CN116601351A

CN116601351A - Method for manufacturing non-woven fabric and non-woven fabric

Info

Publication number: CN116601351A
Application number: CN202180053654.9A
Authority: CN
Inventors: A·M·霍廷克
Original assignee: Nifa Holdings Private Ltd
Current assignee: Nifa Holdings Private Ltd
Priority date: 2020-08-28
Filing date: 2021-08-27
Publication date: 2023-08-15
Also published as: NL2026370B1; WO2022045889A3; BR112023003271A2; WO2022045889A2; EP4204618A2; MX2023002344A; NL2029066B1; US20230295848A1; CN116601351A8; CA3187914A1; JP2023540940A; NL2029066A

Abstract

The present application provides a method for manufacturing a nonwoven fabric, comprising: i) Applying a dispersion layer comprising a dispersion medium and bio-based first fibers (110) on a support, wherein the bio-based first fibers (110) are fibers derived from microorganisms cultivated in a liquid medium, and wherein a plasticizer has been added to the dispersion prior to said applying; ii) depositing reinforcing second fibers (120) on the dispersion layer, wherein reinforcing second fibers (120) are individual fibers not belonging to the fabric, and wherein the average length of the second fibers is at least 10 times the average length of the first fibers; and iii) removing the dispersion medium to form a nonwoven fabric (100) comprising a network of biobased first fibers (110). Also provided are a nonwoven fabric and a seamless product comprising such a nonwoven fabric.

Description

Method for manufacturing non-woven fabric and non-woven fabric

Technical Field

The present application relates to a method for producing a nonwoven fabric.

Background

Nonwoven fabrics are well known and widely used as durable materials for disposable diapers and surgical gowns, as well as windshields and raincoats.

The nonwoven fabric may be produced by various methods, such as a wet laid method. In the wet laid process, a dispersion of fibers in a dispersion medium is applied to the surface of a support, after which the dispersion medium is removed and the fibers form a web. The fabric conforms to the shape of the support, so in the case of a three-dimensional support having a desired shape, the nonwoven fabric has the desired shape without cutting and sewing. The nonwoven may also have a surface structure, for example if an embossed support is used.

Nonwoven fabrics may be made from a variety of materials, such as synthetic fibers including polyethylene, but fabrics based on natural materials are desirable, including their tactile (skin feel) characteristics.

It is known in the art to make nonwoven fabrics from biobased fibers (i.e., fibers from biological (i.e., natural) sources), but they may lack the desired strength and/or durability. In e.g. WO 2020/006133 A1, the second material is embedded in the matrix of the bio-based fibers in the form of a woven fabric layer to provide strength to the bio-based fibers. However, according to WO 2020/006133 A1, bio-based fibres in the form of a fungal matrix grow into the woven fabric layer, which is a time consuming and difficult to control process and requires that the bio-based fibres remain active during the production of the nonwoven.

CA2718435A1 teaches the application of fibers in an isotropic orientation, where the fibers are oriented transverse to the product material. These transversely oriented fibers are intended to provide a particular hand but do not contribute substantially to the strength of the product material, particularly the fibers do not form a web.

Disclosure of Invention

It is an object of the present application to provide a biofiber-based nonwoven fabric having an enhanced strength and/or durability without impairing the skin feel in a simple manner.

To this end, according to a first aspect, the present application provides a method comprising the steps of:

i) Applying a dispersion layer comprising a dispersion medium and bio-based first fibers on a support;

ii) depositing reinforcing second fibers on the dispersion layer, wherein the reinforcing second fibers are discrete fibers; and

iii) The dispersion medium is removed to form a nonwoven fabric comprising a biobased first web.

In this way, the nonwoven fabric based on the bio-based first fibers provides enhanced strength while

The simplicity of the process is substantially maintained,

substantially maintaining the skin feel of the side of the nonwoven facing the support.

The second fibers will typically be applied in whole, for example as a suspension, using a brush or by spraying. In the present application, separate fibers means that they are individual fibers. Thus, they are not part of a fabric, whether woven, nonwoven, or a fabric of fibers interconnected by glue or heat (fiber melt) or by the addition of binders or cross-linking agents.

