed based on type of the composite waste material, size of the composite waste material, source of composite waste material, and the like. Optionally, the method further comprises removing non-prepreg material from the composite waste material. Examples of the non-prepreg material could be, but are not limited to, a backing film, a fibre sheet.

Optionally, the step of removing resins from the plurality of pieces of the composite waste material to obtain the plurality of patches is described, for example, in GB application no. GB2209448.6, titled "APPARATUS FOR DISSOLVING POLYMER BOUND TO COMPOSITE MATERIAL AND METHOD FOR FABRICATION THEREOF" and filed on June 28, 2022, which has been incorporated herein by reference. Optionally, the step of removing the resins from the plurality of pieces of the composite waste material is performed to obtain the plurality of patches of required thickness, strength, and structural stability.

It will be appreciated that the aforesaid steps of obtaining the composite waste material, sorting and separating the composite waste material and removal of resins form the plurality of pieces of the composite waste material is performed before applying the plurality of patches on the polymer-coated backing material.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of the words, for example "comprising" and "comprises" , mean "including but not limited to", and do not exclude other components, integers or steps. Moreover, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Preferred features of each aspect of the invention may be as described in connection with any of the other aspects. Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the following diagrams wherein:

FIG. 1 is a schematic illustration of a recycled composite textile, in accordance with an embodiment of the present disclosure;

FIG. 2 is a schematic illustration of steps for arranging a plurality of patches when manufacturing a recycled composite textile, in accordance with an embodiment of the present disclosure;

FIG. 3 is an illustration of a recycled composite textile having a multilayer structure, in accordance with an embodiment of the present disclosure; and

FIG. 4 is an illustration of a flowchart depicting steps of a method for manufacturing a recycled composite textile, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

Referring to FIG. 1, illustrated is a schematic illustration of a recycled composite textile 100 in accordance with an embodiment of the present disclosure. The recycled composite textile 100 comprises a backing material 102 coated with a polymer (106) and a plurality of patches 104 arranged on the polymer 106 as at least one layer. As shown, a first side (namely, a top side) 102A of the backing material 102 is coated with the polymer 106, and the plurality of patches 104 are arranged on the first side 102A of the backing material 102. The plurality of patches 104 are arranged in a manner that each patch is arranged directly on the polymer 106 or on a binder (not shown) applied on at least one other patch of another layer, and wherein the patches 104 in a given layer are arranged in a non-overlapping or minimally overlapping manner. FIG. 1 is merely an example, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.

Referring to FIG. 2, illustrated is a schematic illustration of steps for arranging a plurality of patches (depicted as multiple hatched patches) when manufacturing a recycled composite textile, in accordance with an embodiment of the present disclosure. A step of arranging the plurality of patches comprises depositing the patches that are to be arranged in the given layer over a target area 202 of the given layer and distributing the patches randomly on the polymer or on the binder applied on at least one other patch of another layer on top of which the given layer is to be formed. Such deposition is depicted at 204 and distribution is depicted at 206. The method further comprises inspecting for presence of gaps in the target area 202 and when it is determined that at least one gap (depicted, for example, as gaps 208, 210, and others) is present in the target area 202, at least redistributing loose patches in the given layer to cover the at least one gap 208, 210. An outcome of such redistribution is represented at 212.

FIG. 2 is merely an example, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.

Referring to FIG. 3, illustrated is a schematic illustration of a recycled composite textile 300 having a multi-layer structure, in accordance with an embodiment of the present disclosure. The recycled composite textile 300 comprises a backing material 302, a polymer 304 coated on the backing material 302, a first layer 306 of patches, a binder 308 applied on the first layer 306 of patches, a second layer 310 of patches, a binder 312 applied on the second layer 310 of patches, and a third layer 314 of patches.

FIG. 3 is merely an example, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.

Referring to FIG. 4, illustrated is a flowchart depicting steps of a method for manufacturing a recycled composite textile, in accordance with an embodiment of the present disclosure. At step 402, a backing material is laid on a flat surface. At step 404, a polymer is applied on the backing material. At step 406, a plurality of patches are arranged on the polymer, wherein the plurality of patches are arranged as at least one layer in a manner that each patch is arranged directly on the polymer or on a binder applied on at least one other patch of another layer, and wherein patches in a given layer are arranged in a non-overlapping or minimally overlapping manner. At step 408, the plurality of patches arranged as the at least one layer are pressed to obtain a recycled composite textile. The aforementioned steps are only illustrative, and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.