WO2023194736A1 - Coated knitted or woven materials of natural plant-based fibres - Google Patents
Coated knitted or woven materials of natural plant-based fibres Download PDFInfo
- Publication number
- WO2023194736A1 WO2023194736A1 PCT/GB2023/050919 GB2023050919W WO2023194736A1 WO 2023194736 A1 WO2023194736 A1 WO 2023194736A1 GB 2023050919 W GB2023050919 W GB 2023050919W WO 2023194736 A1 WO2023194736 A1 WO 2023194736A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibre
- knitted
- coated textile
- textile material
- natural
- Prior art date
Links
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Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
- D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
- D02G1/0206—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting
- D02G1/0266—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting false-twisting machines
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/04—Blended or other yarns or threads containing components made from different materials
-
- 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
- D06N3/0009—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 knitted 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
- D06N3/0086—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
- D06N3/0095—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 inversion technique; by transfer processes
-
- 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
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
- D10B2201/01—Natural vegetable fibres
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
- D10B2201/20—Cellulose-derived artificial fibres
- D10B2201/22—Cellulose-derived artificial fibres made from cellulose solutions
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
- D10B2331/041—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET] derived from hydroxy-carboxylic acids, e.g. lactones
Definitions
- the present invention relates to a novel coated knitted or woven textile material made substantially from natural, plant-based fibres; to uses thereof and to methods of manufacturing such materials.
- the present invention relates to a coated knitted or woven textile material made substantially from natural, plant-based fibres; said material being stretchable.
- the present invention is based on the use of a wide range of natural leaf or stem fibres, including, but not limited to, pineapple leaf fibre (PALF).
- PAF pineapple leaf fibre
- the main sources of pineapple originate from Brazil, Thailand and the Philippines.
- pineapple leaf fibre which is used as a filament or blended with cotton, nylon or similar natural or synthetic based fibres and spun into yarn.
- the yarn produced may be used in the making of woven textiles, etc.
- pineapple leaf fibres used to make the new natural knitted or woven material hereinafter described are a by-product of the pineapple fruit harvest. Currently they are left to decompose after the fruit harvest. Thus, the income of pineapple farmers in Bangladesh, Ivory Coast, the Philippines and elsewhere, would be enhanced by the fibre extraction processes needed in the production of this new natural knitted or woven material hereinafter described.
- the technology, when completed, will be transferable to other regions of the world which are large producers of pineapple.
- a suitable use of pineapple leaf fibre would be economically beneficial to pineapple farmers, it would also provide a material from renewable resources that is otherwise often discarded as waste material.
- the natural material is environmentally advantageous because, inter alia, it does not require additional land, energy and fertiliser for the crop, as is the case for other natural, plant-based fibres such as cotton. Nor does it compete for land resources used in the food industry which contrasts to cotton.
- WO 2011/148136 describes a composite nonwoven material comprising a natural leaf or stem fibre and a polymer material.
- the composite nonwoven material described therein provides a good natural coated textile material.
- the composite nonwoven material will generally have a density of 300g m" 2 or greater and a thickness of about 2.5-3.0 mm.
- the composite nonwoven material is generally inelastic and is not considered to be stretchable.
- the natural knitted or woven material may be suitable for, inter alia, use in automotive industries and the like.
- a stretchable coated textile material comprising a natural knitted or woven material made substantially from plant-based yarns including natural fibres and wherein said natural knitted or woven material is coated with a stretchable polymer material.
- the material comprises a knitted material.
- the material comprises a woven material.
- the present invention relates to coated knitted or woven material made substantially from plant based yarns; said material resembling leather and being stretchable.
- the natural plant-based yarns will generally comprise plant based fibres. More particularly, the plant based yarns comprise natural leaf or stem fibres.
- Leaf fibres generally comprise naturally occurring or cultivated fibres that have a high cellulose content, e.g. about 70% w/w or more.
- the natural, plant-based knitted or woven material used in the present invention may comprise a yarn from a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres.
- the natural knitted or woven material may comprise leaf fibre or a stem fibre and mixtures thereof.
- the natural fibre comprises a leaf fibre.
- the natural material comprises only leaf fibre, it may be based on a single source of leaf, e.g.
- the knitted or woven material used in the present invention may comprise a blend of a natural plant-based fibre and a biobased synthetic fibre.
- Biobased fibres are produced from renewable sources, they are generally biodegradable, compostable and eco-friendly.
- Biobased fibres include, but shall not be limited to, PLA (poly-lactic acid) fibre, chitosan fibre, algae based fibre, bacterial cellulose fibre, collagen fibre, spider silk fibre, milk-weed fibre, milk fibre and bio-wash/enzyme fibre; including combinations thereof.
- a preferred yarn is made from a leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF.
- abaca or sisal Agave sisalana
- Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc.
- stem fibre is included in a composite material of the invention may comprise a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp.
- An especially preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), pineapple.
- Ananas Comosus (Linn)
- pineapple ananas Comosus
- mixtures of leaf and stem fibres for example, fibres that may have a relatively high content of pineapple leaf fibres, may be used in the yarns of this aspect of the invention.
- the yarn comprises a composite material including leaf and stem fibres, preferably a majority of the material comprises a leaf fibre, such as PALF.
- the leaf fibre may comprise at least 20% w/w of the leaf/ stem fibre content, preferably at least 30% w/w of the leaf/ stem fibre content, preferably at least 40% w/w of the leaf/ stem fibre content, preferably at least 50% w/w of the leaf/ stem fibre content, preferably at least 60% w/w of the leaf/ stem fibre content, preferably at least 70% w/w of the leaf/ stem fibre content preferably at least 80% w/w of the leaf/ stem fibre content, preferably at least 90% w/w of leaf/ stem fibre content and especially at least 95% w/w of the leaf/ stem fibre content.
- the leaf fibre is PALF
- the natural fibre element of the knitted or woven material may comprise about 100% w/w leaf fibre, i.e. no stem fibre is present.
- the leaf or stem fibre is delignified prior to use using conventional delignification methods known in the art or other delignification methods described herein.
- pineapple cultivars may be used in the materials or processes of the present invention.
- the pineapple, Ananas comosus has several cultivars and other subspecies taxa. Here they are pomologicaly (by fruit characteristics) sorted into three groups:
- Spanish group - is a group which can be recognized by white flesh and leaves with spines on the edge o Red Spanish o Singapur Spanish o Sugar Loaf
- Queen group they can be recognized by yellow and/or golden yellow flesh and leaves with spines on the border o Abacachi o Cabazoni o Pernambuca o Queen o Victoria
- Cayenne group - can by recognized by yellow flesh and leaves without spines on the borders o Baronne Rothschild o Cayenne
- the knitted or woven material may comprise a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres.
- a preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Lirm), e.g. PALF.
- abaca or sisal Agave sisalana
- Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc.
- stem fibre When a stem fibre is included in the PALF composite, a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp.
- the knitted or woven material will generally comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre or other natural cellulosic derived fibres.
- the percentage of natural leaf or stem fibre is based on the weight of the uncoated knitted or woven material.
- the knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres.
- the remainder of the knitted or woven material will comprise a biobased fibre, which shall include, but shall not be limited to, PLA (poly-lactic acid) fibre; or a semi-synthetic fibre, such as, viscose, lyocell, tencel, recycled cotton, etc.
- a biobased fibre which shall include, but shall not be limited to, PLA (poly-lactic acid) fibre; or a semi-synthetic fibre, such as, viscose, lyocell, tencel, recycled cotton, etc.
- PLA poly-lactic acid
- semi-synthetic fibre such as, viscose, lyocell, tencel, recycled cotton, etc.
- the semi-synthetic fibre such as, viscose, lyocell, tencel, recycled cotton, etc. may be present in the yarn itself and/or in the knitted or woven material.
- the semi-synthetic fibre may be tencel.
- a yarn comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi-synthetic fibre.
- a knitted or woven material comprising such a yarn, i.e. comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi-synthetic fibre.
- the knitted or woven material may comprise a blend of yarns.
- the knitted or woven material may be produced using conventional knitting methods known per se.
- the knitted or woven material may be produced by employing a continuous yarn or set of yarns to form a series of interlocking loops. Knitted fabrics can generally be stretched to a greater degree than woven fabrics.
- the knitted material may be produced as a weft knit (also known as a filling knit) or warp knit, or any combination thereof.
- a warp knit is usually closer, flatter, and less elastic than a filling knit. They are made on a chain loom, with each warp controlled by a separate needle. The loops interlock along the length of the fabric.
