Note: Descriptions are shown in the official language in which they were submitted.
ABSTRACT
The present invention relates to a method of manufacturing a non-synthetic
textile
surface structure, and to the non-synthetic textile surface structure itself.
CA 03225712 2024- 1- 12
METHOD FOR PRODUCING A VEGETABLE PLANAR TEXTILE STRUCTURE
The present invention relates to a method for producing a non-synthetic
textile surface
structure and to the non-synthetic textile surface structure.
BACKGROUND
Leather has always been an important material for the manufacture of clothing
and
objects. However, real leather is generally rejected by the growing number of
vegans. In
addition, the use of leather has been criticized for various ecological and
ethical reasons.
Among other things, the production of leather causes considerable CO2
emissions
during the rearing of the animals. Ecologically questionable chemicals are
often used in
tanneries during further processing. Although it is a by-product of the meat
industry,
animal suffering has become a decisive argument against leather.
For these reasons, many products that are traditionally made from or with
leather are
therefore offered in artificial leather (e.g. bags, furniture or car interior
panels).
However, in most cases, artificial leather is based on synthetic, petroleum-
based
components (e.g. PU coatings, carrier materials made of synthetic fibers),
which limits
biodegradability and leads to other ecological problems, such as the abrasion
of
microplastics.
The production of artificial leather or leather-like substitutes is known in
general. For
example, DE 16 35 546 C3 describes a process for the production of leather-
like sheet
material from an aqueous slurry.
DE 10 2006 001 095 Al goes into a similar direction, describing a process for
producing
a leather-containing surface structure with a top layer and a backing layer.
After these two processes, however, genuine leather is still used, at least in
fiber form.
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CA 03225712 2024- 1- 12
OBJECT OF THE INVENTION
The underlying object is to provide an improved leather substitute and a
suitable
manufacturing process therefor.
SUMMARY
The problem is solved by a process for producing a non-synthetic textile
surface
structure, comprising the steps: a) providing a pulp comprising at least one
liquid, in
particular water, at least one non-synthetic fiber material, at least one
binder, at least
one process additive; b) producing a non-synthetic textile surface structure
by at least
partially separating the liquid, in particular the water, from the pulp;
wherein the at least
one binder comprises at least one natural latex.
The method according to the invention may additionally comprise one or more of
the
following sub-steps in step a): al) providing the non-synthetic fiber
material, wherein the
non-synthetic fiber material comprises or consists of shortened and/or un-
shortened
fibers; and/or a2) adding the at least one liquid, in particular water, to the
non-synthetic
fiber material; and/or a3) mechanical preparation of the non-synthetic fiber
material;
and/or a4) cleaning of the non-synthetic fiber material; and/or a5) addition
of the at least
one binder; and/or a6) addition of the at least one process additive; and/or
a7) addition
of at least one auxiliary agent; and/or a8) production of the pulp.
The method according to the invention may additionally comprise one or more of
the
following sub-steps in step b): bl ) applying the pulp provided in step a) to
a liquid-
permeable carrier element, in particular a water-permeable carrier element for
at least
partial separation of the at least one liquid, in particular the water; and/or
b2) producing
a pulp layer comprising the pulp from step a), wherein the at least one
liquid, in particular
the water, is at least partially removed from the pulp layer; and/or b3)
drying the pulp
layer; and/or b4) carrying out a moulding process on the pulp layer, in
particular on the
dried pulp layer to obtain the non-synthetic textile surface structure; and/or
b5) adding at
least one auxiliary agent.
The method according to the invention can additionally comprise, during
mechanical
preparation in step a3), splitting the non-synthetic fiber material into
fibers, or fibrillating
it.
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The process according to the invention may comprise the at least one process
additive
which is selected from the group consisting of polysaccharides, in particular
starch,
modified starch, cationically modified starch, cellulose or derivatives
thereof, in particular
carboxymethylated cellulose, cellulose acetate, hydroxypropyl methylcellu
lose,
aluminium sulphate, or mixtures thereof.
The method according to the invention may further comprise the at least one
binder,
which further comprises synthetic latex.
The method according to the invention may additionally comprise at least one
auxiliary
agent, wherein the at least one auxiliary agent is selected from plasticizers,
fillers, dyes,
pigments, UV protection agents, hydrophobicizing agents, antimicrobial agents,
flame
retardants, wet strength agents, sizing agents or mixtures thereof.
