Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
  • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
  • D06N3/0006—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using woven fabrics
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
  • D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
  • D06N3/0061—Organic fillers or organic fibrous fillers, e.g. ground leather waste, wood bark, cork powder, vegetable flour; Other organic compounding ingredients; Post-treatment with organic compounds
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
  • D06N3/0072—Slicing; Manufacturing two webs at one time
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
  • D06N3/0077—Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
  • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
  • D06N3/183—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials the layers are one next to the other
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2201/00—Chemical constitution of the fibres, threads or yarns
  • D06N2201/04—Vegetal fibres
  • D06N2201/042—Cellulose fibres, e.g. cotton
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2203/00—Macromolecular materials of the coating layers
  • D06N2203/02—Natural macromolecular compounds or derivatives thereof
  • D06N2203/022—Natural rubber
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2205/00—Condition, form or state of the materials
  • D06N2205/02—Dispersion
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2211/00—Specially adapted uses
  • D06N2211/10—Clothing
  • D06N2211/106—Footwear

Definitions

• the present application relates to a system and method of producing different bio-based textile composite materials and products. These bio-based textile composite materials may be used for products in various industries, such as footwear and accessories.
• the present application relates to a method of producing different bio-based mushroom textile materials using bio-based and biodegradable/compostable man-made-cellulosic fiber and vulcanized, non-chemically modified natural rubber.
• the man-made-cellulosic fiber is preferably as close to one hundred percent bio-based and biodegradable as possible, and may, for example, be manufactured from materials obtained from certified sustainable managed forests. These certified sustainable forests may be, for example, those certified by the Forest Stewardship Counsel or other agencies that certify and manage sustainable forests.
• the mushroom containing material and natural rubber material are applied as one or more coatings to a backing comprised of the man-made-cellulosic fiber and natural rubber, with the coatings and backing material being further treated during and after the application of the one or more coatings to produce a bio-based textile composition.
• Synthetic polymeric materials instead of genuine leather within the footwear and accessories industry is increasing due to activities from consumer organizations globally rallying against the use of genuine leather.
• Synthetic polymeric materials are commonly retrieved from crude oil through extensive production processes, with the production of these crude oil-based synthetic polymers creating a negative impact on the environment and contributing to climate change.
• These types of synthetic polymers are almost non-biodegradable, contaminate the global oceans and remain in the environment for thousands of years, and, in many cases, are not recyclable.
• the present application is directed to a system and method for creating different bio-based, natural composite textile materials. These materials may be used, for example, as alternatives to textiles made from genuine leather and synthetic polymers for consumer goods such as footwear and accessories.
• the replacement of synthetic polymeric materials with materials created using naturally derived polymers and other bio-based materials helps to move towards increasing sustainability in the consumer goods industry.
• the present application uses nature-provided materials that are obtainable without causing harm to the environment, and which, when separated, purified, and processed into composite materials present cost-efficient replacements to synthetic polymeric materials.
• the nature-provided materials used may include, for example, natural rubber and mushroom materials.
• the natural materials, such as natural rubber mushrooms may be, for example combined with man-made-cellulosic fibers preferably sourced from a sustainable forest, to prepare a bio-based and sustainable but coated textile material and materials.
• the natural composite materials may include, for example, natural rubber, mushroom materials, and regenerated cellulose fibers such as man-made cellulosic fibers, such as cotton and jute.
• the reinforcement backing material may be, for example, made from non-woven regenerated cellulose fibers or a woven material produced from natural and sustainable fibers.
• This reinforcement backing may be a woven or non-woven man-made cellulosic fiber made of, for example, viscose, lyocell, modal and/or any other cellulose based non-woven fabric.
• the cellulose-based man-made cellulosic fibers are preferably sourced from certified sustainable managed forests.
