CN117751217A

CN117751217A - Method for producing plant textile fabric

Info

Publication number: CN117751217A
Application number: CN202280052936.1A
Authority: CN
Inventors: 卢卡斯·富尔曼
Original assignee: Lewo Technology Co ltd
Current assignee: Lewo Technology Co ltd
Priority date: 2021-07-28
Filing date: 2022-07-28
Publication date: 2024-03-22
Also published as: DE102021119667A1; WO2023006924A1; CA3225712A1; EP4377512A1; KR20240034192A

Abstract

The present invention relates to a method for producing a non-synthetic textile fabric and to the non-synthetic textile fabric itself.

Description

Method for producing plant textile fabric

Technical Field

The present invention relates to a method for producing a non-synthetic textile fabric and to said non-synthetic textile fabric.

Background

Leather has been one of the important materials for making apparel and articles. However, more and more vegetarian subjects fundamentally reject dermis. In addition, leather use has also been criticized for various ecological and ethical reasons. Leather production also causes a large amount of CO, especially when raising animals ₂ And (5) discharging. Tanneries often use ecologically problematic chemicals during further processing. Although it is a byproduct of the meat industry, animal pain has now become a decisive argument against leather.

For the above reasons, many products made conventionally from leather or made using leather are therefore made of artificial leather (for example, bag-making products, furniture or automotive interiors).

However, artificial leather is in most cases based on synthetic petroleum-based components (e.g. PU coatings made of synthetic fibers, carrier materials), which limits biodegradability and leads to other ecological problems, such as wear of the microplastic.

The production of artificial leather or leather-like substitutes is known in principle. DE 1635546C3 describes a process for producing leather-like sheets from aqueous suspensions.

DE 102006001095A1 follows a similar direction in which a method for producing leather-containing textiles with a cover layer and a carrier layer is described.

However, according to both methods described above, dermis is still used, at least in fibrous form.

Object of the Invention

It is therefore an object of the present invention to provide an improved leather substitute and a suitable method of manufacturing the same.

Disclosure of Invention

According to the invention, the object is achieved by a method for producing a non-synthetic textile fabric, comprising the steps of: a) Providing a slurry comprising at least one liquid, in particular water, at least one non-synthetic fibrous material, at least one binder, at least one processing additive; b) Generating a non-synthetic textile fabric by at least partially separating the liquid, in particular water, from the slurry; wherein the at least one binder comprises at least one natural latex.

The method according to the invention may further comprise one or more of the following sub-steps in step a): a1 Providing a non-synthetic fibrous material, wherein the non-synthetic fibrous material comprises or consists of foreshortened and/or un-foreshortened fibers; and/or a 2) adding at least one liquid, in particular water, to the non-synthetic fibrous material; and/or a 3) machining the non-synthetic fibrous material; and/or a 4) cleaning the non-synthetic fibrous material; and/or a 5) adding at least one binder; and/or a 6) adding at least one processing additive; and/or a 7) adding at least one auxiliary agent; and/or a 8) producing a slurry.

The method according to the invention may further comprise one or more of the following sub-steps in step b): b1 Applying the slurry provided in step a) to a liquid-permeable carrier element, in particular a water-permeable carrier element, for at least partially separating the at least one liquid, in particular water; and/or b 2) generating a slurry layer comprising the slurry from step a), wherein the at least one liquid, in particular water, is at least partially removed from the slurry layer; and/or b 3) drying the slurry layer; and/or b 4) shaping the size layer, in particular the dried size layer, to obtain the non-synthetic textile fabric; and/or b 5) adding at least one auxiliary agent.

The method according to the invention may further comprise separating the non-synthetic fibrous material into fibers and fibrillating it during the machining in step a 3).

The method according to the invention may comprise at least one processing additive selected from the group consisting of: polysaccharides, in particular starches, modified starches, cationically modified starches; cellulose or derivatives thereof, in particular carboxymethyl cellulose, cellulose acetate, hydroxypropyl methylcellulose; aluminum sulfate; or a mixture thereof.

The method according to the invention may further comprise at least one binder, said binder further comprising a synthetic latex.

The method according to the invention may additionally have at least one auxiliary agent, wherein the at least one auxiliary agent is selected from plasticizers, fillers, colorants, pigments, UV-protective agents, hydrophobing agents, antibacterial agents, flame retardants, wet-strength agents, sizing agents or mixtures thereof.

In the method according to the invention, the non-synthetic fibrous material may be selected from plant fibrous materials, preferably natural fibers; pulp (zellstonf); preferably recycled pulp; a fabric made of natural fibers, preferably recycled fabric made of natural fibers; or a mixture thereof.

The method according to the invention may further comprise the steps of: c) And b) post-treating the non-synthetic textile fabric produced in the step b).

According to the invention, it also relates to the use of cationic starch as processing additive, preferably in the process according to the invention.