- the material of the invention comprises a knitted material it may optionally comprise a 3D knitted material.
- the polymer coating comprises a stretchable polymer coating.
- the amount of polymer coated onto the natural knitted or woven material may vary, but will generally be from about 1 to 40% w/w of a polymer, based on the weight of the total composite coated material; or from about 1 to 20% w/w of a polymer.
- the amount of polymer may be from about 1 to 40% w/w, or from about 2 to 40% w/w, or from about 3 to 40% w/w, or from about 4 to 40% w/w, or from about 5 to 40% w/w, or from about 5 to 20% w/w, from about 5 to 20% w/w; based on the weight of the total composite coated material.
- the polymer coating comprises a fusible polymer.
- the fusible polymer may be applied at a temperature of about 180°C or less, preferably about 170°C or less, preferably about 160°C or less, preferably about 150°C or less, preferably about 140°C or less, preferably about 130°C or less, preferably about 120°C or less, preferably about 110°C or less, preferably about 100°C or less, more preferably about 90°C, more preferably about 80°C or less, more preferably about 60°C or less.
- the polymer may be applied at a temperature of from about 50 to 120°C, preferably from about 60 to 110°C, preferably from about 60 to 110°C, preferably from about 70 to 100°C, more preferably from about 70 to 80°C.
- the application of the polymer can be conducted at room temperature, but then is cured at a higher temperature.
- the stretchable polymer material may comprise a curable material, such as a resin.
- the curable material may be cured by any conventional means, thus, it may be temperature curable, e.g. heat curable; light curable, e.g. UV curable; chemically curable; etc.
- a suitable curable material may comprise a resin, such as an olephinic resin, e.g. a polyurethane (PU).
- PU polyurethane
- Any polyurethane conventionally used in textiles may be used, including hydrophilic polyurethanes.
- a polyurethane derived from renewable resources may be preferred. It will be understood that a variety of renewable polyurethanes may be used.
- polyurethanes include, but shall not be limited to, polyurethanes derived from corn sugars, vegetable oils, including safflower, sunflower, soybean and castor oils, etc. Mixtures of polyurethanes may also be used, including mixtures of conventional (fossil fuel derived) polyurethanes and renewable polyurethanes.
- the curable polymer material may comprise a pigmented curable resin.
- a pigmented curable resin may comprise a resin as herein described, including a colour pigment.
- the pigment may be applied in a different curable material. The choice of such pigments will be well understood by the person skilled in the art and will comprise conventional pigments.
- the pigmented curable resin may be applied as a coating to the knitted or woven material, such that the coated knitted or woven material is provided with a colour finishing.
- Such fusible polymers may comprise a synthetic polymer or, preferably, a natural, e.g. biodegradable polymer.
- Such polymers include, but shall not be limited to, acrylonitrile butadiene styrene (ABS); acrylic (PMMA); polyetheretherketone; cellulose acetate; cyclic olefin copolymer (COC); ethylene vinyl acetate (EVA); ethylene vinyl alcohol (EVOH); fluoroplastics, such as, PTFE, FEP, PF A, CTFE, ECTFE and ETFE; ionomers; acrylic/PVC alloy; liquid crystal polymer (LCP); polyoxymethylene (POM or acetal); polyacrylates (Acrylic); polyacrylonitrile (PAN or acrylonitrile); polyamide (PA or Nylon); polyamide-imide (PAI); polyaryletherketone (PAE)
- Hydrophilic polymers include, but shall not be limited to, one or more resins, such as one or more polyurethanes, e.g. polyurethanes derived from renewable resources, etc. or one or more biopolymers, such as polylactic acid (PL A), poly-3 -hydroxybutyrate, etc.
- resins such as one or more polyurethanes, e.g. polyurethanes derived from renewable resources, etc.
- biopolymers such as polylactic acid (PL A), poly-3 -hydroxybutyrate, etc.
- the amount of stretch in the stretchable coated textile material of the invention may generally be measured a Stretch Percentage.
- a knitted or woven material that measure Im at rest and stretches to 1.5m is said to have a Stretch Percentage of about 100%.
- the stretchable coated textile material of the present invention may have a Stretch Percentage of from about 1% to about 100%; or from about 2% to about 100%; or from about 3% to about 100%; or from about 4% to about 100%; or from about 5% to about 100%; or from about 10% to about 100%; or from about 10% to about 50%; or from about 10% to about 40%; or from about 10% to about 30%; or from about 20% to about 30%; e.g. 25%.
- the tensile strength of the stretchable coated textile material may vary depending, inter alia, upon the source of the leaf fibre, the method of delignifying, etc.
- Pineapple leaf fibre is especially suitable since it produces fibres or yarns which are, inter alia, fine, e.g. they may have a denier or linear density of from about 10 to 20 tex; or from about 14 to 18 tex; or from about 15 to 17 tex, e g. 16 tex.
- a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows no cracking after >100,000 flexes dry (determined by BS EN ISO 17694:2016). This compares with about 60,000 cycles to cracking which is exhibited in the nonwoven product described in International Patent application No. WO 2011/148136.
- a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows no or little abrasion or very slight - modification of brightness after >51,200 revolutions (determined by BS EN ISO 12947-2:2016 or BS EN 5470- 2:2003).
- a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a tear (BS EN ISO 4674-1:2016 Method B) strength of >31 N (Direction I) and/or >46 N (Direction II).
- a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a tensile strength (BS EN ISO 1421 :2016 Method 1 - Strip) (load at break) of >84 N (Direction I) and/or >65 N (Direction II)
- a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows an elongation at break of >200% (Direction I) and/or >77.0 % (Direction II).
- a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a maximum load of >228.0 N (Direction I) and/or >435 N (Direction II).
- a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows an elongation at maximum load of >194% (Direction I) and/or >67.9% (Direction II). This compares with an elongation of about 25% which is exhibited in the nonwoven product described in International Patent application No. WO 2011/148136.
- the Fabric Weight of the knitted or woven material may vary. The Fabric Weight may be measured in grams per square metre or g/m 2 (also abbreviated as GSM).
- the Fabric Weight of the knitted or woven material may be from about 10 to about 1,000 g/m 2 ; or from about 20 to about 1,000 g/m 2 ; or from about 30 to about 1,000 g/m 2 ; or from about 40 to about 1,000 g/m 2 ; or from about 50 to about 1,000 g/m 2 ; or from about 50 to about 500 g/m 2 ; or from about 50 to about 400 g/m 2 ; or from about 50 to about 300 g/m 2 ; or from about 50 to about 200 g/m 2 ; or from about 100 to about 200 g/m 2 .
- a method of making a stretchable coated textile material as herein described comprising: a) knitting or weaving a plurality of natural PALF yarns, to form a natural knitted or woven material including natural fibres; b) applying a fusible polymer material to the natural knitted or woven material.
- the method according to this aspect of the invention may comprise the use of PALF yarns or a mixture of PALF yarns and other natural plant-based yarns.
- the method of the inventions comprises the use of a comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi- synthetic fibre; or a combination thereof.
- the aforementioned method produces the stretchable coated textile material of the invention.
- the material comprises a knitted material.
- the material comprises a woven material.
- the stretchable coated textile material may be produced by following steps a) and b) followed by curing the curable material.
- curing is meant any method conventionally known to the person skilled for causing a material to set.
- curing may refer to thermally, e.g. heating, a material, for example, heating a resin at a temperature above the fusing temperature of the resin, visible or non-visible light setting, e.g. UV curing, etc.
- the manufacture of the natural knitted or woven material according to the present invention desirably utilises leaf and/or stem fibres that have been delignified or partially delignified.
- Chemical processes of delignifying are known in the art. Chemical products have been used for the conventional delignifying process of PALF. More precisely, conventional delignifying has been made using sodium hydroxide (NaOH) or hydrolysis of small sugars.
- the step of delignifying comprises enzyme delignifying.
- various enzymes types may be used, such as a biopectinase (a complex of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase), a pectinase, a hemicellulose, a lactase, a perolase and a cellulase.
- a biopectinase a complex of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase
- pectinase a complex of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase
- pectinase a complex of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase
- pectinase a complex
- Pectinase, hemicellulase and cellulase enzymes can dissolve pectin, hemicelluloses and cellulose materials, respectively.
- Cellulase enzyme is well known for the polishing of fibrils in the surface of cotton fabrics.
- cellulase is not commonly used for fibres treatment has it can degrade fibres and reduce its resistance.
- cellulase may be used in low quantity as an additive to the enzymatic process.
