High tensile regenerated cellulose fibers via cyclic freeze-thawing enabled dissolution in phosphoric acid for textile-to-textile recycling of waste cotton fabrics

Recycling of waste cotton fabrics (WCFs) is a desirable solution to address the problems brought up by fast fashion, but it remains challenging due to inherent limitations in preparing stable and spinnable dopes by dissolving high molecular weight cellulose efficiently and cost effectively. Herein, we show that despite the prevailing concerns of cellulose degradation via glycosidic hydrolysis when dissolved in acids, fast and nondestructive direct dissolution of WCFs in aqueous phosphoric acid (a.q. PA) could be realized using a cyclic freeze-thawing procedure, which combined with subsequent adjustment of degree of polymerization (DP) and degassing yielded stable and spinnable dopes. Regenerated cellulose fibers (RCFs) with favorable tensile strength (414.2 +/- 14.3 MPa) and flexibility (15.4 +/- 1.5 %) could be obtained by carefully adjusting the coagulation conditions to induce oriented and compact packing of the cellulose chains. The method was shown to be conveniently extended to dissolve reactively dyed WCFs, showing great potential as a cheap and green alternative to heavily explored ionic liquids (ILs) and N-methylmorpholine-N-oxide (NMMO)-based systems for textile-to-textile recycling of WCFs.