According to the invention, it also relates to a non-synthetic textile fabric obtained by the method according to the invention.

According to the invention, it also relates to a non-synthetic textile fabric comprising a non-synthetic fibrous material, at least one processing additive, at least one binder, wherein the at least one binder comprises natural latex.

The non-synthetic textile fabric according to the invention may further comprise at least one auxiliary agent selected from plasticizers, colorants, UV-protective agents, hydrophobing agents, antibacterial agents, flame retardants, wet strength agents, sizing agents, pigments or mixtures thereof.

According to the invention, the use of the non-synthetic textile fabric according to the invention as a leather substitute, in particular for the production of fashion items (shoe parts and shoe surface materials, bags, accessories, clothing), furniture (seat covers, furniture surfaces), automotive interiors, stationery (e.g. book covers), facade covers or floor coverings.

According to the invention, it also relates to a leather substitute comprising the non-synthetic textile fabric according to the invention.

Furthermore, the leather substitute according to the invention has decorations, engraving, embossing, embroidery, coatings, decorations or mixtures thereof.

Detailed Description

The object is achieved by a method for producing a non-synthetic textile fabric according to the invention, comprising the steps of: a) Providing a slurry comprising at least one liquid, in particular water, at least one non-synthetic fibrous material, at least one binder, at least one processing additive; b) Generating a non-synthetic textile fabric by at least partially separating the liquid, in particular water, from the slurry; wherein the at least one binder comprises at least one natural latex.

The method according to the invention has the advantage that a non-synthetic textile fabric can be produced which can be used as a leather substitute.

The term "slurry" in the sense of the present application refers to a fibrous, in particular fibrous, pasty mixture comprising at least one liquid, in particular water, at least one non-synthetic fibrous material, at least one binder, in particular a plant-based binder, and at least one processing additive, in particular a plant-based processing additive. The pulp used in the method according to the invention is similar in its properties to known pulp from e.g. paper manufacture. The density of the substance in the slurry (the concentration of the fibers in the slurry) can preferably be adjusted to a value between 0.1 and 5% by weight.

The at least one liquid contains water. In one embodiment, the slurry is an aqueous slurry, meaning that the liquid is water. The water may be selected from distilled water or tap water or mixtures thereof. The liquid may also contain an organic solvent or oil. In one embodiment, the liquid is a mixture of water and oil. The proportion of oil in the liquid may be in the range of 5 to 40 wt% based on the dry weight of the non-synthetic fibrous material used.

The at least one non-synthetic fibrous material is preferably selected from plant fibrous materials, preferably from natural fibers; pulp; preferably recycled pulp; a fabric made of natural fibers, preferably recycled fabric made of natural fibers; or a mixture thereof. In one embodiment, the non-synthetic fibrous material is not in the form of a felt (Vlies) or woven fabric (Gewebe), but rather is in the form of a pile of loose, isolated fibers, such as in the form of balls or coils. The non-synthetic fibrous material does not contain any synthetic fibers, i.e. fibers made from petroleum-based polymers. In addition, the non-synthetic fibrous material does not contain any leather fibres of animal origin. This has the advantage that a non-synthetic fabric can be obtained which does not contain any leather fibres of animal origin or any fibres made of petroleum-based polymers.

The natural fibers may be produced as a byproduct of agricultural products or may be obtained from annual plants. Examples of plants from which natural fibers can be obtained are: hemp (plant), banana, pineapple, silphie, flax, kenaf, jute, cotton, sisal, agave, abaca, ramie, karia leaf, coconut and kapok. According to the invention, hemp fibers are particularly preferred. Mixtures of the above natural fibers may also be used. For economic and ecological reasons, it has proven to be advantageous if natural fibers obtained as by-products of agricultural products are used as non-synthetic fiber materials. Thus, under the condition that other conditions are unchanged, CO ₂ The balance is better than just growing plants for fiber production. It is also advantageous if the additional value of the plant is not based solely on fibers and allows for economic expansion.

In the sense of the present application, "pulp" refers to a fibrous material consisting of cellulose and made by chemical and mechanical processing of fiber-containing plants or wood. The plant may be selected from the plants disclosed previously, from which natural fibers may also be obtained. The pulp may also consist of recycled pulp or at least have a proportion of recycled pulp.

Furthermore, the non-synthetic fibrous material may be selected from textiles made from natural fibers, preferably from recycled textiles made from natural fibers, such as for example, a duvet garment composed of natural fibers (e.g., jute, cotton, sisal, or hemp) suitable for making garments.