- a preferred group of enzymes which may be mentioned are consisting of polygalacturonase, pectinesterase, pectinic lyase, hemicellulase, hypozyme lactase or perolase; and mixtures thereof. Specific mixtures which may be mentioned include a mixture of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase (Biopectinase), a mixture of polygalacturonase and a mixture of hypozyme lactase and perolase.
- a preferred enzyme is a mixture of polygalacturonase and hemicellulase.
- a further preferred enzyme is a mixture of hypozyme lactase and perolase.
- the mixture may comprise from 1% to 10% w/w polygalacturonase and from 05% to 2% w/w hemicellulase, e.g. a mixture of 5% polygalacturonase and 1% hemicellulase.
- the amount of enzymes may vary depending upon, inter alia, the nature of the leaf and/or stem fibre being delignified.
- the use of the knitted or woven PALF material in the manufacture of the stretchable coated textile material is novel per se.
- a knitted or woven PALF material made substantially from PALF natural plant-based yarns including natural fibres in the manufacture of a stretchable coated textile material as herein described is novel per se.
- the knitted or woven PALF material will generally comprise yarns comprising from 5 to about 30% w/w natural leaf or stem fibre, the remainder comprising a biobased fibre or a semi- synthetic fibre as herein described.
- the percentage of natural leaf or stem fibre is based on the weight of the knitted or woven material.
- the yarn or the knitted or woven PALF material may comprise yarns comprising from 5 to about 30% w/w natural leaf or stem fibre; or from about 5 to about 25% w/w natural leaf or stem fibre; or from about 10 to about 25% w/w natural leaf or stem fibre; or from about 10 to about 20% w/w natural leaf or stem fibre; or from about 10 to about 15% w/w natural leaf or stem fibre.
- the knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre.
- the amount of biobased fibre or a semi-synthetic fibre such as, viscose, lyocell, tencel, recycled cotton, etc., may be from about 70 to about 95% w/w of the yarn or the knitted or woven material.
- a preferred yarn is made from a leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF.
- fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF.
- Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc.
- stem fibre is included in a composite material of the invention may comprise a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp; and other cellulose derived fibres, such as, grass(es) bamboo, straw and cotton.
- a leaf fibre for example, a leaf fibre that comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), pineapple.
- a leaf fibre that comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), pineapple.
- mixtures of leaf and stem fibres for example, fibres that may have a relatively high content of pineapple leaf fibres, may be used in the yarns of this aspect of the invention.
- the yarn comprises a composite material including leaf and stem fibres, preferably a majority of the material comprises a leaf fibre, such as PALF.
- the leaf fibre may comprise at least 50% w/w of the leaf stem fibre content, preferably at least 60% w/w of the leaf/ stem fibre content, preferably at least 70% w/w of the leaf/ stem fibre content preferably at least 80% w/w of the leaf/ stem fibre content, preferably at least 90% w/w of leaf/ stem fibre content and especially at least 95% w/w of the leaf/ stem fibre content.
- a major part of the leaf fibre is PALF.
- the leaf fibre content is PALF, preferably at least 60% w/w of the leaf fibre content is PALF, preferably at least 87% w/w of the leaf fibre content is PALF, preferably at least 80%w/w of the leaf fibre content is PALF, preferably at least 90% w/w of the leaf fibre content is PALF and especially at least 95% w/w of the leaf fibre content is PALF.
- the yarn or knitted or woven material may comprise about 80% w/w leaf fibre.
- the leaf or stem fibre is delignified prior to use using conventional delignifying methods known in the art or other delignifying methods described herein.
- the knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre.
- the remainder of the knitted or woven material will comprise a biobased fibre, such as, PLA (poly-lactic acid) fibre, or a semi-synthetic fibre, such as, such as, viscose, lyocell, tencel, recycled cotton, etc..
- the amount of biobased fibre or semisynthetic fibre may be from 70 to about 95% w/w of the yarn or knitted or woven material.
- the knitted or woven material may comprise a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres.
- a preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF.
- abaca or sisal Agave sisalana
- Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc.
- stem fibre When a stem fibre is included in the PALF composite, a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp.
- the knitted or woven material will generally comprise a natural knitted or woven fibre, wherein the knitted or woven fibre material will comprise from about 5 to about 30% w/w natural leaf or stem fibre.
- the percentage of natural leaf or stem fibre is based on the weight of the uncoated knitted or woven material.
- Figure 1 illustrates yarns of different sizes; all with composition of 30% PALF, 70% TENCELTM lyocell;
- Figure 2 illustrates a sample of plain jersey knitted fabric, using a yarn of figure 1;
- Figures 3 and 4 illustrate the finished coated knitted fabric of figure 2.
- the PALF pineapple leaf fibre
- the PALF fibres were then mixed and blended with other cellulose based fibres (e.g. lyocell). Both types of fibres are taken through an opener and carding machine where the fibres are weighed to the correct percentage ratio (e.g. 30% w/w PALF 70% w/w Lyocell). The fibres were then taken through a cottonised carding process and through a draw frame before being spun.
- the sliver was taken through the first spinning stage where the yarn twist and spinning speed was controlled, this establishes the yarn characteristics (e.g. strength, size, hairiness, elongation).
- the yarn was spun with a technology, (e.g. ring spinning) giving the yarn the final outcome. Once the spinning was complete the yarn was wound onto a cone ready for shipment.
- the yarn was distributed onto the amount of cones needed for the specific machine for the knitting manufacturing.
- the construction was chosen and the gauge of machine and needle alignment is chosen accordingly.
- the machine gauge was highly dependent on the yarn size (e.g. Ne20/2 will use a machine gauge of approx. 10 - 14 depending on the desired weight and handle).
- the fabric was inspected once produced, removed from the knitting machine and moved to the finishing facility, where it was washed and stented. In some cases the fabric underwent an enzymatic wash or special finishing (e.g. a hydrophilic wash). Once the fabric has been finished it was dried and then assessed for chemical and physical performance characteristics.
- PALF is the base component of the material, the PALF was extracted from the leaves by a semi-automatic mechanical process, then washed with water and dried under the sun, that acts as a natural bleaching agent.
- the fibres were then processed to achieve textile grade.
- the textile grade fibres were then blended with Tencel in a 30:70 w/w ratio of PALF: Tencel, and consequently spun in to an Nel6/1 yarn in a dry process.
- the yarn was able to be knitted into a jersey construction that provides the necessary elastic property.
- the fabric was then stabilised by washing to get a consistent knitted fabric substrate.
- a transfer paper coated with a finishing resin composition was used to transfer the coating polymer resin onto the surface of the knitted fabric substrate using a calendaring machine, with a thick blade to apply the composition. The paper was not removed at this stage. The coating polymer resin composition adhered to the knitted fabric.
- Antifoaming agent e.g. BG-Print ASF - BGH, 0.3-1% w/w
- Thickener e.g. Cresaclear TE 1-2% w/w
- auxiliary chemicals e g. cross linker, extra finishes, thickener, pigment, metallic powder, etc. 0-7% w/w
- the resulting coated fabric was then dried and cured in a press under heat and pressure (with the transfer paper in situ) at a temperature of 90°C to 150°C, and a pressure: of lkg/cm 2 to 4kg/cm 2 , for 1 to 30 seconds, e.g. 120°C at 1.5kg/cm 2 to 2kg/cm 2 for 10 seconds or 150°C for 60 seconds.
- the flex resistance of the stretchable coated textile material was determined using the test method of ISO 17694:2016.
- ISO 17694:2016 specifies a test method for determining the flex resistance for footwear, e.g. uppers and linings, irrespective of the material in order to assess the suitability for the end use.
- the abrasion resistance of the stretchable coated textile material was determined using the test method of BS EN ISO 12947-2:2016.
- BS EN ISO 12947-2:2016 specifies the procedure for the determination of specimen breakdown (end-point of test) by inspection at fixed intervals and is applicable to all textile fabrics (uncoated) including nonwovens apart from fabrics where the specifier indicates the end performance as having a low abrasion wear life.
- the results of the abrasion resistance test are shown in Table 1.
- BS EN 5470-2:2003 specifies the procedure for the determination of resistance of a material to wet and dry abrasion of a coated material.
- the tear strength of the stretchable coated textile material was determined using the test method of BS EN ISO 4674-1:2016 Method B.
- BS EN ISO 4674-1 :2016 specifies two methods for determining the forces necessary to initiate and propagate tearing of a coated fabric using the constant rate of tear method. The methods described are the following:
- the Tensile strength and elongation of the stretchable coated textile material was determined using the test method of BS EN ISO 1421:2016 Method 1 - Strip.