• Such forests may be those certified by the Forest Stewardship Council or similar agencies that use their expertise to promote responsible management of the world’s forests by bringing together experts from the environmental, economic and social areas. These certified sustainable managed forests are carbon neutral with every tree that is cut being replaced with additionally planted trees. The use of such certified materials in consumer goods allows the customer to trace where the material comes from based on assigned tracking information. This tracking information is included with shipments of any materials harvested from the forest.
• the method and system use the man-made cellulosic fibers to produce a textured reinforcement backing material.
• the man-made cellulosic fiber blend may be made from viscose and lyocell and is considered bio-based and bio-degradable.
• the man-made cellulosic fiber blend forming the reinforcement backing material may be made such that it does not contain any additional synthetic fibers to add additional material strength.
• the reinforcement backing material may have an area density to provide sufficient strength and permeability for use in consumer textile products.
• the reinforcement backing material may have varying densities which may apply for different final applications, one example being an area density of around 500g/m 2 . Other densities may apply for different product applications and required performances.
• This reinforcement backing material may be created through a needle punching process and/or hydroentanglement process to create a non-woven backing material.
• Needle-punched non-woven fabrics can be made from various fibrous webs, fiber entanglement and frictions after fine needle barbs are repeatedly penetrated through fibrous web.
• the needle punched fabrics have a fibrous network with the non-woven fabrics providing specific functions including for example, resilience, stretch and softness.
• the non-woven fabric can also be made by hydroentanglement, where fibers are subjected to high pressure water streams, joining them together.
• the reinforcement backing material serves as an enforcement/backing material in the production of manufactured products.
• the bio-based, natural composite materials are applied to the reinforcement backing material in one or more coating layers, resulting in a bio-based and substantially biodegradable textile material that provides high performance in consumer industries, such as the footwear industry.
• coatings are applied to the man-made cellulosic fiber blend non-woven backing.
• Natural, substantially biodegradable materials that can be used to create these coatings include mushrooms and natural rubber, color pigments or dyes, and finishing additives.
• mushrooms such as common Oyster mushrooms can be used as ingredients in a base-coating directly applied to the non-woven backing.
• the mushrooms that may be used in creating the coatings can be those that are considered waste mushrooms for not meeting strict requirements necessary to enter the food industry. These mushrooms are normally treated as animal food or are otherwise not harvested or are discarded.
• the natural rubber used to produce the coating material for one or more of the coating layers may be retrieved from local sources.
• This natural rubber can be, for example, latex with a portion including solids, which are only stabilized with low amounts of ammonia and further treated with common vulcanization agents.
• the natural rubber is bio-based and can substantially biodegrade over time.
• a natural polymerization process is used to ensure that the latex is not vulcanized.
• the latex natural rubber may be obtained from certified sustainable forests, such as from Vietnam Forest Stewardship Council certified plantations and certified sustainable forests.
• the system and method may be used to make high performance products, with some products including additional chemicals to enhance certain properties thereof.
• chemicals such as polyurethane and butadiene may be added to the natural, biodegradable mushrooms and rubbers used in the one or more coatings applied to the non-woven backing material.
• the coatings may be applied as separate layers, with the non-woven backing and any applied coating layers being allowed to dry and set before any subsequent layers are applied.
• the system and method may further include pressing or flattening the non-woven backing material and any applied coating layers before, during, or after such layers being dried and set.
• Color pigments or dyes may be added as ingredients to one or more of the coating layers in order to produce a desired color or patterns in the final product.
• a softener agent may also be used in the one or more coatings or may be added to the final textile product after all coatings have been applied. This softening agent may be substantially biodegradable over time and may be made from biodegradable crude oil.
• the system and method can create materials for use in the leather industry and minimizes carbon footprint, water, and chemical consumption.
• Figure 1 illustrates the general principle of a roller coater system.
• Figure 2 illustrates an exemplary roller coater.
• Figure 3 illustrates applying a slurry using a doctor blade application.
• Figure 4 illustrates a Foulard application system used to apply the coatings.