In the sense of the present application, the term "binder" refers to a substance that elastically connects the fibers of the non-synthetic fibrous material to each other to form a three-dimensional network. According to the invention, the at least one binder comprises a plant-based binder made of natural latex. The natural latex may be obtained from rubber tree (Hevea Brasilensis), guayule (Parthenium argentatum), russian dandelion (Taraxacum koksaghyz), or a mixture thereof. The latter can also be planted in europe in particular, so that this raw material can be purchased locally, which makes it more environmentally friendly. The at least one binder preferably consists of natural latex. In one embodiment, the binder may further comprise a synthetic latex, for example obtained from petroleum-based polymers. For example, by using latex or rubber or latex-based or rubber-based adhesives, leather-like or higher degrees of softness can be achieved in the final product, i.e. in the leather substitute or in the non-synthetic facings according to the invention.

In the sense of the present application, the term "processing additive" refers to a precipitant capable of forming a three-dimensional network generated by the non-synthetic fibrous material and the binder. The at least one processing additive is selected from the group consisting of: polysaccharides, in particular starches, modified starches, cationically modified starches; cellulose or derivatives thereof, in particular carboxymethyl cellulose, cellulose acetate, hydroxypropyl methylcellulose; aluminum sulfate (also known as alum); or a mixture thereof. The at least one processing additive is preferably a plant processing additive selected from polysaccharides, in particular starch, or cellulose, or mixtures thereof. The use of polysaccharides, in particular cationic starches, has the following advantages: it is at least partially soluble in water (in cold and warm water) and plays its role in the neutral range. Whereby the slurry is no longer acidic or contaminated with acid. In addition, the use of metal salts which are harmful to health and the environment is avoided. According to the invention, cationic starch is also used in particular as a processing additive, preferably in the process according to the invention.

Step a) of the method according to the invention may comprise one or more of the following sub-steps:

a1 Providing a non-synthetic fibrous material, wherein the non-synthetic fibrous material comprises or consists of foreshortened and/or un-foreshortened fibers; and/or

a2 At least one liquid, in particular water, is added to the non-synthetic fibrous material; and/or

a3 Machining the non-synthetic fibrous material; and/or

a4 Cleaning the non-synthetic fibrous material; and/or

a5 At least one binder is added; and/or

a6 At least one processing additive is added; and/or

a7 At least one auxiliary agent is added; and/or

a8 A) producing a slurry.

In step a 1), a non-synthetic fibrous material is provided, wherein the non-synthetic fibrous material comprises or consists of foreshortened and/or non-foreshortened fibers. The non-synthetic fibrous materials used according to the present invention generally have to be processed to achieve uniform distribution and increased strength to the greatest possible extent. Depending on the type and acquisition of the non-synthetic fibrous material, it must also be unwound, for example by means of a carding machine. For example, in the case of textiles, it must be cut into small pieces, for example, using a crusher or the like.

In step a 2), the provided non-synthetic fibrous material which may have undergone step a 1) is mixed with at least one liquid as described above. This may be accomplished by placing the non-synthetic fibrous material in a suitable container and then adding the liquid or by using the reverse order. The fiber concentration can be adjusted as desired. The fiber concentration may be at least 0.1 wt%, or at least 0.2 wt%, or at least 0.3 wt%, or at least 0.5 wt%, or at least 0.7 wt%, or at least 1 wt%, or at least 1.3 wt%, or at least 1.5 wt%, or at least 2 wt%, or at least 2.5 wt%, or at least 3 wt%, and/or at most 10 wt%, or at most 9 wt%, or at most 8 wt%, or at most 7 wt%, or at most 6 wt%, or at most 5 wt%, or at most 4 wt%. In particular, the fiber concentration may be at least 0.1 wt% to 10 wt%, or 0.1 wt% to 8 wt%, or 0.1 wt% to 5 wt%.

In step a 3), the non-synthetic fibrous material is mechanically processed. The non-synthetic fibrous material may undergo at least steps a 2) and a 4). In the sense of the present application, the term "machining" refers to subjecting a non-synthetic fibrous material to a mechanical process comprising separating the non-synthetic fibrous material into fibers and fibrillating the fibers. This has the advantage that the fibre bundles are broken down into individual fibres, which increases the contact surface between the fibres and the binder. In this way, a more tear resistant and more homogeneous material may be formed in a subsequent process. In this connection, essentially all methods known from the prior art are suitable. According to the invention, the non-synthetic fibrous material is machined in the form of a grinding process. To this end, the non-synthetic fibrous material is introduced into a grinding apparatus and subjected to a grinding process. Suitable grinding devices are cone refiners, disc refiners and beating machinesPapillon refiner, PFI refiner, jokro refiner. One or more milling processes may be performed. The milling process may be adjusted according to the desired degree of milling of the non-synthetic fibrous material to be achieved. Generally, higher grinding levels also provide better product quality. Typically the milling process lasts from 1 minute to 2 hours. In principle, however, the duration of the grinding process depends on the degree of grinding to be achieved and on the energy input during the grinding processHow high (kWh/t fiber) is. During the milling process, the fibers are shortened, separated and fibrillated. A homogeneous fiber suspension is obtained. The suspension may then be cleaned, washed or concentrated again using a pressure classifier.