In the process according to the invention, the non-synthetic fiber material
may be
selected from vegetable fiber material, preferably from natural fibers,
cellulose,
preferably recycled cellulose, textiles made of natural fibers, preferably
from recycled
textiles made of natural fibers, or mixtures thereof.
The process according to the invention may further comprise the following
step: c)
carrying out a post-treatment on the non-synthetic textile surface structure
produced in
step b).
Also according to the invention is the use of cationic starch as a process
additive in the
process according to the invention.
Also according to the invention is a non-synthetic textile surface structure,
obtainable by
the process according to the invention.
Also according to the invention is a non-synthetic textile surface structure
comprising
non-synthetic fiber material, at least one process additive, at least one
binder, wherein
the at least one binder comprises natural latex.
The non-synthetic textile surface structure according to the invention may
further
comprise at least one auxiliary agent selected from plasticizers, dyes, UV
protection
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CA 03225712 2024- 1- 12
agents, hydrophobicizing agents, antimicrobial agents, flame retardants, wet
strength
agents, sizing agents, pigments, or mixtures thereof.
Further according to the invention is the use of the non-synthetic textile
surface structure
according to the invention as a leather substitute, in particular for the
manufacture of
fashion (shoe components, bags, accessories, clothing), furniture (seat
covers, furniture
surfaces), car interiors, stationery (e.g. covers), facade paneling or floor
coverings.
Also according to the invention is a leather substitute comprising the non-
synthetic textile
surface structure according to the invention.
Furthermore, the leather substitute according to the invention comprises
decorations,
engravings, embossings, embroideries, coatings, adhesions, or mixtures
thereof.
DETAILED DESCRIPTION OF THE INVENTION
The object is solved by a process for producing a non-synthetic textile
surface structure,
comprising the steps: a) providing a pulp comprising at least one liquid, in
particular
water, at least one non-synthetic fiber material, at least one binder, at
least one process
additive; b) producing a non-synthetic textile surface structure by at least
partially
separating the liquid, in particular the water, from the pulp, wherein the at
least one binder
comprises at least one natural latex.
The method according to the invention has the advantage that a non-synthetic
textile
surface structure can be produced, which can be used as a leather substitute.
The term "pulp" as used in the present application refers to a fibrous, pulpy
mixture, in
particular a fibrous, pulpy substance, comprising at least one liquid, in
particular water,
at least one non-synthetic fiber material, at least one binder, in particular
a plant-based
binder, and at least one process additive, in particular a plant-based process
additive.
The pulp used in the process according to the invention is similar in its
properties to the
pulp known, for example, from paper production. The fiber concentration in the
pulp can
preferably be set to a value between 0.1 % and 5 % by weight.
The at least one liquid comprises water. In one embodiment, the pulp is an
aqueous
pulp, which means that the liquid is water. The water may be selected from
distilled water
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CA 03225712 2024- 1- 12
or tap water or mixtures thereof. The liquid may further comprise organic
solvents or oils.
In one embodiment, the liquid is a mixture of water and oils. The proportion
of oil in the
liquid may be in the range of 10 % to 30 % by weight, based on the dry weight
of the
non-synthetic fiber material used.
The at least one non-synthetic fiber material is preferably selected from
vegetable fiber
material, preferably natural fibers, cellulose, preferably recycled cellulose,
textiles made
of natural fibers, preferably recycled textiles made of natural fibers, or
mixtures thereof.
In one embodiment, the non-synthetic fiber material is not present as a non-
woven or
woven material, but rather in the form of an accumulation of loose, isolated
fibers, e.g.
in the form of a bale or ball. The non-synthetic fiber material does not
contain any
synthetic fibers, i.e., fibers obtained from petroleum-based polymers.
Furthermore, the
non-synthetic fiber material does not contain any leather fibers of animal
origin. This has
the advantage that a non-synthetic textile surface structure can be obtained,
which
contains no leather fibers of animal origin, and also no fibers which have
been produced
from petroleum-based polymers.
Natural fibers can be by-products of agricultural products or obtained from
annual plants.
Examples of plants from which the natural fibers can be obtained are hemp,
bananas,
pineapple, silphia, flax, kenaf, jute, cotton, sisal, agave, abaca, ramie,
curaua, coconut
and kapok. Hemp fibers are particularly preferred according to the invention.