At most, a portion of the dispersion medium may be removed prior to application of the second fibers to allow the second fibers to embed into the wet matrix of the first fibers. Removal typically involves drying, for example by passing drying air across the surface of the dispersion layer, taking care not to blow it away. The air may be heated air. In this way, the redistribution or dripping of the dispersion applied in step i) under gravity is reduced. Thus, irregularities formed by, for example, dispersion dripping can be reduced, and production of nonwoven fabrics on non-horizontal surfaces can be facilitated.

It is known in the art to manufacture nonwoven fabrics with enhanced strength by chemical treatment or chemical modification of biobased fibers or nonwoven fabrics. Such treatment may reduce the desired properties of the nonwoven fabric in terms of skin feel. The present application allows avoiding these if chemical treatments or modifications require chemicals that are not desired to be used. Reducing or even eliminating the use of chemicals makes the process more sustainable.

The nonwoven may be produced after step iii) without the additional step of interconnecting the first fibers after the formation of the web. This reduces the effort to produce the nonwoven by avoiding chemical bonding, thermal bonding, mechanical bonding or any other step required to connect the first fibers to each other.

In the present application, the term bio-based first fiber includes refined bio-based first fibers, such as mycelium, cellulose, etc., but also chemically produced or processed bio-based first fibers, such as viscose or lyocell.

The first fibers are preferably dispersed in a water-based dispersion medium. The dispersing fluid may be any fluid suitable for wet processes and may be based on other volatile liquids such as alcohols, e.g. methanol, ethanol or propanol, any other organic volatile fluid or a combination of these liquids, e.g. water and ethanol. In this way, elimination of the dispersion medium can be promoted, or the first fibers can be dispersed in the dispersion medium more effectively. Preferably, the dispersion medium is non-toxic and/or natural and/or environmentally friendly.

The concentration of the first fibres in the dispersion is at least 0.1% w/v, preferably at least 5% w/v, more preferably at least 10% w/v, and most preferably at least 15% w/v. Preferably, the concentration of the first fibers in the dispersion is less than 60% w/v.

In one embodiment, after step iii), the first fibers comprise 20-80% by weight of the nonwoven fabric; the second fiber accounts for 1-40% of the weight of the non-woven fabric; and the plasticizer comprises 5-50% by weight of the nonwoven fabric, wherein the combined weight% of the first fibers, the second fibers and the plasticizer is at least 65%, preferably at least 80% by weight of the nonwoven fabric; and wherein the weight percent of the second fibers is less than the weight percent of the first fibers.

Preferably, the first fibers have a diameter of less than 50 microns, more preferably less than 25 microns, even more preferably less than 15 microns, and most preferably less than 8 microns. In this way, the surface of the mesh facing the support structure adopts a smooth texture after elimination of the dispersion medium.

The reinforced second fibers may be i) fibers having a higher tensile strength than the first fibers, and/or ii) fibers having an average length at least 3 times, preferably at least 10 times, the average length of the first fibers.

Typically, the second fiber has a cylindrical cross-section, but may also be flat, curved, bent or any other elongated form. The method may also be performed with a second fiber, wherein the circumferential surface of the second fiber is microfibrillated. In this way, the strength and/or durability of the web may be improved.

The diameter of the second fibers is preferably less than 100 microns, more preferably in the range of 15 to 50 microns. In this way, the second fibers provide strength to the nonwoven, but also allow for a more uniform distribution of the first fibers.

The second fibers are preferably at least 0.3 mm, more preferably at least 2mm, even more preferably at least 5 mm, and most preferably at least 10 mm long. In this way, the strength and durability of the nonwoven fabric produced according to the method are improved.

In a plane projected parallel to the surface of the web, the second fibers typically cover 10% -90%, preferably 20% -75%, more preferably 30% -50% of the total surface of the first fibers lying in that plane.

The second fibers may be added, for example, by flocking, air laying, fiber spinning, or electrospinning. In this way, the distribution of the second fibers can be precisely controlled and portions of the nonwoven fabric having different properties can be provided by using different deposition techniques in different portions of the nonwoven fabric.

The surface of the support may be a flat surface, but may also be a three-dimensional shaped surface or a structured surface. In this way, a two-dimensional sheet, a three-dimensional shaped web or a web with a structure can be produced. The surface of the support may be provided by the surface of the mould, but may also be the surface of a net previously formed on the mould, whether or not formed by the method according to the application. The mould may for example be a human torso.

