Covers Utilizing Recycled Polyester Fibers

1 . A cover, comprising a nonwoven fabric comprising a plurality of recycled polyester fibers; wherein the plurality of recycled polyester fibers comprise a pre-consumer waste, a post-consumer polyester, a post-industrial waste polyester, or a combination thereof

2 . The cover of claim 1 , wherein the plurality of recycled polyester fibers comprise a recycled polyester terephthalate (rPET).

3 . The cover of claim 1 , wherein the plurality of recycled polyester fibers comprises a plurality of staple fibers.

4 . The cover of claim 3 , wherein the plurality of staple fibers comprise an average length from about 0.5 centimeters (cm) to about 20 cm.

5 . The cover of claim 3 , wherein the plurality of staple fibers comprise a blend of a first plurality of staple fibers having a first average length and a second plurality of staple fibers having a second average length, wherein the first average length is less than the second average length.

6 . The cover of claim 5 , wherein the first average length ranges from about 0.5 to about 5 cm and the second average length ranges from about 8 to about 20 cm.

7 . The cover of claim 3 , wherein the plurality of staple fibers comprise an average diameter from about 5 microns to about 30 microns.

8 . The cover of claim 3 , wherein the nonwoven fabric comprises a plurality of mechanical bonds between the plurality of staple fibers, wherein the plurality of staple fibers are physically entangled with each other.

9 . The cover of claim 8 , wherein the nonwoven fabric further comprises one or more thermal bond sites.

10 . The cover of claim 9 , wherein the one or more thermal bond sites comprises a plurality of individual thermal bond sites defining a thermal bonded pattern.

11 . The cover of claim 10 , wherein the thermal bonded pattern defines a thermal bonded area from about 3 to about 40%.

12 . The cover of claim 10 , wherein the one or more thermal bond sites is a single thermal bond site of a bond area of 100% forming an area bonded nonwoven fabric.

13 . The cover of claim 12 , wherein at least a portion of the plurality of fibers has softened and at least partially flowed to forma microporous film structure on the outermost surface of the nonwoven fabric.

14 . The cover of claim 1 , wherein the plurality of recycled polyester fibers account for about 20% to about 100% by weight of a total fiber amount of the nonwoven fabric.

15 . The cover of claim 1 , wherein the nonwoven fabric has a moisture vapor transmission rate of at least about 500 grams/m 2 /24 hours according to BS 7209, a hydrostatic head of at least about 60 mm according to EN ISO 20811, or both.

16 . The cover of claim 1 , wherein the cover at least partially encapsulates a crop, wherein the crop comprises hay, straw, root vegetables, wood chips, bark, or any combination thereof

17 . A method of forming a cover, comprising:

(i) providing or forming a plurality of recycled polyester staple fibers;

(ii) forming a dry laid web of the plurality of recycled polyester staple fibers;

(iii) cross-lapping the dry laid web upon itself to form a cross-lapped web; and

(iv) consolidating the cross-lapped web to provide a cover.

18 . The method of claim 17 , wherein the cross-lapped web has from about 2 to about 20 layers, and wherein the cross-lapped web has a first layer oriented in a first direction and a second layer oriented in a second direction, wherein the second direction is offset from the first direction by an angle of from about 10 degrees to about 90 degrees.

19 . The method of claim 17 , wherein consolidating the cross-lapped web comprises subjecting the cross-lapped web to needle-punching operation, a hydroentanglement operation, or both.

20 . The method of claim 19 , wherein consolidating the cross-lapped web further comprises subjecting the cross-lapped web to a thermal bonding operation, ultrasonic bonding operation, an adhesive bonding operation, or any combination thereof