Mixtures of
the above-mentioned natural fibers can also be used. For economic and
ecological
reasons, it is advantageous if as non-synthetic fiber material natural fibers
are used,
which have been obtained as by-products of agricultural products. In this way,
the CO2
balance is ceteris paribus better compared with plants that are only planted
for fiber
production. It is also advantageous if the value of the plant is not solely
based on the
fibers, and economic scaling is possible.
For the purposes of the present application, "cellulose" means a fibrous
material which
consists of cellulose and which results from the chemical and mechanical
processing of
fiber-containing plants or wood. The plants can be selected from the plants
disclosed
above, from which the natural fibers can also be obtained. The cellulose may
also consist
of recycled cellulose or at least comprise recycled cellulose.
Furthermore, the non-synthetic fiber material can be selected from textiles
made from
natural fibers, preferably from recycled textiles made from natural fibers,
for example old
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CA 03225712 2024- 1- 12
clothing made from natural fibers suitable for making clothing, such as jute,
cotton, sisal
or hemp.
The term "binder" as used in the present application is understood to mean a
substance
which elastically binds fibers of the non-synthetic fiber material together to
form a three-
dimensional network. According to the invention, the at least one binder
comprises a
plant-based binder of natural latex. Natural latex can be obtained from the
rubber tree
(Hevea Brasilensis), guayle (Parthenium argentatum), Russian dandelion
(Taraxacum
koksaghyz), or mixtures thereof. The latter in particular can also be
cultivated in Europe,
so that this raw material can be sourced regionally and thus in a more climate-
friendly
way. Preferably, the at least one binder consists of natural latex. In one
embodiment,
however, the binder can also comprise synthetic latex, which is, for example,
obtained
from petroleum-based polymers. By using latex or rubber, or a latex- or rubber-
based
binder, a leather-like, softer texture is achieved in the end product, i.e.,
in the leather
substitute or in the non-synthetic textile surface structure according to the
invention.
The term "process additive" as used in the present application refers to a
precipitating
agent which enables the formation of the three-dimensional network of non-
synthetic
fiber material and binder. The at least one process additive is selected from
the group
consisting of polysaccharides, in particular starch, modified starch,
cationically modified
starch, cellulose or derivatives thereof, in particular carboxymethylated
cellulose,
cellulose acetate, hydroxypropyl methylcellulose, aluminium sulphate (also
called alum),
or mixtures thereof. The at least one process additive is preferably a
vegetable process
additive selected from polysaccharides, in particular starch or cellulose or
mixtures
thereof. The use of polysaccharide, in particular cationic starch, has the
advantage that
it is at least partially water-soluble (in both cold and warm water) and
develops its effect
in the neutral range. The pulp is therefore no longer acidic or contaminated
with acid. In
addition, the use of metal salts that are harmful to health and environment is
avoided. In
particular, the use of cationic starch as a process additive is also in
accordance with the
invention, preferably in the process according to the invention.
Step a) of the method according to the invention may comprise one or more of
the
following sub steps:
al) providing the non-synthetic fiber material, wherein the non-synthetic
fiber
material comprises or consists of shortened and/or un-shortened fibers; and/or
a2) adding the at least one liquid, in particular water, to the non-synthetic
fiber
material; and/or
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CA 03225712 2024- 1- 12
a3) mechanically processing the non-synthetic fiber material; and/or
a4) cleaning the non-synthetic fiber material; and/or
a5) adding at least one binder; and/or
a6) adding at least one process additive; and/or
a7) adding at least one auxiliary agent; and/or
a8) production of the pulp.
In step al), the non-synthetic fiber material is provided, wherein the non-
synthetic fiber
material comprises or consists of shortened and/or un-shortened fibers. The
non-
synthetic fiber material used in the process according to the invention
generally has to
be prepared in order to achieve a homogeneous distribution and an increased
strength.
Depending on the type and extraction of the non-synthetic fiber material, it
must also be
unravelled, for example using a carding machine. In the case of textiles, the
textiles must
first be chopped into small pieces, for example using a shredder.
In step a2), the at least one liquid already described above is added to the
provided non-
synthetic fiber material which may have passed through step al). This can be
done by
placing the non-synthetic fiber material in a suitable container and then
adding the liquid,
or by using a reverse order. The fiber concentration can be adjusted as
required. The
fiber concentration may be at least 0.1 wt%, or at least 0.2 wt%, or at least
0.3 wt%, or
at least 0.5 wt%, or at least 0.7 wt%, or at least 1 wt%, or at least 1.3 wt%,
or at least 1.