The nonwoven may be removed from the support, but this is not required if it is desired to provide the support with a nonwoven, i.e. the nonwoven is part of the product. If the nonwoven is to be removed from the support, the support typically has a surface that aids in the removal of the fabric (optionally without excessive adhesion to the fabric). If it is a product, the opposite is true.

According to an advantageous embodiment, the dispersion layer in step i) is applied by spraying.

Spraying the dispersion allows for a more controlled application of the dispersion layer and the first fibers, resulting in a higher quality nonwoven. For example, there is less risk of bubble formation, resulting in a more uniform and consistent layer of dispersion, resulting in a higher quality nonwoven.

According to an advantageous embodiment, step i) is preceded by a step comprising the steps of:

-providing a dispersion of bio-based first fibres, said first fibres being dispersed in a dispersion medium, and

-removing at least a portion of the dispersion medium so as to form a web on the support; said steps are performed at least once and step i) comprises applying said dispersion layer to said web.

In this way, thicker nonwoven fabrics can be made with a well controlled thickness and the second fibers protrude to the side of the fabric facing the support, thereby reducing the risk of delamination of the nonwoven. The dispersion medium is usually eliminated by evaporation, which can be facilitated by heating and/or the supply of dry air.

Furthermore, this embodiment facilitates the manufacture of the nonwoven in a non-horizontal direction, as a stack of relatively thin layers may be applied and dried to obtain a desired thickness of the nonwoven, rather than applying relatively thick layers at once. Typically, this step is performed at least 2 times, preferably at least 5 times, more preferably at least 10 times.

According to an advantageous embodiment, the method further comprises a step between steps ii) and iii), applying a further layer of dispersion on top of the dispersion layer, said further dispersion comprising a further dispersion medium and bio-based third fibers.

In this way, the method provides another web that provides the skin feel determined by the last applied bio-based third fibers to the side of the fabric facing away from the support.

The strength of the fabric can be increased by better embedding the second fibers.

The further dispersion medium of the further dispersion may be the same dispersion medium as the dispersion medium or have a different composition. In addition, the bio-based third fiber may be the same fiber as the first or second fiber, or may be a fiber having different properties, such as antimicrobial or skin care properties.

According to a particularly preferred embodiment, the bio-based first fiber is a fiber derived from a microorganism cultivated in a liquid medium.

This makes it possible to bypass the production of plant-based fibers, which typically require large pieces of land, pesticides, and expensive harvesting, followed by extensive fiber processing. In contrast, the growth of microorganisms such as mycelium in a bioreactor can be effectively performed and the mycelium can be simply harvested (e.g. by filtration), or even without a harvesting step, and the liquid medium is a dispersion medium. Optionally, the mycelium may be diluted or resuspended in a dispersion medium (water) and then ready to form a nonwoven fabric.

The microorganism may be, for example, a fungus, protozoa, bacteria or algae.

In addition to, or instead of being derived from a microorganism, the first fiber may comprise bio-based material derived from fungal mycelium, yeast, algae, bacteria, cultured animal or plant cells, as well as derived from animal and/or plant cells cultured in a liquid medium. The cultured animal or plant cells may be cultured, for example, in a bioreactor.

According to an advantageous embodiment, the bio-based first fiber is in the form of a biological material selected from the group consisting of: fungal mycelia, yeast, algae, bacteria, cultured animal or plant cells, fibers derived from animal and/or plant cells cultured in a liquid medium, pulp, leaf pulp, stem pulp, leather fibers, collagen, and/or micronized and/or microfibrillated forms of any of the foregoing materials.

In this way, the resources used to form the mesh are inexpensive and readily available.

According to an advantageous embodiment, the bio-based first fibers are not chemically treated.

In this way, the nonwoven fabric can be produced faster and safer, since no chemical treatments or chemical modifications are required. Suitable biological materials may be, for example, harvested fungal mycelia, algal material, bacteria, cultured animal or plant cells, fibers derived from animal and/or plant cells cultured in a liquid medium, pulped plant material such as pulped fruits, leaves and/or stems, fibers from collagen. The biological material may also be micronized and/or microfibrillated, thereby increasing the hairiness of the fibers and enhancing the inter-binding capacity.