- BS EN ISO 1421:2016 Method 1 - Strip.
- ISO 1421 :2016 specifies two methods for the determination of the tensile strength of fabrics coated with rubber or plastics.
- Method 1 the strip test method, which is a method for the determination of tensile strength and elongation at break.
- - Method 2 the grab test method, which is a method for the determination of tensile strength only.
- the methods apply to test pieces in equilibrium with specific standard atmospheres for testing and to wet test pieces. Both methods require the use of a constant rate of extension (CRE) tensile-testing machine.
- CRE constant rate of extension
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Abstract
There is described a stretchable coated textile material comprising a natural knitted or woven material made substantially from plant-based yarns including natural fibres; and wherein said natural knitted or woven material is coated with a stretchable polymer material; methods of manufacturing and uses thereof.
Description
Coated Knitted or Woven Materials of Natural Plant-Based Fibres
Field of the Invention
The present invention relates to a novel coated knitted or woven textile material made substantially from natural, plant-based fibres; to uses thereof and to methods of manufacturing such materials.
More particularly, the present invention relates to a coated knitted or woven textile material made substantially from natural, plant-based fibres; said material being stretchable.
Background to the Invention
The present invention is based on the use of a wide range of natural leaf or stem fibres, including, but not limited to, pineapple leaf fibre (PALF).
The main sources of pineapple originate from Brazil, Thailand and the Philippines.
In Brazil, Thailand, the Philippines and elsewhere, when the pineapple fruit is harvested, the pineapple leaves are mostly left to rot. Hitherto, a small amount has been used to extract pineapple leaf fibre, which is used as a filament or blended with cotton, nylon or similar natural or synthetic based fibres and spun into yarn. The yarn produced may be used in the making of woven textiles, etc.
In 2008 the top 20 pineapple producing countries produced more than 17 million MT of pineapple as is illustrated in Table I:
The pineapple leaf fibres used to make the new natural knitted or woven material hereinafter described are a by-product of the pineapple fruit harvest. Currently they are left to decompose after the fruit harvest. Thus, the income of pineapple farmers in Bangladesh, Ivory Coast, the Philippines and elsewhere, would be enhanced by the fibre extraction processes needed in the production of this new natural knitted or woven material hereinafter described. The technology, when completed, will be transferable to other regions of the world which are large producers of pineapple. A suitable use of pineapple leaf fibre would be economically beneficial to pineapple
farmers, it would also provide a material from renewable resources that is otherwise often discarded as waste material.
The natural material is environmentally advantageous because, inter alia, it does not require additional land, energy and fertiliser for the crop, as is the case for other natural, plant-based fibres such as cotton. Nor does it compete for land resources used in the food industry which contrasts to cotton.
International Patent application No. WO 2011/148136 describes a composite nonwoven material comprising a natural leaf or stem fibre and a polymer material. The composite nonwoven material described therein provides a good natural coated textile material. However, the composite nonwoven material will generally have a density of 300g m"2 or greater and a thickness of about 2.5-3.0 mm. Furthermore, the composite nonwoven material is generally inelastic and is not considered to be stretchable.
Thus, there is a need for a more stretchable coated textile material that is generally biodegradable. Furthermore, the natural knitted or woven material may be suitable for, inter alia, use in automotive industries and the like.
Summary of the Invention
Thus, according to a first aspect of the present invention, there is provided a stretchable coated textile material comprising a natural knitted or woven material
made substantially from plant-based yarns including natural fibres and wherein said natural knitted or woven material is coated with a stretchable polymer material.
According to one aspect of the invention the material comprises a knitted material.
According to another aspect of the invention the material comprises a woven material.
More particularly, the present invention relates to coated knitted or woven material made substantially from plant based yarns; said material resembling leather and being stretchable.
The natural plant-based yarns will generally comprise plant based fibres. More particularly, the plant based yarns comprise natural leaf or stem fibres. Leaf fibres generally comprise naturally occurring or cultivated fibres that have a high cellulose content, e.g. about 70% w/w or more. The natural, plant-based knitted or woven material used in the present invention may comprise a yarn from a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres. The natural knitted or woven material may comprise leaf fibre or a stem fibre and mixtures thereof. Preferably, the natural fibre comprises a leaf fibre. When the natural material comprises only leaf fibre, it may be based on a single source of leaf, e.g. PALF, or a mixture of leaves. The knitted or woven material used in the present invention may comprise a blend of a natural plant-based fibre and a biobased synthetic fibre. Biobased fibres are produced from renewable sources, they are generally biodegradable, compostable and eco-friendly. Biobased fibres include, but shall not be limited to, PLA (poly-lactic acid) fibre, chitosan fibre,
algae based fibre, bacterial cellulose fibre, collagen fibre, spider silk fibre, milk-weed fibre, milk fibre and bio-wash/enzyme fibre; including combinations thereof.
A preferred yarn is made from a leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF. Alternatively, fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF. Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc. When a stem fibre is included in a composite material of the invention may comprise a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp. An especially preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), pineapple. However, it will be understood by the person skilled in the art that mixtures of leaf and stem fibres, for example, fibres that may have a relatively high content of pineapple leaf fibres, may be used in the yarns of this aspect of the invention. When the yarn comprises a composite material including leaf and stem fibres, preferably a majority of the material comprises a leaf fibre, such as PALF. Thus, in the yarn used in the knitted or woven material of the invention the leaf fibre may comprise at least 20% w/w of the leaf/ stem fibre content, preferably at least 30% w/w of the leaf/ stem fibre content, preferably at least 40% w/w of the leaf/ stem fibre content, preferably at least 50% w/w of the leaf/ stem fibre content, preferably at least 60% w/w of the leaf/ stem fibre content, preferably at least 70% w/w of the leaf/ stem fibre content preferably at least 80% w/w of the leaf/ stem fibre content, preferably at least 90% w/w of leaf/ stem fibre content and especially at least 95% w/w of the leaf/ stem fibre content. When a mixture of leaf fibres is used it is desirable that a major part of the leaf fibre is PALF.
Thus, at least 50% w/w of the leaf fibre content is PALF, preferably at least 60% w/w of the leaf fibre content is PALF, preferably at least 70% w/w of the leaf fibre content is PALF, preferably at least 80% w/w of the leaf fibre content is PALF, preferably at least 90% w/w of the leaf fibre content is PALF and especially at least 95% w/w of the leaf fibre content is PALF. In one aspect of the present invention when the leaf fibre is PALF, the natural fibre element of the knitted or woven material may comprise about 100% w/w leaf fibre, i.e. no stem fibre is present. Preferably the leaf or stem fibre is delignified prior to use using conventional delignification methods known in the art or other delignification methods described herein.
It will be understood by the person skilled in the art that any of the known pineapple cultivars may be used in the materials or processes of the present invention. The pineapple, Ananas comosus, has several cultivars and other subspecies taxa. Here they are pomologicaly (by fruit characteristics) sorted into three groups:
• Spanish group - is a group which can be recognized by white flesh and leaves with spines on the edge o Red Spanish o Singapur Spanish o Sugar Loaf
• Queen group - they can be recognized by yellow and/or golden yellow flesh and leaves with spines on the border o Abacachi o Cabazoni o Pernambuca o Queen
o Victoria
Cayenne group - can by recognized by yellow flesh and leaves without spines on the borders o Baronne Rothschild o Cayenne
■ Hilo o Monte Lirio
The knitted or woven material may comprise a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres.
A preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Lirm), e.g. PALF. Alternatively, fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF. Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc.
When a stem fibre is included in the PALF composite, a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp.
The knitted or woven material will generally comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre or other natural cellulosic derived fibres. For the avoidance of doubt, the percentage of natural leaf or stem fibre is based on the weight
of the uncoated knitted or woven material. The knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres. The remainder of the knitted or woven material will comprise a biobased fibre, which shall include, but shall not be limited to, PLA (poly-lactic acid) fibre; or a semi-synthetic fibre, such as, viscose, lyocell, tencel, recycled cotton, etc. Thus, the amount of biobased fibre or a semi- synthetic fibre may be from about 70 to about 95% w/w of the knitted or woven yarn material. It should be understood that the semi-synthetic fibre, such as, viscose, lyocell, tencel, recycled cotton, etc. may be present in the yarn itself and/or in the knitted or woven material. In a particular aspect of the invention the semi-synthetic fibre may be tencel.
Thus, according to one aspect of the invention there is provided a yarn comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi-synthetic fibre.
According to another aspect of the invention there is provided a knitted or woven material comprising such a yarn, i.e. comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi-synthetic fibre.