5 % by weight, or at least 2 % by weight, or at least 2.5 % by weight, or at
least 3 % by
weight, and/or up to 10 % by weight, or up to 9 % by weight, or up to 8 % by
weight, or
up to 7 % by weight, or up to 6 % by weight, or up to 5 % by weight, or up to
4 % by
weight. In particular, the fiber concentration may be at least 0.1 wt% up to
10 wt%, or 0.1
wt% up to 8 wt%, or 0.1 wt% up to 5 wt%.
In step a3), the non-synthetic fiber material is mechanically processed. The
non-synthetic
fiber material may have undergone at least steps a2) and a4). The term
"mechanical
preparation" as used in the present application means that the non-synthetic
fiber
material is subjected to a mechanical process comprising separating the non-
synthetic
fiber material into fibers and fibrillating the fibers.
In step a3), the non-synthetic fiber material is mechanically processed. The
non-synthetic
fiber material may have undergone at least steps a2) and a4). The term
"mechanical
preparation" as used in the present application means that the non-synthetic
fiber
material is subjected to a mechanical process comprising separating the non-
synthetic
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CA 03225712 2024- 1- 12
fiber material into fibers and fibrillating the fibers. This has the advantage
that the fiber
bundles are broken down into their individual fibers, which increases the
contact surface
between the fibers and the binder. In this way, a more tear-resistant and
homogeneous
material can be formed in the subsequent process. Essentially all processes
known in
the prior art are suitable for this purpose. According to the invention, the
non-synthetic
fiber material is mechanically processed in the form of a grinding process.
For this
purpose, the non-synthetic fiber material is introduced into a grinding unit
and subjected
to a grinding process. Suitable grinding units are cone refiners, disc
refiners, Hollander,
Papillon refiners, PFI mills and Jokro mills. One or more grinding processes
can be
carried out. The grinding processes can be adjusted depending on the desired
degree
of grinding of the non-synthetic fiber material. Usually, a higher degree of
grinding also
provides a better product quality. Typically, a grinding process takes between
1 minute
and 2 hours. But in principle, the duration of the grinding process depends on
the
targeted degree of grinding as well as the energy input (kWhit fiber) during
the grinding
process. During the grinding process, the fibers are shortened, separated and
fibrillated.
The result is a homogeneous fiber suspension. The suspension can then be
cleaned,
rinsed or thickened again using a pressure screen.
In step a4), the non-synthetic fiber material is cleaned. It has been found to
be
advantageous for the quality and processability of the non-synthetic fiber
material if the
non-synthetic fiber material is freed from of foreign bodies (such as dust,
splinters/woody
parts, other impurities) before or after step al) or before or after step a2)
or before or
after step a3). In step a4), the non-synthetic fiber material can therefore be
freed from
foreign bodies, in for example a mechanical way. Furthermore, the cleaning may
also
comprise one or more washing processes, and/or alkaline boiling and/or
enzymatic
treatment. For example, the non-synthetic fiber material can be boiled in an
alkaline
medium to break down the fibers, and to remove lignin. If the lignin remains
in the non-
synthetic fiber material, a natural colouring results, depending on the origin
of the non-
synthetic fiber material. If this natural colouring is not desired, alkaline
boiling can be
applied. Alkaline boiling not only removes lignin, but also reduces the
strength of the
non-synthetic fiber material. Purification generally has the advantage that
undesirable
components such as foreign bodies or interfering chemical compounds such as
pectin
or lignin can be at least partially, preferably completely, removed. This
supports or
simplifies the fibrillation in step a3) or can facilitate or accelerate the
separation of the
liquid in step b).
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CA 03225712 2024- 1- 12
In step a5), the at least one binder can be added. For example, the binder can
be
provided in a suitable container, and the non-synthetic fiber material, which
has
optionally undergone steps al) and/or a2) and/or a3) and/or a4) and/or a6),
can be
added to the binder. The sequence can also be inverse, i.e., the non-synthetic
fiber
material, which has optionally undergone steps al) and/or a2) and/or a3)
and/or a4)
and/or a6), is placed in a suitable container and the binder is added. Binder
and non-
synthetic fiber material can be mixed in this step. The weight ratio of binder
to non-
synthetic fiber material can be varied depending on the desired property of
the non-
synthetic textile surface structure. For example, if more latex is used than
fiber material,
the result is a more rubber-like non-synthetic surface structure. Typical
weight ratios of
non-synthetic fiber material : latex or binder are in the range of 1:0.2 to
1:3, or 1:0.3 to
1:3, or 1:0.5 to 1:2.5, or 1:0.7 to 1:2.