According to an advantageous embodiment, the second fibers are selected from natural fibers, regenerated fibers, recycled fibers, synthetic fibers, functional fibers or any combination thereof, preferably the second fibers are hydrophilic.

In this way, the second fibers may be selected to provide the nonwoven fabric with desired characteristics. Natural fibers may be used if the nonwoven fabric needs to be biodegradable and may be extracted from plant materials (e.g., wood, grass, leaves, cellulose) or animal materials (e.g., wool, mohair, cashmere, angora, silk, spider silk). However, mineral materials such as chrysotile, asbestos, chrysotile, tremolite and actinolite may also be used as the second fiber. Preferably, the fibers are natural fibers. Regenerated fibers may be suitable for the same purpose and may be made of materials such as viscose, lyocell, cellulose acetate, azlon or any other modified cellulose. In addition, it is possible to use regenerated fibers that are too short, which must be discarded to produce a woven fabric. Synthetic fibers may reduce the cost of the nonwoven fabric and suitable synthetic fibers may be made from materials such as polypropylene, polyester, spandex, polyvinyl chloride, and the like. By using a second type of fiber made from aramid, liquid Crystal Polymer (LCP), carbon fiber, glass fiber, and metal fiber, the nonwoven fabric may be provided with special properties, such as resistance to environmental conditions, such as abrasion, tearing, and/or higher temperatures. Fibers with special properties impart electrical resistance or conductivity to the produced nonwoven fabric, thus providing the user with the utility of protecting or measuring biological functions such as heart rate or muscle function. Fiber blends of any of these materials can be used to impart a variety of properties. Hydrophilic fibers provide better adhesion to the first bio-based fibers.

According to an advantageous embodiment, the second fibers are added isotropically with respect to each other.

The isotropic orientation of the second fibers with respect to each other may for example be achieved by carding the second fibers prior to step ii). The resulting isotropically oriented second fibers may be applied manually in step ii) or in a direction parallel to the support by using e.g. a robot. In this way, the isotropic orientation of the second fibers provides improved strength to the nonwoven when the second fibers are added to the dispersion layer.

CA2718435A1 also applies the second fibers in an isotropic orientation; however, these fibers are oriented transversely to the support and thus do not substantially affect the strength of the nonwoven.

According to an advantageous embodiment, the second fibers are anisotropically added with respect to each other.

This may be achieved, for example, by electrostatic flocking, wherein an electric charge is applied to the support at the same time as the second fibres are added. This results in at least a portion of the second fibers being oriented perpendicular to the support. After removal of the charge, the at least partially vertically oriented second fibers will fall off and adopt an orientation parallel to the support but random with respect to each other. Such anisotropic orientation may improve the softness of the nonwoven fabric.

According to an advantageous embodiment, a plasticizer is added to the dispersion prior to step i), wherein the plasticizer is preferably a sugar, sugar alcohol, polyol ester and/or alpha-hydroxy acid, or a combination thereof, more preferably sorbitol and citric acid. Typically, the plasticizer content of the resulting nonwoven is from 5 to 50% by weight, preferably from 10 to 30% by weight.

The addition of the plasticizer may make the obtained nonwoven fabric more durable. Plasticizers may protect the nonwoven from becoming brittle, brittle and/or hard. Examples of plasticizers are glycols, glyceryl triacetate, polymeric polyols, quillaja, but also include complex compositions such as honey, molasses, aloe, castor oil, glycerides, triglycerides and other mineral or organic oils or any combination thereof.

According to an advantageous embodiment, after all other steps, a step of applying a coating on at least one, preferably all, exposed surfaces of the nonwoven.

The coating may be, for example, a flexible, protective, and/or reinforced coating. In this way, the durability of the nonwoven may be improved by maintaining the dispersion medium and/or maintaining the plasticizer in the nonwoven after consolidation of the web and/or additional web. The coating may be biodegradable and/or uv resistant and optionally include color pigments.

According to an advantageous embodiment, the method comprises the step of applying and adhering at least one component to the web.

In this way, additional functions can be embedded in the nonwoven. Components such as technical components, e.g., led lighting, sensors, RFID tags or NFC chips, or decorations, e.g., spangles, beads, strings, decals, and lace, may be directly bonded without the need to adhere, stitch, or otherwise join the assembly to the nonwoven, thereby reducing the cost and number of steps in the reinforced nonwoven production process.