In step a 4), the non-synthetic fiber material is cleaned. It has proved to be advantageous for the quality and workability of the non-synthetic fiber material if foreign bodies (e.g. dust, chips/wood parts, other contaminants) of the non-synthetic fiber material are removed before or after step a 1) or before or after step a 2) or before or after step a 3). In step a 4), foreign bodies of non-synthetic fiber material may be removed, for example mechanically. In addition, the cleaning may also include one or more washing processes and/or alkaline cooking and/or enzymatic treatments. For example, the non-synthetic fibrous material may be subjected to alkaline digestion to break down the fibers, i.e., for example, digestion of the fibers to remove lignin. If lignin remains in the non-synthetic fibrous material, natural color will be produced depending on its source. If such natural color is not required, alkaline cooking may be performed. Alkaline cooking of lignin also reduces strength. Cleaning generally has the following advantages: unwanted components, such as foreign substances or interfering compounds, such as pectin or lignin, can be at least partially, preferably completely, removed. This supports or simplifies the fibrillation in step a 3) or may facilitate or accelerate the separation of the liquid in step b).

In step a 5), at least one binder may be added. The binder may for example be placed in a suitable container and the non-synthetic fibrous material optionally subjected to steps a 1) and/or a 2) and/or a 3) and/or a 4) and/or a 6) may be added to the binder. The sequence may also be reversed, i.e. the non-synthetic fibrous material optionally subjected to steps a 1) and/or a 2) and/or a 3) and/or a 4) and/or a 6) is placed in a suitable container and a binder is added thereto. The binder and non-synthetic fibrous material may be mixed in this step. The weight ratio of binder to non-synthetic fibrous material may vary depending on the desired properties of the non-synthetic textile fabric. For example, if more latex is used than fibrous material, a more rubbery non-synthetic facing is obtained. Typical weight ratios of non-synthetic fibrous material to latex or binder are in the range of 1:0.2 to 1:3, or 1:0.3 to 1:3, or 1:0.5 to 1:2.5, or 1:0.7 to 1:2.

In step a 6), at least one processing additive may be added. The processing additive may for example be placed in a suitable container and the non-synthetic fibrous material optionally subjected to step a 1) and/or a 2) and/or a 3) and/or a 4) and/or a 5) may be added to the processing additive. The sequence may also be reversed, i.e. the non-synthetic fibrous material optionally subjected to steps a 1) and/or a 2) and/or a 3) and/or a 4) and/or a 5) is placed in a suitable container and the processing additive is added thereto. The processing additive and the non-synthetic fibrous material may be mixed in this step. Typical weight ratios of non-synthetic fibrous material to processing additives are in the range of 1:0.02 to 1:0.2, or 1:0.03 to 1:0.2, or 1:0.05 to 1:0.15.

In step a 7), at least one auxiliary agent may be added. The auxiliary agent may for example be placed in a suitable container and the non-synthetic fibrous material optionally subjected to step a 1) and/or a 2) and/or a 3) and/or a 4) and/or a 5) and/or a 6) may be added to the auxiliary agent. The sequence may also be reversed, i.e. optionally through steps a 1) and/or a 2) and/or a 3) and/or a 4) and/or a 5) and/or a 6) the non-synthetic fibrous material is placed in a suitable container and at least one auxiliary is added thereto. The adjunct and non-synthetic fibrous material can be mixed in this step.

Suitable adjuvants may be selected from plasticizers, fillers, colorants, pigments, UV protectants, hydrophobing agents, antibacterial agents, flame retardants, wet strength agents, sizing agents or mixtures thereof.

If the nonwoven fabric according to the invention is to be given a greater softness, plasticizers are used. Various types of plasticizers may be used in accordance with the present invention. Preferably, the use of inorganic chemical plasticizers is avoided. In particular, a selected plant-based plasticizer may be used, wherein the plant-based plasticizer may be selected from: modified natural oils, anhydrides of vegetable-based alkenyl succinic acids, vegetable-based alkylated ketene dimers, vegetable-based polyols, or mixtures thereof. The plant-based modified oil may be sulfated. This has the advantage that these oils are easily emulsified. In general, such natural oils may be vegetable-based oils selected from sunflower oil, turkish red oil (sulfated castor oil) or rapeseed oil. Furthermore, the natural oil may also be of animal origin, such as fish oil. Plasticizers, especially modified vegetable oils, remain in the material in the form of small droplets, thereby creating free space in such a way that the individual fibers can move more freely between each other. Thereby making the material softer and more flexible. Typical weight ratios of non-synthetic fibrous material to plasticizer are in the range of 1:0.01 to 1:0.4, or 1:0.05 to 1:0.35, or 1:0.1 to 1:0.4.