• Figure 5 illustrates an embossing machine which is used to press or flatten the surface of the reinforcement backing material with the base coat.
• Figure 6 illustrates base coated reinforcement backing material with bio-based slurry after the first treatment step.
• Figure 7 provides a flow diagram of the process of creating a bio-based natural fabric.
• Figure 8 shows an example of the construction of the coated material with the reinforcement material.
• Figure 9 illustrates a system for making adjustments to the thickness of the materials.
• the system and method described herein implements a process directed to creating different bio-based, natural rubber and mushroom containing materials applied onto a reinforcement fabric backing material.
• the resulting product may be used to produce footwear and other consumer goods.
• the reinforcement backing may be a non-woven man-made cellulosic fiber made of viscose, lyocell, modal and/or any other cellulose based non-woven fabric, or it may be a woven material produced from natural and sustainable fibers.
• the coating layers may include, for example, a base-coating layer, an intermediate coating layer, and a final topcoat layer.
• the base-coating layer may be formed from a mixed slurry containing one or more of mushrooms, mushroom material, and natural rubber ingredients. Certain of the layers, such as the intermediate layer, may contain only natural rubber and color pigments or dyes. Other layers, such as the finishing layer, may include bio-based ingredients to provide desired performance and appearance characteristics to the final product.
• the layers, and in particular the base-coating layer may be pressed and flattened before a subsequent coating layer is applied. After all coating layers have been applied and set, the thickness and amount of the resulting material comprised of the reinforcement backing material and all applied coating layers may be adjusted. For example, the resulting material may be trimmed or cut to a desired shape, size, and thickness.
• a base-coating may be prepared and a base reinforcement backing material provided.
• the base-coating may then be applied to the reinforcement backing material one or both sides.
• the base-coat slurry may be created through combination of ingredients which are added into a mixing bowl in desired rations and in a desired order.
• the mushrooms used in the system and method described herein are, for example, farmed mushrooms which are not used for human consumption. These mushrooms do not meet food industry requirements such as size, freshness and color and are generally repurposed as animal food or disposed.
• the mushrooms are used as filling material in the final product and are grinded to a fine mushroom powder with a particle size of 0.2 mm prior to preparation of the final slurry. All ingredients are mixed together, including the mushroom material, natural latex, water, additional required water based performance chemicals, natural plasticizer and pigments or dyes, which are mixed together at the same time.
• the latex is only stabilized with ammonia from the later supplier. No additions of stabilizing and/or vulcanizing agents are required to stabilize the natural rubber in the slurry, and thus no stabilizing or vulcanizing agents need to be added to the slurry.
• a mixer such as an air pressured mixer, is used to mix the slurry until a homogenous solution is reached.
• Other mixers and devices can be used to mix the slurry including, for example a hydraulic mixer, mechanical mixer, agitator, or stirrer.
• This base-coat slurry is then applied to the reinforcement backing material.
• the base-coat slurry may be applied using, for example, a roller coater machine, doctor blade, Foulard system, brushes, or other application devices that spread the coating on the backing material.
• the base-coat slurry may be continuously mixed as it is applied using these systems.
• the base-coat slurry may be continuously mixed as it is added to the roller coater machine.
• mixing devices, stirrers, or agitators may be included in the container with the slurry so as to continuously mix it to keep it as a substantially homogenous solution.
• One or more base-coatings may be applied to the reinforcement backing material to achieve the desired thickness of properties of the reinforcement backing material with the applied bio-based slurry. This coated material may also be pressed or flattened after application of one or more base coatings.
• the pressing or flattening of the base-coated reinforcement backing material is done to level and even the surface while preparing for the next treatment and application of additional coating layers.
• the resultant base-coated reinforcement backing material may be prepared for application of one or more additional, intermediate coating layers.
• the intermediate coating layers may be applied using the same techniques as described above with respect to the base-coatings and may add a thin layer of material.