According to an advantageous embodiment, the method comprises a dyeing step. This step is generally carried out before step ii), for example by mixing the dyes and/or pigments in the dispersion applied in step i).

Preferably, in this step, the dye and/or pigment is applied together with at least one selected from the first and second fibers. In this way, the dye and/or pigment is absorbed in the fabric along with the fibers, avoiding a separate dyeing step. In particular, no additional liquid may be required to mix the dye and/or pigment into the fabric. The dye and/or pigment is embedded in the fabric, so that the dye of the fabric is not damaged easily when the fabric is used.

Furthermore, there is no longer a need to wash the textile to remove excess dye, which is often a tedious step in the production of most advanced textiles.

In one embodiment, step ii) is completed within 2 hours, preferably within 0.5 hours, after the start of step i). Thus, steps i) and ii) of the method of the application can be performed rapidly, in particular without having to wait for fungal cells etc. to provide the first fibres.

In one embodiment, step iii) is performed and completed within 72 hours after the start of step ii), preferably within 5 hours. This may allow the nonwoven to be produced within 4 days, particularly in combination with the previous embodiments.

According to a second aspect, the present application relates to a nonwoven fabric, wherein the nonwoven fabric is obtainable by a method according to any of the preceding claims. Preferably, the nonwoven fabric has a seamless circumferential surface.

According to a third aspect, the present application provides a nonwoven fabric, preferably obtained using the method of the present application, comprising biobased first fibres and reinforcing second fibres, wherein the first and second fibres are irreversibly embedded in a matrix comprising a plasticizer; wherein the biobased first fiber is a fiber derived from a microorganism that has been cultured in a liquid medium, and wherein the second fiber has an average length that is at least 10 times the average length of the first fiber.

In addition to the plasticizer, the matrix generally contains some moisture, for example from the dispersion medium of step i) which may already be according to the claimed process.

In one embodiment, the plasticizer comprises an amorphous matrix comprising hydroxyl acid and a polyol.

In a preferred embodiment, the first fibers comprise 20 to 80% by weight of the nonwoven fabric; the second fiber accounts for 1-40% of the weight of the non-woven fabric; the plasticizer accounts for 5-50% of the weight of the non-woven fabric; wherein the combined weight percentage of the first fibers, the second fibers and the plasticizer is at least 65%, preferably at least 80% of the weight of the nonwoven fabric; and wherein the weight percent of the second fibers is less than the weight percent of the first fibers.

In one embodiment, oil and/or fat droplets are embedded in a matrix, the largest diameter of the droplets being in the range of 1 μm to 20 μm. For example, the oil droplets may comprise a dry oil or a non-dry oil. Optionally, a desiccant is also included in the matrix.

According to a fourth aspect, the present application provides a shaped seamless garment, accessory or footwear to be worn, or any other three-dimensional seamless nonwoven product, comprising the nonwoven of the second or third aspect and/or the nonwoven fabric produced according to the first aspect of the application. Accordingly, the present application provides a seamless garment, accessory, footwear or other product.

Drawings

The application will now be described with reference to the following examples section and with reference to the accompanying drawings, in which

Fig. 1 shows a schematic view of a cross section of a nonwoven fabric;

figures 2A-2C show a schematic view of another embodiment of a nonwoven fabric according to the application and a first detail and a second detail thereof, respectively;

figures 3A-3C show a schematic view of a further embodiment of a nonwoven fabric according to the application and a first detail and a second detail thereof, respectively; and

fig. 4 shows an embodiment of a nonwoven in the form of a bag, which nonwoven has a three-dimensional non-planar shape and is manufactured according to the method of the application.

Detailed Description

Fig. 1 shows a schematic representation of a cross-section of a nonwoven fabric 100 comprising first fibers 110 and second fibers 120 produced according to the present application. The first fibers 110 are derived from cultured mycelia and dispersed in a dispersion medium. A first layer comprising a dispersion of first fibers 110 is applied to the support and second fibers 120 are added to the dispersion layer. A second layer of dispersion was added on top of the first layer of dispersion and the dispersion medium was removed by evaporation at room temperature. In the resulting nonwoven, the first fibers 110 are present as a continuous web with no distinguishable boundaries between the first fibers 110 applied in the first layer of the dispersion and the first fibers 110 applied in the second layer of the dispersion. The second fibers 120 are embedded in a continuous web of the first fibers 110.