Fillers may be used if the non-synthetic fabric of the present invention should form a smooth surface and/or should have higher flexibility. The filler may be selected from silicates, such as kaolin; carbonates, such as chalk or gypsum; metal oxides such as titanium oxide or aluminum oxide; barium sulfate; nanocellulose, such as CNC (cellulose nanocrystals), CNF (cellulose nanofibrils), FNC (fibrillated nanocellulose); or a mixture thereof. Typical weight ratios of non-synthetic fibrous material to filler are in the range of 1:0.1 to 1:1, or 1:0.15 to 1:0.9, or 1:0.2 to 1:0.8.

If the non-synthetic textile fabric should have a particular color, colorants may be used. Thus, the non-synthetic textile fabric may be dyed, wherein the dyeing process may be performed at different points in time in the process. Dyeing may be carried out before, during or after step a). The non-synthetic fibrous material or slurry may be colored. The colorant may be selected from inorganic pigments such as carbon, metal oxides or metal sulfates; natural pigments such as saffron, indigo pigment, onion skin, quebracho extract, madder root extract, luteolin extract, brasilin extract, and sappan wood extract; synthetic dyes, such as direct dyes, cationic dyes, vat dyes, reactive dyes, chromogenic dyes, food dyes; or a mixture thereof. The material to be dyed may be coloured in a suitable liquid/suspension. In addition, the finished non-synthetic textile fabric may be colored by coating a colorant on the surface. Alternatively, colorants/pigments may be added to the slurry. The coloring of the material is achieved by treating the colored fibers. This prevents color wear, for example, during painting.

In step a 8) a slurry is produced, wherein at least the non-synthetic fiber material, the at least one binder, the at least one processing additive and the at least one liquid are brought into contact with each other and mixed, thereby producing the slurry.

The above-described sub-steps a 1) to a 8) of step a) of the method according to the invention may be performed in any order or in parallel. For example, a portion of the non-synthetic fibrous material may be subjected to step a 2) while another portion of the non-synthetic fibrous material is subjected to step a 5). Preferably, step a 6) is performed as the last sub-step in step a).

Further, the method according to the invention further comprises a step b), wherein step b) may comprise one or more of the following sub-steps:

b1 Applying the slurry provided in step a) to a liquid-permeable carrier element, in particular a water-permeable carrier element, for at least partially separating the at least one liquid, in particular water; and/or

b2 Generating a slurry layer comprising the slurry from step a), wherein the at least one liquid, in particular water, is at least partially removed from the slurry layer; and/or

b3 Drying the slurry layer; and/or

b4 Forming said size layer, in particular a dried size layer, to obtain said non-synthetic textile fabric; and/or

b5 At least one auxiliary agent is added.

In step b 1), the slurry provided in step a) is applied onto a liquid-permeable carrier element, in particular a water-permeable carrier element, for at least partially separating the at least one liquid, in particular water. The application may be achieved by suitable methods known in the art, such as brushing or pouring. A "liquid permeable carrier element" is a device such as a screen or a perforated plate, onto which a slurry is applied to separate the liquid.

In step b 2) a slurry layer is produced comprising the slurry from step a), wherein the at least one liquid, in particular water, is at least partially removed from the slurry layer. Removal of the at least one liquid is achieved by gravity or by external force (e.g. pressure plate or application of vacuum). After the liquid has been separated, the partially dried or partially dewatered pulp layer is again removed from the liquid-permeable carrier element. The liquid-permeable carrier element is thus different from the carrier materials known in the prior art which remain in the finished product.

In step b 3), the slurry layer produced, for example, in step b 2) is further dried until at least 90%, or at least 95%, or at least 98%, or at least 99% of the at least one liquid has been removed from the slurry layer. Such drying may be carried out by evaporation at room temperature or in a suitable apparatus, such as a drying oven, at elevated temperature and/or elevated pressure. In step b 3), so-called sheet formation takes place. Such sheet formation may occur continuously or discontinuously. Continuous sheet formation requires a large screen (similar to a paper machine) with vacuum suction. Discontinuous sheet formation may use laboratory equipment (e.g., rapidSheet former) or manually, similar to scooping paper.

In step b 4), the slurry layer, in particular the dried slurry layer, is subjected to a forming treatment to obtain the non-synthetic textile fabric. Steps b 3) and b 4) may be performed simultaneously, which means that the drying is also performed simultaneously during the shaping process. Steps b 3) and b 4) may also be carried out sequentially, i.e. step b 4) is carried out after b 3), or vice versa. The shaping process may also be carried out using means known in the art, such as rollers. The shaping performed in step b 4) may comprise pressing and/or embossing of the material. By pressing the material in the dry state, the surface becomes smooth and in some cases also slightly glossy by a satin process.

In step b 5), at least one auxiliary agent may be added, as already described in step a 7) above. Step b 5) may be performed at any time before or after steps b 1) to b 4) or simultaneously therewith.