In step a6), the at least one process additive can be added. The process
additive can,
for example, be provided in a suitable container, and the non-synthetic fiber
material,
which has optionally undergone steps al) and/or a2) and/or a3) and/or a4)
and/or a5),
can be added to the process additive. The sequence can also be inverse, i.e.,
the non-
synthetic fiber material, which has optionally undergone steps al) and/or a2)
and/or a3)
and/or a4) and/or a5), is placed in a suitable container and the process
additive added.
Process additive and non-synthetic fiber material may be mixed in this step.
Typical
weight ratios of non-synthetic fiber material : process additive are in the
range of 1:0.02
to 1:0.2, or 1:0.03 to 1:0.2, or 1:0.05 to 1:0.15.
In step a7), at least one auxiliary agent can be added. The auxiliary agent
can, for
example, be provided in a suitable container, and the non-synthetic fiber
material, which
has optionally undergone steps al) and/or a2) and/or a3) and/or a4) and/or a5)
and/or
a6), can be added to the auxiliary agent. The sequence can also be inverse,
i.e., the
non-synthetic fiber material, which has optionally undergone steps al) and/or
a2) and/or
a3) and/or a4) and/or a5) and/or a6), is placed in a suitable container, and
the at least
one auxiliary agent added. The auxiliary agent and the non-synthetic fiber
material can
be mixed in this step.
Suitable additives can be selected from plasticizers, fillers, dyes, pigments,
UV protection
agents, hydrophobicizing agents, antimicrobial agents, flame retardants, wet
strength
agents, sizing agents, or mixtures thereof.
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Plasticizers are used when the non-synthetic textile surface structure
according to the
invention shall be more supple. Various types of plasticizers can be used
according to
the invention. Preferably, inorganic chemical plasticizers are avoided. In
particular, plant-
based plasticizers can be used, wherein the plant-based plasticizers can be
selected
from modified natural oils, plant-based anhydrides of alkenyl succinic acid,
plant-based
alkylated ketene dimers, plant-based polyhydric alcohols or mixtures thereof.
The plant-
based, modified oils can be sulphated. This has the advantage that these oils
are easy
to emulsify. In general, such natural oils can be plant-based oils, which are
selected from
sunflower oil, Turkish red oil (sulphated castor oil) or rapeseed oil.
Furthermore, the
natural oils can also be of animal origin, such as fish oil. The plasticizers,
especially the
modified plant-based oils, remain in the material as small droplets and thus
create free
spaces so that the individual fibers can move more freely. This makes the
material softer
and more supple. Typical weight ratios of non-synthetic fiber material :
softener are in
the range of 1:0.01 to 1:0.4, or 1:0.05 to 1:0.35, or 1:0.1 to 1:0.3.
Fillers can be used if the non-synthetic sheet material according to the
invention is to
form a smooth surface and/or is to have a higher suppleness. Fillers can be
selected
from silicates, such as kaolin; carbonates, such as chalk or gypsum; metal
oxides, such
as titanium oxide or aluminium oxide; barium sulphate; nanocellulose, such as
CNC
(cellulose nanocrystals), CNF (cellulose nanofibrils), FNC (fibrillated
nanocellulose); or
mixtures thereof. Typical weight ratios of non-synthetic fiber material :
filler are in the
range of 1:0.1 to 1:1, or 1:0.15 to 1:0.9, or 1:0.2 to 1:0.8.
Dyes can be used if the non-synthetic textile surface structure is to have a
specific colour.