For the production of nonwoven fabrics, fungal biomass in the form of schizophyllum commune mycelium from the basidiomycete group was grown in 1 liter Duran Erlenmeyer in standard malt extract. The growth procedure followed standard incubation procedures at 30℃and 200rpm. Mycelium was harvested by buchner filtration. Citric acid and sorbitol are premixed with water and then added to the harvested mycelium and the remaining growth medium to form a dispersion comprising the first fibers.

In step a), a first layer of the dispersion is applied on the mould by spraying the dispersion onto the solid and 3D shaped support surface using a spraying machine for spraying the coating. In step b), the dispersion medium is removed by evaporation at room temperature. The dispersion medium was evaporated until a contact dried Mycelium (MYC) net was formed on the support.

Repeating steps a) and b) again. Subsequently, in step c), another layer of dispersion is applied on top of the web. In step d), individual second fibers, for example Polyamide (PA) 100dtex or carded rayon (CV) 28dtex, are applied to the fabric by flocking with FK1-PRO, while simultaneously applying carded flax (LI) by hand. For example, rayon fibers are 12mm long with a circular circumferential surface between the ends. The area of the first fibers covered by the second fibers is 30-50% in a plane projected parallel to the surface of the second web.

Steps a), b), c) and d) are then repeated twice, and finally steps a) and b) are performed once.

The obtained nonwoven fabric was taken out of the mold. In the cross section of the nonwoven, no individual web or first fibers are distinguishable, but rather appear as a single web of first fibers, with second fibers embedded within the single web of first fibers. The second fibers are not present in the nonwoven as distinct continuous layers. In contrast, the second fibers applied in the same step are substantially aligned with any one of the outer surfaces of the nonwoven fabric and may be in contact with each other and may be aligned at different angles and cross each other.

Extension and peak forces were measured from each nonwoven to evaluate the effect of the second fibers on the nonwoven. The tensile and peak forces were measured according to EN13934-01, but the size of the sample tested was 4x 4cm. The experiment may be performed as a single experiment or repeated. As a control, a nonwoven fabric of pure mycelium was used.

Table 1 shows the effect of various second fibers on tensile and peak forces

The addition of the second fibers resulted in peak values 1.6-6.8 times higher than the nonwoven fabric of pure mycelium, indicating that the addition of the second fibers imparts strength to the nonwoven fabric.

Furthermore, a panel consisting of 5 persons evaluated the skin feel of the nonwoven fabric, which independently evaluated the same skin feel of the nonwoven fabric comprising the second fibers as the nonwoven skin feel from the pure mycelium.

Fig. 2A shows a schematic cross-sectional view of another nonwoven fabric 200 comprising first bio-based fibers 210 and second reinforcing fibers 220 produced according to the present application. In cross-section, the fabric 200 has an upper outer surface 201 and a lower outer surface 202 disposed between the first and second fibers. Although in the example shown the first and second fibers are embedded in a single melt layer, it should be understood that the nonwoven may comprise a stack of multiple melt layers of first and third fibers. The first fibers form a web reinforced by the second fibers.

Fig. 2B shows a detail of section II-B of fig. 2A, wherein the first fiber 210 and the second fiber 220 are shown in more detail. It can be seen that the first fibers are several orders of magnitude smaller than the second fibers 220. In the example shown, the average diameter of the first fibers 210 shown in more detail in fig. 2C is about 2 μm, while the average diameter of the second fibers 220 is 100 μm. It can be seen that the larger second fibers 220 are substantially aligned with the upper and lower outer surfaces 201, 202 such that their centerlines are substantially parallel to these surfaces 201, 201. The first fibers 210, which are much smaller, are substantially randomly oriented and are substantially out of alignment with the first and second outer surfaces.

The first and second fibers are embedded in a matrix 230 comprising a plasticizer, which matrix 230, in addition to helping to hold the first and third fibers substantially in place, also provides a degree of flexibility to the nonwoven, allowing it to bend or fold without damaging the nonwoven. The plasticizer preferably comprises 5 to 50% by weight, preferably 15 to 30% by weight, of the finished nonwoven and preferably comprises a mixture of a polyol (e.g. sorbitol) and an alpha-hydroxy acid (e.g. citric acid).