• the sheets of material comprised of the reinforcement backing and any applied base and intermediate coating layers are prepared for application of final topcoats and additives.
• the formulation of the topcoat solution will vary based on the performance expectations of the final material, such as color requirements and surface structure requirements achieved by embossing.
• the sheet material may be allowed to dry or set.
• the final sheet material may be trimmed or cut to adjust the thickness, size, and shape. For example, the thickness may be adjusted based on different requirements of the products which will be made using the sheet material.
• a splitting machine may be used to take a sheet with an original thickness and split it based on various performance requirements for the final products.
• Figure 1 illustrates an exemplary roller coater system that may be used to apply one or more of the coating layers as described above.
• the roller coater system may include a container 101 for holding the coating slurry 102.
• a nozzle or valve 103 may be included on the slurry container, allowing a controlled amount of slurry to flow from the container.
• the nozzle or valve may be connected to a controllable pump allowing a user to adjust the amount of slurry coating dispensed.
• An application coating roller 104 is provided, which is controllable to rotate at various speeds and to contact a reinforcement backing substrate sheet 107 with an adjustable amount of pressure.
• the valve or nozzle 103 dispenses the slurry coating 102 from the container 101 onto the coating application roller 104 and creates a pocket of slurry coating called a nip 105.
• the nip 105 is picked up by the coating application roller 104.
• One or more scraper blades 106 may be included to remove excess coating from the back of the roller 104 and return it to the nip 105.
• the thickness of the coating the coating application roller 104 applies to the reinforcement backing material sheet 107 depends on the amount of coating released from the nozzle 103, and can further be adjusted based on the distance between the scraper blade 106 and the roller and/or the amount of pressure applied to the roller by the scraper blade.
• a conveyer 108 driven by one or more conveyer drive rollers 109 or other drive mechanisms moves the reinforcement backing material sheet 107 under the coating application roller 104.
• the application coating roller 104 which picks up the nip 105, transfers the nip as a coating layer onto the backing material sheet 107 and compresses it into the sheet as it passes under the coating roller 104.
• the conveyer 108 may move the sheet 107 to an exit or holding area after the coating layer has been applied.
• the reinforcement backing material sheet 107 to be coated may itself be directly transported by conveyer rollers 109 so that it passes underneath the coating roller 104.
• a mixer 110 may be included in the slurry container.
• the sheet 107 may be transitioned into a drying mechanism 111, such as a tunnel oven.
• the sheet is left in the drying mechanism until the water content of the sheet has been reduced to an acceptable amount for further processing.
• the sheet may be left in a tunnel oven at a temperature set within a range of 85°C to 140°C to remove water and start the polymerization process of the latex in the slurry coating. Other drying times and temperatures may be used to remove or reduce the remaining water.
• the treated sheets may be hung to ensure the sheets are sufficiently dry for the next processing steps.
• Figure 2 illustrates another view of a roller coater system that may be used to apply the one or more coating layers.
• the system may include a control panel with touch screen 201, a squeegee blade with linear insertion device 202 configured to dispense and apply the coating, and a working area 203 with a conveyer system.
• the system may further include one or more drive motors 204 configured to operate rollers to move materials placed on the working area 203.
• the system may be mounted on rails 205, such that the position of the working area relative to the coating application system and squeegee can be adjusted.
• Figure 3 illustrates an exemplary doctor blade application system which can be used to apply the one or more coatings and coating slurries as described above.
• a container 301 may be provided that contains the slurry coating 302.
• a valve or nozzle 303 may be included on the container 301, allowing a controlled amount of the slurry coating 302 to be dispensed.
• a mixer 304 may be included in the container 301, in order to maintain a homogeneous consistency of the slurry coating.
• the slurry coating 302 may be dispensed into a coating area onto a conveyer system 305, and a doctor blade 306 may be positioned above the conveyer system 305.