It is within the scope of the present invention for the knitted or woven material to comprise a blend of yarns.
The knitted or woven material may be produced using conventional knitting methods known per se. Thus, the knitted or woven material may be produced by employing a continuous yarn or set of yarns to form a series of interlocking loops. Knitted fabrics can generally be stretched to a greater degree than woven fabrics. It will be understood that the knitted material may be produced as a weft knit (also known as a filling knit) or warp knit, or any combination thereof. A warp knit is usually closer, flatter, and less elastic than a filling knit. They are made on a chain loom, with each warp controlled by a separate needle. The loops interlock along the length of the fabric. When the material of the invention comprises a knitted material it may optionally comprise a 3D knitted material.
The polymer coating comprises a stretchable polymer coating. The amount of polymer coated onto the natural knitted or woven material may vary, but will generally be from about 1 to 40% w/w of a polymer, based on the weight of the total composite coated material; or from about 1 to 20% w/w of a polymer.
The amount of polymer may be from about 1 to 40% w/w, or from about 2 to 40% w/w, or from about 3 to 40% w/w, or from about 4 to 40% w/w, or from about 5 to 40% w/w, or from about 5 to 20% w/w, from about 5 to 20% w/w; based on the weight of the total composite coated material.
The polymer coating comprises a fusible polymer. The fusible polymer may be applied at a temperature of about 180°C or less, preferably about 170°C or less, preferably about 160°C or less, preferably about 150°C or less, preferably about 140°C or less, preferably about 130°C or less, preferably about 120°C or less,
preferably about 110°C or less, preferably about 100°C or less, more preferably about 90°C, more preferably about 80°C or less, more preferably about 60°C or less. Thus, the polymer may be applied at a temperature of from about 50 to 120°C, preferably from about 60 to 110°C, preferably from about 60 to 110°C, preferably from about 70 to 100°C, more preferably from about 70 to 80°C. The application of the polymer can be conducted at room temperature, but then is cured at a higher temperature.
The stretchable polymer material may comprise a curable material, such as a resin. The curable material may be cured by any conventional means, thus, it may be temperature curable, e.g. heat curable; light curable, e.g. UV curable; chemically curable; etc. Thus, a suitable curable material may comprise a resin, such as an olephinic resin, e.g. a polyurethane (PU). Any polyurethane conventionally used in textiles may be used, including hydrophilic polyurethanes. However, in one aspect of the invention a polyurethane derived from renewable resources may be preferred. It will be understood that a variety of renewable polyurethanes may be used. Such polyurethanes include, but shall not be limited to, polyurethanes derived from corn sugars, vegetable oils, including safflower, sunflower, soybean and castor oils, etc. Mixtures of polyurethanes may also be used, including mixtures of conventional (fossil fuel derived) polyurethanes and renewable polyurethanes.
In a further aspect of the invention the curable polymer material may comprise a pigmented curable resin. Thus, for example, a pigmented curable resin may comprise a resin as herein described, including a colour pigment. Alternatively, the pigment may be applied in a different curable material.
The choice of such pigments will be well understood by the person skilled in the art and will comprise conventional pigments.
The pigmented curable resin may be applied as a coating to the knitted or woven material, such that the coated knitted or woven material is provided with a colour finishing.
A variety of fusible polymers known to the person skilled in the art may be used in the coating of the material of the present invention. Such polymers may comprise a synthetic polymer or, preferably, a natural, e.g. biodegradable polymer. Such polymers include, but shall not be limited to, acrylonitrile butadiene styrene (ABS); acrylic (PMMA); polyetheretherketone; cellulose acetate; cyclic olefin copolymer (COC); ethylene vinyl acetate (EVA); ethylene vinyl alcohol (EVOH); fluoroplastics, such as, PTFE, FEP, PF A, CTFE, ECTFE and ETFE; ionomers; acrylic/PVC alloy; liquid crystal polymer (LCP); polyoxymethylene (POM or acetal); polyacrylates (Acrylic); polyacrylonitrile (PAN or acrylonitrile); polyamide (PA or Nylon); polyamide-imide (PAI); polyaryletherketone (PAEK or Ketone); polybutadiene (PBD); polybutylene (PB); polybutylene terephthalate (PBT); polycaprolactone (PCL); polychlorotrifluoroethylene (PCTFE); polyethylene terephthalate (PET); polycyclohexylene dimethylene terephthalate (PCT); polycarbonate (PC); polyhydroxyalkanoates (PHAs); polyketone (PK); polyester; polyethylene (PE); polyetheretherketone (PEEK); polyetherketoneketone (PEKK); polyetherimide (PEI); chlorinated polyethylene (CPE); polyimide (PI); polylactic acid (PLA); polymethylpentene (PMP); polyphenylene oxide (PPO); polyphenylene sulphide (PPS); polyphthalamide (PPA); polypropylene (PP); polystyrene (PS); polysulphone
(PSU); polytrimethylene terephthalate (PTT); polyurethane (PU); polyvinyl acetate (PVA); polyvinyl chloride (PVC); polyvinylidene chloride (PVDC); and styreneacrylonitrile (SAN); etc. Desirably the polymer is hydrophilic.
Hydrophilic polymers include, but shall not be limited to, one or more resins, such as one or more polyurethanes, e.g. polyurethanes derived from renewable resources, etc. or one or more biopolymers, such as polylactic acid (PL A), poly-3 -hydroxybutyrate, etc.
The amount of stretch in the stretchable coated textile material of the invention may generally be measured a Stretch Percentage. For example, a knitted or woven material that measure Im at rest and stretches to 1.5m is said to have a Stretch Percentage of about 100%.
Thus, the stretchable coated textile material of the present invention may have a Stretch Percentage of from about 1% to about 100%; or from about 2% to about 100%; or from about 3% to about 100%; or from about 4% to about 100%; or from about 5% to about 100%; or from about 10% to about 100%; or from about 10% to about 50%; or from about 10% to about 40%; or from about 10% to about 30%; or from about 20% to about 30%; e.g. 25%.
The tensile strength of the stretchable coated textile material may vary depending, inter alia, upon the source of the leaf fibre, the method of delignifying, etc. Pineapple leaf fibre is especially suitable since it produces fibres or yarns which are, inter alia,
fine, e.g. they may have a denier or linear density of from about 10 to 20 tex; or from about 14 to 18 tex; or from about 15 to 17 tex, e g. 16 tex.
According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows no cracking after >100,000 flexes dry (determined by BS EN ISO 17694:2016). This compares with about 60,000 cycles to cracking which is exhibited in the nonwoven product described in International Patent application No. WO 2011/148136.
According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows no or little abrasion or very slight - modification of brightness after >51,200 revolutions (determined by BS EN ISO 12947-2:2016 or BS EN 5470- 2:2003).
According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a tear (BS EN ISO 4674-1:2016 Method B) strength of >31 N (Direction I) and/or >46 N (Direction II).
According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a tensile strength (BS EN ISO 1421 :2016 Method 1 - Strip) (load at break) of >84 N (Direction I) and/or >65 N (Direction II)
According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows an elongation at break of >200% (Direction I) and/or >77.0 % (Direction II).
According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a maximum load of >228.0 N (Direction I) and/or >435 N (Direction II).
According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows an elongation at maximum load of >194% (Direction I) and/or >67.9% (Direction II). This compares with an elongation of about 25% which is exhibited in the nonwoven product described in International Patent application No. WO 2011/148136.
The Fabric Weight of the knitted or woven material may vary. The Fabric Weight may be measured in grams per square metre or g/m2 (also abbreviated as GSM). The Fabric Weight of the knitted or woven material may be from about 10 to about 1,000 g/m2; or from about 20 to about 1,000 g/m2; or from about 30 to about 1,000 g/m2; or from about 40 to about 1,000 g/m2; or from about 50 to about 1,000 g/m2; or from about 50 to about 500 g/m2; or from about 50 to about 400 g/m2; or from about 50 to about 300 g/m2; or from about 50 to about 200 g/m2; or from about 100 to about 200 g/m2.
According to a further aspect of the invention there is provided a method of making a stretchable coated textile material as herein described; said method comprising: a) knitting or weaving a plurality of natural PALF yarns, to form a natural knitted or woven material including natural fibres; b) applying a fusible polymer material to the natural knitted or woven material.
The method according to this aspect of the invention may comprise the use of PALF yarns or a mixture of PALF yarns and other natural plant-based yarns. In particular, the method of the inventions comprises the use of a comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi- synthetic fibre; or a combination thereof.