The non-synthetic textile surface structure can therefore be dyed, whereby the
dyeing
process can be carried out at different times during the process. For example,
the dyeing
can be carried out before, during or after step a). Either the non-synthetic
fiber material
or the pulp can be dyed. The dyes can be selected from inorganic pigments such
as
carbon, metal oxides or metal sulphates; natural dyes such as saffron, indigo,
onion peel,
quebracho wood extract, madder root extract, woad extract, brazilin, blue wood
extract,
synthetic dyes, such as direct dyes, cationic dyes, vat dyes, reactive dyes,
developing
dyes, food dyes, or mixtures thereof. The material to be coloured can be
placed in a
corresponding liquid/suspension. In addition, the finished non-synthetic
textile surface
structure can be dyed by applying dyes to the surface. Alternatively,
dyes/pigments can
be added to the pulp. By processing dyed fibers, the material is dyed
throughly. This
prevents colour abrasion - as is the case with a paint finish, for example.
CA 03225712 2024- 1- 12
In step a8), the pulp is produced, wherein the non-synthetic fiber material,
the at least
one binder, the at least one process additive and the at least one liquid are
brought into
contact with each other and mixed, so that the pulp is formed.
The sub-steps al) to a8) of step a) of the method according to the invention
can be
carried out in any order, or even in parallel. For example, a portion of the
non-synthetic
fiber material may be subjected to step a2) while another portion of the non-
synthetic
fiber material is subjected to step a5). Preferably, step a6) is performed or
carried out as
the last sub-step in step a).
Furthermore, the method according to the invention comprises step b), wherein
step b)
may comprise one or more of the following substeps:
bl) applying the pulp provided in step a) to a liquid-permeable carrier
element,
in particular a water-permeable carrier element for at least partial
separation
of the at least one liquid, in particular the water; and/or
b2) producing a pulp layer comprising the pulp from step a), wherein the at
least
one liquid, in particular the water, is at least partially removed from the
pulp
layer; and/or
b3) drying the pulp layer; and/or
b4) carrying out a moulding process on the pulp layer, in particular on the
dried
pulp layer, to obtain the non-synthetic textile surface structure; and/or
b5) adding at least one auxiliary agent.
In step bl ), the pulp provided in step a) is applied to a liquid-permeable
carrier element,
in particular a water-permeable carrier element for at least partial
separation of the at
least one liquid, in particular the water. The application can be carried out
by suitable
methods known from the prior art, such as brushing or pouring. The "liquid-
permeable
carrier element" is a device such as a sieve or a perforated plate onto which
the pulp is
applied to separate the liquid.
In step b2), a pulp layer is produced, comprising the pulp from step a),
wherein the at
least one liquid, in particular the water, is at least partially removed from
the pulp layer.
The at least one liquid is removed either by the action of gravity or by the
action of an
external force such as a pressure plate or the application of a vacuum. Once
the liquid
has been removed, the partially dried or partially dehydrated pulp layer is
removed from
the liquid-permeable carrier element. This distinguishes the liquid-permeable
carrier
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CA 03225712 2024- 1- 12
element from carrier materials known from the prior art, which remain in the
finished
product.
In step b3), the pulp layer which was produced, for example, in step b2) is
further dried
until at least 90%, or at least 95%, or at least 98%, or at least 99% of the
at least one
liquid has been removed from the pulp layer. The drying can take place either
at room
temperature by evaporation or in suitable devices such as drying ovens at
elevated
temperatures and/or pressure. In step b3) the so-called sheet formation takes
place. This
sheet formation can be continuous or discontinuous. Continuous sheet formation
requires large screening machines with vacuum suction (similar to a paper
machine).
Discontinuous sheet formation can be carried out using laboratory equipment
(e.g.
Rapid-Kothen sheet formers) or by hand, similar to paper scooping.
In step b4), a moulding process is carried out on the pulp layer, in
particular on the dried
pulp layer, to obtain the non-synthetic textile surface structure. Steps b3)
and b4) can be
carried out simultaneously, i.e., drying takes place at the same time as the
moulding
process. However, steps b3) and b4) can also take place one after the other,
i.e., step
b4) after b3) or vice versa. The moulding process can also be carried out
using devices
known from the prior art, such as rollers. The moulding performed in step b4)
may include
pressing and/or embossing the material. By pressing the material in the dried
state, the
surface becomes smooth, in some cases also slightly glossy by satinising.
In step b5), at least one auxiliary agent can be added, as already described
above in
step a7). Step b5) can be carried out at any time before or after or at the
same time as
steps b1) to b4).
The above-described substeps b1) to b5) of step b) of the method according to
the
invention can be carried out in any order or in parallel.