The above-described sub-steps b 1) to b 5) of step b) of the method according to the invention may be performed in any order or in parallel.

The method according to the invention may further comprise step c):

c) And b) post-treating the non-synthetic textile fabric produced in the step b).

The post-treatment may consist of one or more treatments selected from the group consisting of: rolling, riveting and/or milling; equipped with uv protection and/or flame protection and/or antimicrobial protection (e.g. by application of nanosilver), hydrophobing (e.g. by application of a polymer emulsion); applying a wet strength agent and/or sizing agent; embroidering; (laser) engraving; embossing (e.g., using a plate or roller); coating/coating (e.g., using proteins or waxes); coloring the surface; pigment applications (e.g. effect pigments). The purpose of the post-treatment is to refine or impart specific properties to the non-synthetic textile fabric. Such post-treatments according to the present invention include coating or impregnating the non-synthetic textile fabric, for example hydrophobizing the surface with wax. For example, the surface may also be engraved using a laser or embroidered using a suitable device. The material may be provided with embossments to obtain a particular look and feel; for example, the look and feel of animal leather may be created by grain embossing. Logo, typeface, etc. may also be embossed. As already described, further mechanical processing can also be carried out, for example by rolling, riveting and/or grinding. This can loosen the fibers from each other, leading to the material losing stability and thus becoming softer or more flexible.

An embodiment of the method for producing a non-synthetic fabric according to the invention has the following steps: a1 Providing a non-synthetic fibrous material, wherein the non-synthetic fibrous material comprises foreshortened and/or un-foreshortened fibers

Or of foreshortened and/or non-foreshortened fibres, and a 2) adding at least one liquid, in particular water, to the mixture

In the case of the non-synthetic fibrous material,

a3 Machining the non-synthetic fibrous material,

a5 A) adding a plant-based binder,

a6 Adding a plant processing additive to obtain a slurry,

b1 Applying the slurry to a water permeable carrier element to separate water from the slurry,

b3 A) drying the slurry layer and b 4) shaping,

b) The non-synthetic textile fabric is obtained.

The method according to the invention has the advantage that it can be based entirely on plant-and/or plant-based raw materials, so that it can be carried out on the one hand in a purely vegetable manner and on the other hand in a petroleum-free manner, and that a purely vegetable, petroleum-free product, i.e. a non-synthetic textile fabric according to the invention, can be obtained.

The terms "plant-based", "vegetable" or "natural" are used synonymously in this application and mean excluding synthetic, petroleum-based raw materials/substances, or, for example, subsequent processing of plant-based adhesives based on plant components without the addition of artificial raw materials.

The method according to the invention may preferably be entirely ecological, since the non-synthetic textile produced does not produce any wear of the microplastic in the case of synthetic fibres or artificial leather. By using natural fibers and plant-based raw materials, the product of the method according to the invention may be biodegradable.

Furthermore, the object of the invention is achieved by a non-synthetic textile fabric. In particular, the non-synthetic textile fabric can be obtained by the method according to the invention described above. The non-synthetic textile fabric is preferably constructed as a single layer and is composed entirely of plant material. The non-synthetic textile fabric according to the invention does not comprise any leather of animal origin. The non-synthetic textile fabric according to the invention is preferably free of petroleum-based components. The non-synthetic textile fabric according to the invention is preferably free of chemicals that are harmful to health.

In the sense of the present application, the term "non-synthetic textile fabric" refers to a material similar to real or artificial leather, which can be processed in a similar way and thus can be used as a leather substitute. The fabric is non-woven and may be referred to as felt. A non-synthetic textile fabric in the sense of this application comprises at least one non-synthetic fibrous material, at least one processing additive and at least one binder, said at least one binder comprising natural latex.

Furthermore, the non-synthetic textile fabric according to the invention may comprise at least one auxiliary agent selected from plasticizers, colorants, UV-protective agents, hydrophobing agents, antibacterial agents, flame retardants, wet strength agents, sizing agents, pigments or mixtures thereof. Examples and specific configurations of these adjuvants have been described above in connection with the method according to the invention.

The plant textile has substantially the same advantages as the method according to the invention described above. The non-synthetic textile fabric according to the invention can be made entirely of plant and/or plant-based raw materials, so that it is purely plant on the one hand and petroleum-free on the other hand. By the process flow according to the invention and the raw materials or auxiliaries used, no metal residues are contained. The non-synthetic textile fabric according to the invention does not cause any wear of the microplastic and is also biodegradable.

Unlike animal skins, the thickness of the non-synthetic textile fabric according to the invention is not naturally predetermined, but can be freely selected and controlled. The non-synthetic textile fabric according to the invention may have a thickness commonly used for leather, for example between 0.2 and 5 mm.

Unlike multilayer artificial leather, the non-synthetic textile fabric according to the present invention may be processed in an open-edged manner.