Fig. 3A shows a schematic cross-sectional view of another nonwoven fabric 300 according to the present application. In addition to the bio-based first fibers 310 and the second reinforcing fibers 320 embedded in the matrix 330, the matrix 330 includes a plasticizer and optionally any remaining dispersion medium. Further shown are oil droplets 340 embedded in matrix 330, which may have various sizes, each of which typically has a maximum diameter in the range of 1 μm to 20 μm. The oil droplets 340 may be used to delay the controlled or controlled release of beneficial fat-soluble components and in this embodiment include aloe vera, which provides a good scent. The oil droplets 340 typically have an average diameter that is greater than the average length of the first fibers, e.g., at least 5 times greater than the average length of the first fibers 310.

Fig. 4 shows a perspective view of a non-woven fabric 400 according to the application, which is formed into a non-planar shape, here in the form of a handbag. The nonwoven 400 is manufactured by applying a layer of dispersion to a non-planar support (not shown) having the positive shape of the nonwoven. The layer is typically applied by spraying the dispersion onto a non-planar 3D surface of the support and/or by applying the dispersion to the support using a brush. After applying the dispersion layer comprising the dispersion medium, the first bio-based fibers, and the plasticizer, a layer of reinforcing second fibers is deposited onto the dispersion layer, after which the two layers are dried to form the nonwoven 400. The nonwoven 400 comprises a circumferential surface 401, which circumferential surface 401 is provided with ridges 402 and pits 403. In this embodiment, the dispersion layer is applied on the flexible support, and after the second fibers are applied and the dispersion medium is removed to form the nonwoven fabric 400, the flexible support is folded and removed from the inside of the fabric 400. It will be clear to a person skilled in the art that additionally or alternatively one or more supports may be used to form the positive or negative shape, for example in a similar way as a casting mould used in the casting process, to allow easy removal of the nonwoven fabric from the support. By using one or more supports, the final product can be produced without stitching or glued seams or the like.

Claims

1. A method for manufacturing a nonwoven fabric (100), wherein the method comprises the steps of:

i) Applying a dispersion layer comprising a dispersion medium and bio-based first fibers (110) on a support, wherein the bio-based first fibers (110) are fibers derived from microorganisms cultivated in a liquid medium, and wherein a plasticizer has been added to the dispersion prior to the applying;

ii) depositing reinforcing second fibers (120) on the dispersion layer, wherein the reinforcing second fibers (120) are individual fibers not belonging to the fabric, and wherein the second fibers have an average length at least 10 times the average length of the first fibers; and

iii) The dispersion medium is removed to form a nonwoven fabric (100) comprising a network of biobased first fibers (110).

2. The method of claim 1, wherein the dispersion layer in step i) is applied by spraying.

3. The method of any one of the preceding claims, further comprising removing the nonwoven fabric from the support.

4. The method of any of the preceding claims, wherein the plasticizer is a sugar alcohol, a polyol ester, and/or an alpha hydroxy acid, or a combination thereof.

5. The method of claim 4, wherein the plasticizer comprises a combination of sorbitol and citric acid.

6. The method of any of the preceding claims, wherein the plasticizer comprises one or more of glycols, glyceryl triacetate, polymeric polyols, quillaja, honey, molasses, aloe, castor oil, glycerides, triglycerides, and other mineral or organic oils.

7. The method according to any of the preceding claims, wherein step i) is preceded by the step comprising the steps of:

-providing a dispersion of bio-based first fibers (110), said first fibers (100) being dispersed in a dispersion medium, and

8. The method according to any of the preceding claims, wherein the method further comprises a step between steps ii) and iii): a further layer of dispersion is applied on top of the dispersion layer, the further dispersion comprising a further dispersion medium and bio-based third fibres.

9. The method according to claim 1, wherein the bio-based first fiber (110) is in the form of a biological material selected from fungal mycelium, yeast, algae, bacteria, cultured animal or plant cells, fibers derived from animal and/or plant cells cultured in a liquid medium.

10. The method according to any of the preceding claims, the bio-based first fiber (110) being not chemically treated.

11. The method according to any of the preceding claims, wherein the second fibers (120) are selected from natural fibers, regenerated fibers, recycled fibers, synthetic fibers, functional fibers or any combination thereof, preferably wherein the second fibers (120) are hydrophilic.