The method according to the invention may further comprise a step c):
c) carrying out a post-treatment on the non-synthetic textile surface
structure produced
in step b).
The post-treatment may consist of one or more treatments selected from:
fulling, cleating
and/or milling; equipping with UV protection and/or flame retardancy and/or
antimicrobial
protection (e.g. by applying nano-silver), hydrophobisation (e.g. by applying
a polymer
emulsion); applying wet strength agents and/or sizing agents; embroidering;
(laser)
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engraving; embossing (e.g. by means of plates or rollers); coating (e.g. with
proteins or
waxes); surface dyeing; pigment application (e.g. effect pigments). The aim of
the post-
treatment is to refine the non-synthetic textile surface structure or to
provide it with certain
properties. According to the invention, such post-treatments include coating
or
impregnating the non-synthetic textile surface structure, for example
hydrophobising the
surface with waxes. The surface can also be laser engraved or embroidered
using a
suitable device. The material can be embossed to give it a special look and
feel, for
example grain embossing to create an animal leather look. Logos, lettering
etc. can also
be embossed. As already described, further mechanical processing can also be
carried
out, for example by fulling, cleating and/or milling. This loosens the fibers,
causing the
material to lose stability and thus become softer or more supple.
One embodiment of the method according to the invention for producing a non-
synthetic
textile surface structure comprises the following steps:
al) providing a non-synthetic fiber material, wherein the non-synthetic fiber
material comprises or consists of shortened and/or un-shortened fibers and
a2) adding at least one liquid, in particular water, to the non-synthetic,
fiber
material,
a3) mechanically processing the non-synthetic fiber material,
a5) adding a plant-based binder,
a6) adding a plant-based process additive and obtaining a pulp,
bl ) applying the pulp to a water-permeable carrier element to separate the
water from the pulp,
b3) drying the pulp layer and b4) moulding,
b) obtaining the non-synthetic textile surface structure.
The process according to the invention has the advantage that it can be based
entirely
on plant and/or plant-based raw materials, so that it can be carried out vegan
on the one
hand and petroleum-free on the other hand and can lead to a vegan, petroleum-
free
product, the non-synthetic textile surface structure according to the
invention.
The terms "plant-based" or "natural" are used synonymously in the present
application
and mean that no synthetic, petroleum-based raw materials / substances are
contained,
or, for example, that the plant-based binder is derived from plant components,
without
the addition of artificial raw materials.
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The process according to the invention can preferably be completely
ecological, since
the generated non-synthetic textile surface structure does not emit any
microplastic
abrasion, as is the case with synthetic fibers or artificial leather. By using
natural fibers
and plant-based raw materials, the product of the process according to the
invention can
be biodegradable.
Furthermore, the present problem is solved by a non-synthetic textile surface
structure.
In particular, the non-synthetic textile surface structure is obtainable by
the method
according to the invention described above. Preferably, the non-synthetic
textile surface
structure has a single-layer structure and consists entirely of plant-based
materials. The
non-synthetic textile surface structure according to the invention does not
contain any
leather of animal origin. Preferably, the non-synthetic textile surface
structure according
to the invention is free of petroleum-based components. Preferably, the non-
synthetic
textile surface structure according to the invention is free from chemicals
that are
hazardous to human health.
For the purposes of the present application, the term "non-synthetic textile
surface
structure" refers to a material which is similar to real or artificial
leather, can be processed
like leather and can therefore be used as a substitute for leather. The non-
synthetic
textile surface structure is non-woven. The non-synthetic textile surface
structure within
the meaning of the present application comprises at least one non-synthetic
fiber
material, at least one process additive and at least one binder, wherein the
at least one
binder comprises natural latex.
Furthermore, the non-synthetic textile surface structure according to the
invention may
comprise at least one auxiliary agent selected from plasticizers, dyes, UV
protection
agents, hydrophobicizing agents, antimicrobial agents, flame retardants, wet
strength
agents, sizing agents, pigments, or mixtures thereof. Examples and specific
embodiments of these auxiliaries have already been described above in
connection with
the method according to the invention.
The plant-based textile surface structure basically has the same advantages as
those
mentioned above for the method according to the invention. The non-synthetic
textile
surface structure according to the invention can be produced entirely from
plant and/or
plant-based raw materials, so that it is vegan on the one hand and petroleum-
free on the
other. Due to the process according to the invention and the raw materials or
auxiliaries
used, it cannot contain any metal residues. The non-synthetic textile surface
structure
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according to the invention does not produce any microplastic abrasion and is
also
biodegradable.