The aforementioned method produces the stretchable coated textile material of the invention.
According to one aspect of the invention the material comprises a knitted material.
According to another aspect of the invention the material comprises a woven material.
The stretchable coated textile material may be produced by following steps a) and b) followed by curing the curable material.
By the term “curing” is meant any method conventionally known to the person skilled for causing a material to set. Thus, the term curing may refer to thermally, e.g. heating, a material, for example, heating a resin at a temperature above the fusing temperature of the resin, visible or non-visible light setting, e.g. UV curing, etc.
As herein described, the manufacture of the natural knitted or woven material according to the present invention desirably utilises leaf and/or stem fibres that have been delignified or partially delignified. Chemical processes of delignifying are known in the art. Chemical products have been used for the conventional delignifying process of PALF. More precisely, conventional delignifying has been made using sodium hydroxide (NaOH) or hydrolysis of small sugars.
A novel process of enzyme delignifying of leaf and/or stem fibres is described in
International Patent application No. WO 2011/148136.
According to a further aspect of the invention the step of delignifying comprises enzyme delignifying.
For the enzymatic treatment, various enzymes types may be used, such as a biopectinase (a complex of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase), a pectinase, a hemicellulose, a lactase, a perolase and a cellulase. Those enzymes have been used combined are alone in order to determine the best delignifying formulation. The biopectinase is able to dissolve pectin, hemicellulosic and others materials. Pectinase, hemicellulase and cellulase enzymes can dissolve pectin, hemicelluloses and cellulose materials, respectively. Cellulase enzyme is well known for the polishing of fibrils in the surface of cotton fabrics. However, according to the state of the art, cellulase is not commonly used for fibres treatment has it can degrade fibres and reduce its resistance. In the present invention cellulase may be used in low quantity as an additive to the enzymatic process.
A preferred group of enzymes which may be mentioned are consisting of polygalacturonase, pectinesterase, pectinic lyase, hemicellulase, hypozyme lactase or perolase; and mixtures thereof. Specific mixtures which may be mentioned include a mixture of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase (Biopectinase), a mixture of polygalacturonase and a mixture of hypozyme lactase and perolase. A preferred enzyme is a mixture of polygalacturonase and hemicellulase. A further preferred enzyme is a mixture of hypozyme lactase and perolase.
When a mixture of polygalacturonase and hemicellulase is used the mixture may comprise from 1% to 10% w/w polygalacturonase and from 05% to 2% w/w hemicellulase, e.g. a mixture of 5% polygalacturonase and 1% hemicellulase.
The amount of enzymes may vary depending upon, inter alia, the nature of the leaf and/or stem fibre being delignified.
The use of the knitted or woven PALF material in the manufacture of the stretchable coated textile material is novel per se. Thus, according to a further aspect of the invention there is provided the use of a knitted or woven PALF material made substantially from PALF natural plant-based yarns including natural fibres in the manufacture of a stretchable coated textile material as herein described.
According to one aspect of the invention there is provided the use of a knitted PALF material in the manufacture of a stretchable coated textile material as herein described.
According to another aspect of the invention there is provided the use of a woven PALF material in the manufacture of a stretchable coated textile material as herein described.
According to the invention the knitted or woven PALF material will generally comprise yarns comprising from 5 to about 30% w/w natural leaf or stem fibre, the remainder comprising a biobased fibre or a semi- synthetic fibre as herein described.
For the avoidance of doubt, the percentage of natural leaf or stem fibre is based on the weight of the knitted or woven material.
According to this aspect of the invention the yarn or the knitted or woven PALF material may comprise yarns comprising from 5 to about 30% w/w natural leaf or stem fibre; or from about 5 to about 25% w/w natural leaf or stem fibre; or from about 10 to about 25% w/w natural leaf or stem fibre; or from about 10 to about 20% w/w natural leaf or stem fibre; or from about 10 to about 15% w/w natural leaf or stem fibre. The knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre. Thus, the amount of biobased fibre or a semi-synthetic fibre, such as, viscose, lyocell, tencel, recycled cotton, etc., may be from about 70 to about 95% w/w of the yarn or the knitted or woven material.
A preferred yarn is made from a leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF. Alternatively, fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF. Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc. When a stem fibre is included in a composite material of the invention may comprise a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp; and other cellulose derived fibres, such as, grass(es) bamboo, straw and cotton. An especially preferred is a leaf fibre, for example, a leaf fibre that comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), pineapple. However, it will be understood by the person skilled in the art that mixtures of leaf and stem
fibres, for example, fibres that may have a relatively high content of pineapple leaf fibres, may be used in the yarns of this aspect of the invention. When the yarn comprises a composite material including leaf and stem fibres, preferably a majority of the material comprises a leaf fibre, such as PALF. Thus, in a composite material the leaf fibre may comprise at least 50% w/w of the leaf stem fibre content, preferably at least 60% w/w of the leaf/ stem fibre content, preferably at least 70% w/w of the leaf/ stem fibre content preferably at least 80% w/w of the leaf/ stem fibre content, preferably at least 90% w/w of leaf/ stem fibre content and especially at least 95% w/w of the leaf/ stem fibre content. When a mixture of leaf fibres is used it is desirable that a major part of the leaf fibre is PALF. Thus, at least 50% w/w of the leaf fibre content is PALF, preferably at least 60% w/w of the leaf fibre content is PALF, preferably at least 87% w/w of the leaf fibre content is PALF, preferably at least 80%w/w of the leaf fibre content is PALF, preferably at least 90% w/w of the leaf fibre content is PALF and especially at least 95% w/w of the leaf fibre content is PALF. In one aspect of the present invention when the leaf fibre is PALF, the yarn or knitted or woven material may comprise about 80% w/w leaf fibre. Preferably the leaf or stem fibre is delignified prior to use using conventional delignifying methods known in the art or other delignifying methods described herein. The knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre. The remainder of the knitted or woven material will comprise a biobased fibre, such as, PLA (poly-lactic acid) fibre, or a semi-synthetic fibre, such as, such as, viscose, lyocell, tencel, recycled cotton, etc.. Thus, the amount of biobased fibre or semisynthetic fibre may be from 70 to about 95% w/w of the yarn or knitted or woven material.
The knitted or woven material may comprise a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres.
A preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF. Alternatively, fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF. Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc.
When a stem fibre is included in the PALF composite, a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp.
The knitted or woven material will generally comprise a natural knitted or woven fibre, wherein the knitted or woven fibre material will comprise from about 5 to about 30% w/w natural leaf or stem fibre. For the avoidance of doubt, the percentage of natural leaf or stem fibre is based on the weight of the uncoated knitted or woven material.
The invention will now be described by way of example only and with reference to the accompanying figures in which:
Figure 1 illustrates yarns of different sizes; all with composition of 30% PALF, 70% TENCEL™ lyocell;
Figure 2 illustrates a sample of plain jersey knitted fabric, using a yarn of figure 1; and
Figures 3 and 4 illustrate the finished coated knitted fabric of figure 2.
Example 1
Yarn Production
The PALF (pineapple leaf fibre) was processed into a textile grade standard through purification, cutting and carding processes. The PALF fibres were then mixed and blended with other cellulose based fibres (e.g. lyocell). Both types of fibres are taken through an opener and carding machine where the fibres are weighed to the correct percentage ratio (e.g. 30% w/w PALF 70% w/w Lyocell). The fibres were then taken through a cottonised carding process and through a draw frame before being spun. Once the sliver had been through the draw frames (this process gives the fibres a more homogeneous alignment and is the first stage of identifying the yam’s thickness), the sliver was taken through the first spinning stage where the yarn twist and spinning speed was controlled, this establishes the yarn characteristics (e.g. strength, size, hairiness, elongation). The yarn was spun with a technology, (e.g. ring spinning) giving the yarn the final outcome. Once the spinning was complete the yarn was wound onto a cone ready for shipment.
Example 2
Fabric Production (plain jersey knited fabric)
The yarn was distributed onto the amount of cones needed for the specific machine for the knitting manufacturing.
The construction was chosen and the gauge of machine and needle alignment is chosen accordingly. The machine gauge was highly dependent on the yarn size (e.g. Ne20/2 will use a machine gauge of approx. 10 - 14 depending on the desired weight and handle). The fabric was inspected once produced, removed from the knitting machine and moved to the finishing facility, where it was washed and stented. In some cases the fabric underwent an enzymatic wash or special finishing (e.g. a hydrophilic wash). Once the fabric has been finished it was dried and then assessed for chemical and physical performance characteristics.