12. The method according to any of the preceding claims, wherein the concentration of the first fibers in the dispersion is at least 0.1% w/v, preferably at least 5% w/v, more preferably at least 10% w/v, and most preferably at least 15% w/v.

13. The method according to any of the preceding claims, wherein the first fibers have a diameter of less than 50 microns, more preferably less than 25 microns, even more preferably less than 15 microns, and most preferably less than 8 microns.

14. The method according to any of the preceding claims, wherein the second fibers (120) are isotropically added with respect to each other.

15. The method according to any one of claims 1-13, wherein the second fibers (120) are anisotropically added with respect to each other.

16. The method according to any of the preceding claims, wherein after all other steps a coating is applied on at least one, preferably all, exposed surfaces of the nonwoven (100).

17. The method of any one of the preceding claims, wherein the dispersion further comprises oil droplets.

18. The method according to any one of the preceding claims, wherein the method comprises the step of applying and adhering at least one component to the web.

19. The method of claim 18, wherein the at least one component is selected from led lighting, sensors, RFID tags, or NFC chips, or decorations, such as pails, beads, strings, decals, and lace;

wherein the at least one component is embedded in the nonwoven fabric without the need to bond or stitch the component to the nonwoven fabric.

20. The method according to any of the preceding claims, wherein the method further comprises a dyeing step, preferably wherein a dye or pigment is applied together with at least one fiber selected from the first and second fibers, more preferably wherein no liquid is used for applying the dye and/or pigment other than the dispersion.

21. The method according to any one of the preceding claims, wherein in step iii) the dispersion medium is water-based.

22. The method of any one of the preceding claims, wherein the circumferential surface of the second fiber is microfibrillated.

23. The method according to any of the preceding claims, wherein the second fibers have a cylindrical cross section and a diameter of less than 100 micrometers, more preferably in the range of 15 to 50 micrometers.

24. The method according to any of the preceding claims, wherein the length of the second fibers is at least 0.3 mm, preferably at least 2mm, more preferably at least 5 mm, and more preferably at least 10 mm.

25. The method of any one of the preceding claims, wherein the support has a three-dimensional non-planar surface.

26. The method of any of the preceding claims, wherein in a plane projected parallel to a surface of the web, the second fibers cover 10% -75% of the total surface of the first fibers that lie in the plane.

27. The method according to any of the preceding claims, wherein the dispersion medium is based on alcohols and/or on other organic volatile fluids.

28. The method according to any of the preceding claims, wherein step ii) is performed and completed within 2 hours, preferably within 0.5 hours, after the start of step i).

29. The method according to any of the preceding claims, wherein step iii) is performed and completed within 72 hours, preferably within 5 hours, after the start of step ii).

30. A nonwoven fabric (100), wherein the nonwoven fabric (100) is obtained by a method according to any of the preceding claims.

31. The nonwoven fabric of claim 30, preferably comprising biobased first fibers and reinforced second fibers, wherein the first and second fibers are irreversibly embedded in an amorphous matrix comprising a plasticizer;

wherein the bio-based first fiber (110) is a fiber derived from a microorganism that has been cultured in a liquid medium, and

wherein the average length of the second fibers is at least 10 times the average length of the first fibers.

32. The nonwoven fabric according to claim 30 or 31, wherein the plasticizer is formed of a hydroxy acid and a polyol.

33. The nonwoven fabric according to claim 30, 31 or 32, wherein

The first fiber accounts for 20-80% of the weight of the non-woven fabric;

the second fibers account for 1-40% by weight of the nonwoven fabric; and

the plasticizer accounts for 5-50% of the weight of the non-woven fabric,

wherein the combined weight percentage of the first fibers, the second fibers and the plasticizer is at least 65%, preferably at least 80% of the weight of the nonwoven fabric; and

wherein the weight percent of the second fibers is less than the weight percent of the first fibers.

34. The nonwoven fabric according to any one of claims 30-33, wherein oil droplets and/or fat droplets are embedded in the matrix, the largest diameter of the oil droplets being in the range of 1 μιη to 20 μιη.

35. A shaped seamless garment, accessory or footwear to be worn, or any other three-dimensional seamless nonwoven product, comprising the nonwoven of any of claims 30-34.