• a reinforcement backing material sheet 307 may be provided on the conveyer system, which transports the reinforcement backing material sheet 307 in a direction such that it passes under the dispensing valve or nozzle 303 and also under the doctor blade 304.
• the doctor blade 304 removes excess dispensed coating from the sheet 307, allowing a desired amount of the coating to be transferred to the sheet 307 and compressed into the sheet.
• the sheet 307 may pass into a heating and drying device 308, such as a tunnel oven. After the coating and drying process, the material may be hung for at least 8 hours to dry the sheet and reduce the moisture content before further processing steps.
• the sheet 307 may be kept stationary, with the doctor blade 304 moved over the sheet to remove excess coating material.
• Figure 4 illustrates a Foulard application system that may also be used to apply the coatings.
• This application system is commonly used for coatings through the use of dip and squeeze technology.
• the backing material 401 is attached on a roll 402 that is mounted on an A-frame 403.
• the backing material 401 is then pulled by a plurality of motor-driven rollers 404, such that it is transported into a container 405 containing a slurry mixture.
• the backing material is then transported out of the container 405 and introduced to a mangle roller system 406, where a specific pressure can be applied onto the fabric backing material now coated with the slurry from the container, and the remaining slurry is squeezed out of the fabric.
• the coated backing material may then be introduced into a drying device 407, such as a tunnel dryer.
• a drying device 407 such as a tunnel dryer.
• the systems described in Figures 1-4 may be used to apply one or more of the coatings onto the reinforcement backing material sheet, including base or intermediate coatings.
• the sheet of material may then be dried and compressed or flattened pressed so that the surface of the sheet is leveled and even for further applications of additional coatings.
• Figure 5 illustrates an example of an embossing machine which may be used to flatten the surface of the reinforcement backing material with the base coat applied. Using this machine, the layers, and in particular the base-coating layer applied to the reinforcement backing material, may be pressed and flattened so they are level and even before a subsequent coating layer is applied.
• the embossing machine may include two plates 501, 502 that can be used to apply a controlled amount of pressure on the backing material sheets.
• the machine may further include inputs to allow a user to adjust the pressure 503, temperature 504, and time 505 of the embossing machine. When in use, a temperature and a pressure value are selected, and the sheet material is inserted into the machine and between the plates.
• the temperature and pressure are then applied for a selected time period with the desired side of the sheet facing up to flatten the base coated reinforcement material and prepare for the intermediate coating step.
• a sheet of reinforcing material with the coated side facing up may be placed between the embossing plates 501 and 502 of Figure 5, and a pressure (kg/cm 2 ) 503 may be applied at a temperature of 80°C to 110°C 504 while the upper embossing plate is moving down on the material for a fixed time.
• Figure 6 illustrates an example of such a reinforcement backing material with a base coat applied after it has been compressed and flattened. As shown in the figure, the coated sheet of material has a smooth, evenly coated, and non-sticky surface.
• Figure 7 illustrates a flow diagram of the procedural steps for creating a bio-based, substantially biodegradable textile product according to the systems and methods described herein.
• the process begins in step 710 with the application of a base coating onto a reinforcement backing material sheet.
• the base coating is applied as a slurry coating, using, for example, one or more of the systems as described with respect to Figures 1-4.
• the base coating may be applied to one or more sides of the backing material.
• the base coated backing material is dried using a drying mechanism, such as a tunnel oven or air dryer.
• a reaction/drying time of at least fifteen minutes may be set with a tunnel dryer system that includes an oven capable of applying a temperature between 85°C to 120°C. Other drying temperatures and drying may be used to reduce the water content to an acceptable amount.
• a sheet or other protective cover may be applied to any conveyer system or on the first coated side such that the first coated side is protected as the second side is coated.
• step 720 the surface of the sheet material with the base coats applied is flattened by using a pressing machine or embossing machine.
• This intermediate flattening process allows for the surface material to be leveled and evened while preparing for the next treatment step at 730.