Example 3
Coated Fabric Production
PALF is the base component of the material, the PALF was extracted from the leaves by a semi-automatic mechanical process, then washed with water and dried under the sun, that acts as a natural bleaching agent.
The fibres were then processed to achieve textile grade. First the sugars that act as cement in between the fibres were dissolved by an enzymatic treatment in a batch reactor at temperature around 50 °C. This allowed the fibres to be easily separated in the following steps.
PALF fibres were consequently cut to 38 mm, opened and carded mechanically to get smooth textile grade fibres.
The textile grade fibres were then blended with Tencel in a 30:70 w/w ratio of PALF: Tencel, and consequently spun in to an Nel6/1 yarn in a dry process. The yarn was able to be knitted into a jersey construction that provides the necessary elastic property. The fabric was then stabilised by washing to get a consistent knitted fabric substrate.
A transfer paper coated with a finishing resin composition was used to transfer the coating polymer resin onto the surface of the knitted fabric substrate using a calendaring machine, with a thick blade to apply the composition. The paper was not removed at this stage. The coating polymer resin composition adhered to the knitted fabric.
Materials used:
Water based Polyurethane, soft (standard), e.g. polyurethane PKA, 90-97% w/w
Antifoaming agent, e.g. BG-Print ASF - BGH, 0.3-1% w/w
Thickener e.g. Cresaclear TE 1-2% w/w
Other auxiliary chemicals, e g. cross linker, extra finishes, thickener, pigment, metallic powder, etc. 0-7% w/w
The resulting coated fabric was then dried and cured in a press under heat and pressure (with the transfer paper in situ) at a temperature of 90°C to 150°C, and a
pressure: of lkg/cm2 to 4kg/cm2, for 1 to 30 seconds, e.g. 120°C at 1.5kg/cm2 to 2kg/cm2 for 10 seconds or 150°C for 60 seconds.
Then the paper was released to show the knitted coated material.
Example 4
Flex Resistance Test
The flex resistance of the stretchable coated textile material was determined using the test method of ISO 17694:2016. ISO 17694:2016 specifies a test method for determining the flex resistance for footwear, e.g. uppers and linings, irrespective of the material in order to assess the suitability for the end use.
The results of the flex resistance test are shown in Table 1.
Example 5
Abrasion Resistance Test (1)
The abrasion resistance of the stretchable coated textile material was determined using the test method of BS EN ISO 12947-2:2016. BS EN ISO 12947-2:2016 specifies the procedure for the determination of specimen breakdown (end-point of test) by inspection at fixed intervals and is applicable to all textile fabrics (uncoated) including nonwovens apart from fabrics where the specifier indicates the end performance as having a low abrasion wear life.
The results of the abrasion resistance test are shown in Table 1.
Example 6
Abrasion Resistance Test (2)
The abrasion resistance of the stretchable coated textile material was determined using the test method of BS EN 5470-2:2003. BS EN 5470-2:2003 specifies the procedure for the determination of resistance of a material to wet and dry abrasion of a coated material.
The results of the abrasion resistance test are shown in Table 1.
Example 7
Tear Strength Test
The tear strength of the stretchable coated textile material was determined using the test method of BS EN ISO 4674-1:2016 Method B. BS EN ISO 4674-1 :2016 specifies two methods for determining the forces necessary to initiate and propagate tearing of a coated fabric using the constant rate of tear method. The methods described are the following:
- method A: tongue tear; and
- method B: trouser tear.
The results of the tear strength test are shown in Table 1.
Example 8
Tensile Strength and Elongation Test
The Tensile strength and elongation of the stretchable coated textile material was determined using the test method of BS EN ISO 1421:2016 Method 1 - Strip. BS EN
ISO 1421 :2016 specifies two methods for the determination of the tensile strength of fabrics coated with rubber or plastics.
- Method 1 the strip test method, which is a method for the determination of tensile strength and elongation at break. - Method 2 the grab test method, which is a method for the determination of tensile strength only.
The methods apply to test pieces in equilibrium with specific standard atmospheres for testing and to wet test pieces. Both methods require the use of a constant rate of extension (CRE) tensile-testing machine.
The results of the tear strength test are shown in Table 1.
Claims
1. A stretchable coated textile material comprising a natural knitted or woven material made substantially from plant-based yarns including natural fibres; and wherein said natural knitted or woven material is coated with a stretchable polymer material.
2. A stretchable coated textile material according to claim 1 wherein the natural material is a knitted material.
3. A stretchable coated textile material according to claim 1 wherein the natural material is a woven material.
4. A stretchable coated textile material according to claim 1 wherein the coated knitted or woven material is made substantially from natural plant-based yarns; said coated knitted or woven material resembling leather and being stretchable.
5. A stretchable coated textile material according to any one of the preceding claims wherein the natural knitted or woven material comprises plant based yarns.
6. A stretchable coated textile material according to claim 5 wherein the plant based yarns comprise natural leaf or stem fibres.
7. A stretchable coated textile material according to claim 6 wherein the plant based yarns comprise leaf fibres with a high cellulose content.
8. A stretchable coated textile material according to claim 7 wherein the cellulose content is about 70% w/w or more.
9. A stretchable coated textile material according to any one of the preceding claims wherein the natural knitted or woven material comprises a yarn from a leaf fibre or a stem fibre and mixtures thereof.
10. A stretchable coated textile material according to claim 9 wherein the natural knitted or woven material comprises a yarn from a leaf fibre.
11. A stretchable coated textile material according to claim 10 wherein the leaf fibre is PALF.
12. A stretchable coated textile material according to claim 10 wherein the yarn comprises a composite material including leaf and stem fibres.
13. A stretchable coated textile material according to claim 12 wherein the yarn comprises from about 5 to about 30% w/w of the leaf/ stem fibre content.
14. A stretchable coated textile material according to any one of the preceding claims wherein the leaf or stem fibre is delignified prior to use.
15. A stretchable coated textile material according to any one of the preceding claims wherein the knitted or woven material comprises from about 5 to about 30% w/w natural leaf or stem fibre.
16. A stretchable coated textile material according to any one of the preceding claims wherein the knitted or woven material comprises from about 5 to about 30% natural leaf or stem fibre, the remainder of the knitted or woven material will comprising a biobased fibre or semi- synthetic fibre.
17. A stretchable coated textile material according to claim 16 wherein the amount of biobased fibre or semi-synthetic fibre is from about 70 to about 95% w/w of the knitted or woven material.
18. A stretchable coated textile material according to claim 17 wherein the semisynthetic fibre comprises viscose, lyocell, tencel, recycled cotton, etc.
19. A stretchable coated textile material according to claim 17 wherein the biobased fibre is PLA (poly-lactic acid) fibre.
20. A stretchable coated textile material according to claim 2 wherein the knitted material is produced as a weft knit.
21. A stretchable coated textile material according to claim 2 wherein the knitted material is produced as a warp knit.
22. A stretchable coated textile material according to any one of the preceding claims wherein the amount of stretchable polymer coated onto the natural knitted or woven material is from about 1 to 20% w/w of a polymer, based on the weight of the composite coated material.
23. A stretchable coated textile material according to claim 22 wherein the stretchable polymer is a fusible polymer.
24. A stretchable coated textile material according to claim 23 wherein the fusible polymer is applied at a temperature of about 180°C or less.
25. A stretchable coated textile material according to claims 23 or 24 wherein the fusible polymer comprises a curable resin.
26. A stretchable coated textile material according to claim 25 wherein the curable resin is temperature curable, e.g. heat curable; light curable, e.g. UV curable; or chemically curable.
27. A stretchable coated textile material according to claims 25 or 26 wherein the curable resin is an olephinic resin.
28. A stretchable coated textile material according to claim 27 wherein the olephinic resin is an acrylic resin, such as a hydrophilic polyurethane.
29. A stretchable coated textile material according to any one of claims 25 to 28 wherein the curable resin is a pigmented curable resin.