The non-synthetic textile fabric according to the invention provides a single layer product which can be further processed using conventional treatment methods. For example, it may be sewn, glued, stapled and embroidered.

According to the invention, the use of the non-synthetic textile fabric according to the invention is also disclosed, in particular for the production of textiles, seat covers, bags, applications. Possible fields of application include fashion (shoe parts and shoe surface materials, bags, accessories, clothing), furniture (seating, furniture surfaces), automotive interiors, stationery (e.g. book covers). The non-synthetic textile fabric according to the invention may find additional applications in the construction industry or in interior designs, for example for facade cladding or floor coverings.

According to the invention, it also relates to a leather substitute comprising the non-synthetic textile fabric according to the invention. The leather substitute according to the invention has decorations, engraving, embossing, embroidery, coatings, decorations or mixtures thereof. The leather substitute according to the invention may be combined with other materials that may be generally combined with leather. The leather substitute according to the invention can be processed and used like conventional leather of animal origin or artificial leather. In particular, the leather substitute according to the invention and the non-synthetic textile fabric according to the invention may have the same, similar or even improved properties compared to conventional leather of animal origin or artificial leather. These properties include tensile strength, for example, in the range of 15 to 50N/mm ² Is within the range of (2); elongation at break, for example in the range of 10% to 50%; tear strength, for example in the range of 4 to 40N/mm; residual moisture, for example in the range of 0.5% to 10%; or Martindale abrasion resistance, e.g. in>Within 20000 cycles.

The leather substitute according to the invention differs from the non-synthetic textile fabric according to the invention in that the leather substitute according to the invention has been optimized for the subsequent use, for example by cutting or further (surface) treatment, in order to achieve certain properties. Examples of such (surface) treatments have been described above.

Other objects, features, advantages and possible uses will emerge from the figures and the following description of exemplary embodiments, which do not limit the invention. All the described and/or represented features in the form of illustrations, alone or in any combination, form the subject of the invention, whatever their outline or the cited relation in the claims.

Drawings

Fig. 1 shows a photograph of a non-synthetic fibrous material made from foreshortened fibers.

Fig. 2 shows a photograph of a partially dewatered slurry layer for sheet formation.

Fig. 3 shows a photograph of the finished non-synthetic textile fabric.

In one embodiment, the non-synthetic textile fabric according to the invention is made of hemp fibers. These fibers were purchased from an agricultural agency in germany. These fibers are present in the form of wool, as shown in fig. 1, in the form of balls. These yarns contain, in addition to the fibers to be utilized, a residual portion of wood chips and other impurities. In order to improve the product quality, these chips and foreign bodies can be separated from the remaining fibers in a first method step. The advantage of using hemp fibres is that the plant is not grown for the production of fibres. Thus, these fibers are produced as residues.

In order to be able to produce the tear-resistant and homogeneous facing according to the invention from said fibers, these fibers must first be machined. The processing may be performed on different machines. The process may optionally be carried out using cone refiners or beaters known in the paper industry. At the beginning of the process, the fibers may be mixed with water. In the so-called milling process, the fibers in the milling unit are shortened, separated and fibrillated. A homogeneous fiber suspension is obtained. The suspension may then be cleaned, washed or concentrated again using a pressure classifier.

The next step is to produce a slurry. The preferably diluted (plant) binder and the (plant) processing additive are added sequentially to the fibre suspension. Successful fixation is clearly identified by the naked eye. After standing for a period of time, the fibers flocculated significantly and settled at the bottom of the vessel.

Then a so-called sheet is formed. Sheet formation may be achieved in continuous and discontinuous processes. Continuous sheet formation requires a large screen (similar to a paper machine) with vacuum suction. Discontinuous sheet formation may use laboratory equipment (e.g., rapidSheet former) or manually, similar to scooping paper.

During sheet formation, water is separated from the remaining slurry solids. The slurry is placed on a screen (water permeable carrier element). Such a slurry layer is shown in the photograph of fig. 2. In the manual method, a sieve box is used for this purpose. The water can be discharged through the screen while retaining solids. On the screening machine, the process can be accelerated by applying negative pressure.

The partially dewatered slurry layer in the form of a fibrous mat is then transferred from the screen to the felt (only temporarily) through a back-off screen box. For further dewatering, the fibre mat is pressed between two felts in a press. The remaining liquid must be pressed out as slowly as possible in order not to damage the three-dimensional structure. After pressing, the formed sheet is already tear resistant and easy to handle. The sheet must now be further dried with room air until equilibrium humidity is reached. The drying is carried out in an oven at moderate temperature or in air.

In a continuous process, pressing and drying are carried out by pairs of rollers and cylinders or by calenders.

The surface of the dried material may be further refined by embossing or pressing between metal plates or cylinders.

In this way, a non-synthetic textile fabric according to the invention is obtained. A specific embodiment of such a non-synthetic textile fabric is shown in the photograph of fig. 3.