• the base coated materials may be pressed, such as with an embossing machine applying a temperature and pressure with the desired side facing up.
• step 730 one or more intermediate coatings are then applied. This intermediate coat may be applied as a thin layer on top of the one or more base coatings.
• the formulation of this intermediate coat may be different from the base coat, which can include mushroom and natural rubber materials mixed together in a slurry.
• the intermediate coating may only include the natural rubber material, such as latex, and any color pigments or dyes added thereto to achieve a desired color of the final product. No mushroom materials are included in the intermediate coating layers.
• the color pigments or dyes are for the final color adjustment while the natural rubber, such as latex, adds to the formed natural rubber of the textile sheet and adds additional performance to the material.
• the application of the intermediate coats may be performed in the same manner as the process for applying the base coats as discussed above.
• the thickness of the intermediate coat layer may be, for example, around 12 grams/ft 2 .
• the coated sheets are dried using the drying mechanism, such as a drying tunnel system.
• the drying may be performed at 100°C to 120°Cfor a duration of at least 15 minutes.
• the speed of a conveyer transporting the sheet of material through the drying tunnel may be adjusted such that the sheet is dried in the tunnel oven for at least 15 minutes.
• the coated panels may also be hung to ensure they are sufficiently dry for further processing steps.
• the intermediate coated sheets are then prepared for further processing in step 740.
• Step 740 of Figure 7 is directed to the application of the final coat, also known as the topcoat.
• the formulation of the topcoat is based on the desired performance needs of the final materials.
• the main ingredients and supporting agents of the topcoat include water-based polyurethane (bio-based) and other performance giving water-based substances.
• the application of the final top-coat is applied either by using an industry spray application line with a drying tunnel directly attached thereto, or a roller printing application system and drying system. Test results of the performance of the materials suggest that good results can be achieved with an application of the topcoat with amounts of up to, for example, around 10 grams per square feet.
• the coated sheet may then be trimmed and cut at step 750 to the desired thickness, size, and shape.
• Figure 8 shows an example of the construction of a fully coated reinforcement backing.
• a layer of reinforcement backing material 801 such as non-woven material or woven material, which is coated and penetrated with a first base coat 802 and an intermediate coat 803.
• the base coat 802 may be applied on one or both sides, and the intermediate coat layer may be applied on top of the base coat. When both sides are base coated, the intermediate layer can be selectively applied to one or both of the base coated sides.
• a top coat layer 804 is applied on top of the intermediate layer. When both sides contain an intermediate layer, the top coat may be applied to one or both of the intermediate layered sides.
• the top coat 804 can be applied through a roller coater system or a spray carousel.
• a splitting machine or other cutting device may be used to trim and cut away excess material to make a textile material of desired thickness.
• the final sheet of material may be split into final thicknesses ranging from 0.5 mm to 1.8 mm.
• Figure 9 illustrates an example of a splitting machine for splitting used to adjust the thickness of the material.
• the splitting machine includes a blade 901, such as a band knife.
• Two or more rollers 902 may be used to transport sheet of material 903 such that the blade 901 removes a desired amount to adjust the thickness.
• the height of the blade relative to the sheet of material may be adjusted to adjust the amount trimmed.
• the back side of the material that includes only the reinforcement backing material and some base coating is cut so that layers 801-804 of Figure 8 are maintained upon splitting of the material.
• Other cutting devices such as knives, shears, blades, or scissors may be used to further adjust the size and shape of the trimmed material.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Dispersion Chemistry (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Application Of Or Painting With Fluid Materials (AREA)

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• 2022
  • 2022-12-09 EP EP22903619.9A patent/EP4444951A4/de active Pending
  • 2022-12-09 US US18/078,739 patent/US20230183918A1/en not_active Abandoned
  • 2022-12-09 WO PCT/CN2022/138112 patent/WO2023104202A1/en not_active Ceased

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