30. A stretchable coated textile material according to claim 25 wherein the fusible polymer comprises acrylonitrile butadiene styrene (ABS); acrylic (PMMA); polyetheretherketone; cellulose acetate; cyclic olefin copolymer (COC); ethylene vinyl acetate (EVA); ethylene vinyl alcohol (EVOH); fluoroplastics, such as, PTFE, FEP, PF A, CTFE, ECTFE and ETFE; ionomers; acrylic/PVC alloy; liquid crystal polymer (LCP); polyoxymethylene (POM or acetal); polyacrylates (Acrylic); polyacrylonitrile (PAN or acrylonitrile); polyamide (PA or Nylon); polyamide-imide (PAI); polyaryletherketone (PAEK or Ketone); polybutadiene (PBD); polybutylene (PB); polybutylene terephthalate (PBT); polycaprolactone (PCL); polychlorotrifluoroethylene (PCTFE); polyethylene terephthalate (PET); polycyclohexylene dimethylene terephthalate (PCT); polycarbonate (PC); polyhydroxyalkanoates (PHAs); polyketone (PK); polyester; polyethylene (PE); polyetheretherketone (PEEK); polyetherketoneketone (PEKK); polyetherimide (PEI); chlorinated polyethylene (CPE); polyimide (PI); polylactic acid (PLA); polymethylpentene (PMP); polyphenylene oxide (PPO); polyphenylene sulphide (PPS); polyphthalamide (PPA); polypropylene (PP); polystyrene (PS); polysulphone (PSU); polytrimethylene terephthalate (PTT); polyurethane (PU); polyvinyl acetate (PVA); polyvinyl chloride (PVC); polyvinylidene chloride (PVDC); or styreneacrylonitrile (SAN).
31. A stretchable coated textile material according to any one of claims 25 to 30 wherein the fusible polymer is hydrophilic.
32. A stretchable coated textile material according to claim 31 wherein the hydrophilic fusible polymer comprises one or more polyurethanes, e.g. polyurethanes derived from renewable resources, or one or more biopolymers, such as polylactic acid (PLA), poly-3 -hydroxybutyrate, etc.
33. A stretchable coated textile material according to any one of the preceding claims wherein the amount of stretch in the material has a Stretch Percentage of from about 1% to about 100%.
34. A stretchable coated textile material according to any one of the preceding claims wherein the knitted or woven material has a denier or linear density of from about 10 to 20 tex.
35. A stretchable coated textile material according to any one of the preceding claims wherein the fabric shows no cracking after >100,000 flexes dry (determined by BS EN ISO 17694:2016).
36. A stretchable coated textile material according to any one of the preceding claims wherein the fabric shows no or little abrasion or very slight - modification of brightness after >51,200 revolutions (determined by BS EN ISO 12947-2:2016 or BS EN 5470-2:2003).
37. A stretchable coated textile material according to any one of the preceding claims wherein the fabric shows a tear (BS EN ISO 4674-1:2016 Method B) strength of >31 N (Direction I) and/or >46 N (Direction II).
38. A stretchable coated textile material according to any one of the preceding claims wherein the fabric shows a tensile strength (BS EN ISO 1421 :2016 Method 1 - Strip) (load at break) of >84 N (Direction I) and/or >65 N (Direction II).
39. A stretchable coated textile material according to any one of the preceding claims wherein the fabric shows an elongation at break of >200% (Direction I) and/or >77.0 % (Direction II).
40. A stretchable coated textile material according to any one of the preceding claims wherein the fabric shows a maximum load of >228.0 N (Direction I) and/or >435 N (Direction II).
41. A stretchable coated textile material according to any one of the preceding claims wherein the fabric shows an elongation at maximum load of >194% (Direction I) and/or >67.9% (Direction II).
42. A stretchable coated textile material according to any one of the preceding claims wherein the Fabric Weight of the knitted or woven is from about 10 to about 1,000 g/m2.
43. A stretchable coated textile material according to claim 1 wherein the knitted or woven material comprising such a yarn comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi-synthetic fibre.
44. A method of making a stretchable coated textile material according to claim 1 ; said method comprising: a) knitting or weaving a plurality of plant-based yarns including natural fibres, to form a natural knitted or woven material; b) applying a fusible material to the natural knitted or woven material.
45. A method according to claim 44 wherein the method includes the steps of curing the curable material.
46. A method according to claim 44 wherein the natural material is a knitted material.
47. A method according to claim 44 wherein the natural material is a woven material.
48. A method according to any one of claims 44 to 47 wherein the leaf or stem fibre is delignified prior to use.
49. A method according to claim 48 wherein the step of delignifying comprises enzyme delignifying.
50. A method according to claim 49 wherein the enzyme delignifying comprises the use of one or more of polygalacturonase, pectinesterase, pectinic lyase hemicellulase, hypozyme lactase and perolase; and mixtures thereof.
51. A method according to claims 49 or 50 wherein the enzyme delignifying comprises the use of one or more of a mixture of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase (Biopectinase); a mixture of polygalacturonase and hemicellulose; and hypozyme lactase and perolase.
52. A method according to any one of claims 49 to 51 wherein the enzyme delignifying comprises the use of a mixture of polygalacturonase and hemicellulase.
53. A method according to any one of claims 49 to 52 wherein the enzyme delignifying comprises the use of a mixture of hypozyme lactase and perolase.
54. A method according to claim 53 wherein the enzyme delignifying comprises the use of a mixture comprising from 1% to 10% w/w polygalacturonase and from 05% to 2% w/w hemicellulase.
55. The use of a knitted or woven PALF material made substantially from PALF natural plant-based yarns including natural fibres in the manufacture of a stretchable coated textile material according to claim 1.
56. The use according to claim 55 wherein the material comprises yarns comprising from about 5 to about 30% w/w natural leaf or stem fibre.
57. The use according to claims 55 or 56 wherein the material comprises leaf fibre from the leaves of one or more plants of the Bromeliaceae family.
58. The use according to claim 57 wherein the material comprises leaf PALF.
59. The use according to any one of claims 55 to 58 wherein the material from about 5 to about 30% w/w natural leaf or stem fibre.
60. The use according to any one of claims 55 to 59 wherein the knitted or woven material comprises from about 5 to about 30% w/w natural leaf or stem fibre, the remainder of the knitted or woven material comprising a biobased fibre or a semisynthetic fibre.
61. The use according to any one of claims 55 to 60 wherein the amount of biobased fibre or semi-synthetic fibre is from 70 to about 95% w/w of the knitted or woven material.
62. The use according to claims 61 or 62 wherein the semi- synthetic fibre comprises viscose, lyocell, tencel, recycled cotton, etc.
63. The use according to claims 60 or 61 wherein the biobased fibre is PLA (polylactic acid) fibre.
64. The use according to any one of claims 54 to 63 wherein the natural material comprises a knitted material.
65. The use according to any one of claims 54 to 63 wherein the natural material comprises a woven material.
66. The use according to claim 64 wherein the knitted material is produced as a weft knit.
67. The use according to claim 64 wherein the knitted material is produced as a warp knit.
68. A yarn comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi-synthetic fibre.
69. A stretchable coated textile material, method or knitted PALF material substantially as herein described with reference to the description.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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GB2205133.8 | 2022-04-07 | ||
GBGB2205133.8A GB202205133D0 (en) | 2022-04-07 | 2022-04-07 | Coated knitted or woven materials of natural plant-based fibres |
Publications (1)
Publication Number | Publication Date |
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WO2023194736A1 true WO2023194736A1 (en) | 2023-10-12 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/GB2023/050919 WO2023194736A1 (en) | 2022-04-07 | 2023-04-06 | Coated knitted or woven materials of natural plant-based fibres |
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GB (1) | GB202205133D0 (en) |
WO (1) | WO2023194736A1 (en) |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3440133A (en) * | 1966-03-04 | 1969-04-22 | Ford Motor Co | Coated fabrics having high stretch ratios |
EP0686498A1 (en) * | 1994-06-06 | 1995-12-13 | Akzo Nobel N.V. | Composite material and its use in footwear |
WO2011148136A2 (en) | 2010-05-25 | 2011-12-01 | Ananas Anam Limited | Natural nonwoven materials |
KR20200019481A (en) * | 2018-08-14 | 2020-02-24 | 오성우 | Natural fiber-based leather and preparing method thereof |
-
2022
- 2022-04-07 GB GBGB2205133.8A patent/GB202205133D0/en not_active Ceased
-
2023
- 2023-04-06 WO PCT/GB2023/050919 patent/WO2023194736A1/en unknown
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3440133A (en) * | 1966-03-04 | 1969-04-22 | Ford Motor Co | Coated fabrics having high stretch ratios |
EP0686498A1 (en) * | 1994-06-06 | 1995-12-13 | Akzo Nobel N.V. | Composite material and its use in footwear |
WO2011148136A2 (en) | 2010-05-25 | 2011-12-01 | Ananas Anam Limited | Natural nonwoven materials |
KR20200019481A (en) * | 2018-08-14 | 2020-02-24 | 오성우 | Natural fiber-based leather and preparing method thereof |
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GB202205133D0 (en) | 2022-05-25 |
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