Examples

The present invention will be explained again below using examples, but the present invention is not limited to these examples.

Example 1

200 g of fibers (hemp, long fibers from wool) were added to a beater to 18 liters of water. The subsequent milling process was carried out at standard weight for 30 minutes. 10 g of carbon black (as a color pigment) and 60 g of latex (binder) were added while stirring. 30 g of cationic starch (processing additive) are dissolved in 3 l of water and added. The slurry is stirred and the slurry is precipitated while stirring. The slurry is then placed in a screen box for dewatering. After dewatering, the formed partially dewatered slurry layer was placed between two layers of felt and pressed, then air dried.

A grey/black shell fabric is obtained which has the feel of leather. The fabric is hard after drying.

Example 2

30 grams of hemp fibers were cut to a length of 0.5 cm and filled with water to a total weight of 300 grams. The mixture was placed in a PFI mill and ground for 3 minutes at normal weight. The fiber suspension was then mixed with 1.5 liters of water and whipped in a whipping device. The slurry was then produced by adding 1 gram of sulfated sunflower oil (plasticizer), 10 grams of latex (binder), 2 grams of kaolin (filler) and 1 liter of water. While stirring, 0.01 to 0.02M aluminum sulfate was added as a process additive for precipitating or fixing the slurry until a pH of 5 was reached. The slurry thus obtained is put into a sieve box for dewatering. After dewatering, the formed partially dewatered slurry layer was placed between two layers of felt and pressed, then air dried.

A non-synthetic textile fabric as shown in fig. 3 is obtained, which has the feel and look of leather.

Claims

1. A process for producing a non-synthetic textile fabric, the process comprising the steps of:

a) Providing a slurry comprising at least one liquid, in particular water, at least one non-synthetic fibrous material, at least one binder, at least one processing additive;

b) Generating a non-synthetic textile fabric by at least partially separating the liquid, in particular water, from the slurry;

wherein the at least one binder comprises at least one natural latex.

2. The method of claim 1, wherein step a) comprises one or more of the following sub-steps:

a3 Machining the non-synthetic fibrous material; and/or

a4 Cleaning the non-synthetic fibrous material; and/or

a5 At least one binder is added; and/or

a6 At least one processing additive is added; and/or

a7 At least one auxiliary agent is added; and/or

a8 A) producing a slurry.

3. The method according to at least one of claims 1 or 2, wherein step b) comprises one or more of the following sub-steps:

b3 Drying the slurry layer; and/or

b5 At least one auxiliary agent is added.

4. A method according to at least one of claims 2 or 3, wherein the machining in step a 3) comprises separating the non-synthetic fibrous material into fibers and fibrillating it.

5. The method of at least one of claims 1 to 4, wherein the at least one processing additive is selected from the group consisting of: polysaccharides, in particular starches, modified starches, cationically modified starches; cellulose or derivatives thereof, in particular carboxymethyl cellulose, cellulose acetate, hydroxypropyl methylcellulose; aluminum sulfate; or a mixture thereof.

6. The method of at least one of claims 1 to 5, wherein the at least one binder further comprises a synthetic latex.

7. The method of at least one of claims 1 to 6, wherein the at least one auxiliary agent is selected from plasticizers, fillers, colorants, pigments, UV protectants, hydrophobing agents, antibacterial agents, flame retardants, wet strength agents, sizing agents, or mixtures thereof.

8. The method according to at least one of claims 1 to 7, wherein the non-synthetic fibrous material is selected from plant fibrous materials, preferably natural fibers; pulp; preferably recycled pulp; a fabric made of natural fibers, preferably recycled fabric made of natural fibers; or a mixture thereof.

9. The method according to at least one of claims 1 to 8, wherein the method further comprises the steps of:

10. Use of cationic starch as processing additive, preferably in a method according to at least one of claims 1 to 9.

11. A non-synthetic textile fabric obtained by a method according to at least one of claims 1 to 9.

12. A non-synthetic textile fabric comprising a non-synthetic fibrous material, at least one processing additive, at least one binder, wherein the at least one binder comprises natural latex.

13. The non-synthetic textile fabric of claim 12, further comprising at least one auxiliary selected from the group consisting of plasticizers, colorants, UV protectants, hydrophobing agents, antibacterial agents, flame retardants, wet strength agents, sizing agents, pigments, or mixtures thereof.

14. Use of a non-synthetic textile fabric according to at least one of claims 11 to 13 as a leather substitute, in particular for the production of fashion (shoe parts and shoe surface materials, bags, accessories, clothing), furniture (seating, furniture surfaces), automotive interiors, stationery (e.g. book covers), facade covers or floor coverings.

15. Leather substitute comprising a non-synthetic textile fabric according to at least one of claims 11 to 13.

16. The leather substitute of claim 15, further comprising a decorative, engraving, embossing, embroidery, coating, decal, or a mixture thereof.