In contrast to animal skins, the thickness of the non-synthetic textile
surface structure
according to the invention is not predetermined by nature, but can be freely
selected and
controlled. The non-synthetic textile surface structure according to the
invention can
have a thickness that is customary for leather, and can have, for example, a
thickness
of between 0.2 and 5 mm.
The non-synthetic textile surface structure according to the invention can -
unlike multi-
layer artificial leather - be processed with open edges.
The non-synthetic textile surface structure according to the invention is a
single-layer
product that can be further processed using conventional methods. For example,
it can
be sewn, glued, nailed and embroidered.
Further according to the invention is the use of the non-synthetic textile
surface structure
according to the invention, in particular for the manufacture of textiles,
seat covers, bags,
applications. Possible areas of application are in fashion (shoe components,
bags,
accessories, clothing), furniture (seat covers, furniture surfaces), car
interiors, stationery
(e.g. covers). The non-synthetic textile surface structure according to the
invention can
also be used in the construction industry or in interior design, e.g., for
façade paneling
or floor coverings.
Also according to the invention is a leather substitute comprising the non-
synthetic textile
surface structure according to the invention. The leather substitute according
to the
invention can comprise decorations, engravings, embossings, embroideries,
coatings,
adhesions or mixtures thereof. The leather substitute according to the
invention can be
combined with other materials that can usually be combined with leather. The
leather
substitute according to the invention can be processed and used like
conventional
leather of animal origin or artificial leather. In particular, the leather
substitute according
to the invention, as well as the non-synthetic textile surface structure
according to the
invention, can have the same, similar or even improved properties compared to
conventional leather of animal origin or artificial leather. Such properties
include tensile
strengths, for example in the range from 15 to 50 NI/rnm2, elongation at
break, for
example in the range from 10 to 50%, tear resistance, for example in the range
from 4
CA 03225712 2024- 1- 12
to 40 N/mm, residual moisture, for example in the range from 0.5 to 10%, or
abrasion
resistance, for example in the range of >20,000 cycles according to
Martindale.
The leather substitute according to the invention differs from the non-
synthetic textile
surface structure according to the invention in that the leather substitute
according to the
invention has already been optimised for the subsequent application, for
example by
cutting or further (surface) treatments, in order to achieve certain
properties. Examples
of such (surface) treatments have already been described above.
Further objectives, features, advantages and possible applications are shown
in the
figures and in the following non-limiting examples of embodiments of the
invention. All
the features described and/or illustrated form the object of the invention,
either
individually or in any combination, even independently of their summary in the
claims or
their relationship to one another.
Fig. 1 shows a photographic representation of a non-synthetic fiber material
made from
un-shortened fibers;
Fig. 2 shows a photographic representation of a partially dewatered pulp layer
for sheet
formation; and
Fig. 3 shows a photographic representation of a finished non-synthetic textile
surface
structure.
In one embodiment, the non-synthetic textile surface structure according to
the invention
is made from hemp fibers. The fibers are obtained from a farm in Germany. The
fibers
are available as wool, as shown photographically in Figure 1, in the form of
bales. In
addition to the fibers, the wool contains residual wooden splinters and other
impurities.
To improve the product quality, these wooden splinters and impurities can be
separated
from the remaining fibers in a first process step. The use of hemp fibers has
the
advantage that the plants are not cultivated for the purpose of fiber
production. The fibers
are therefore a by-product.
In order to be able to produce a tear-resistant and homogeneous surface
structure from
the fibers in accordance with the present invention, they must first be
mechanically
processed. The preparation can be carried out in various machines. The process
can be
carried out either with a cone refiner known from the paper industry or with a
Hollander.
Water can be added to the fibers prior to the process. During the so-called
refining
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process, the fibers are shortened, separated and fibrillated in the refining
units. The result
is a homogeneous fiber suspension. The suspension can then be cleaned, rinsed
or
thickened again using a pressure screen.
In the next step, the pulp is produced. The preferably diluted (plant-based)
binder and
the (plant-based) process additive are added to the fiber suspension one after
the other.
Successful fixation is clearly visible to the eye. The fibers flocculate
noticeably and settle
at the bottom of the container after a resting period.
The so-called sheet is then formed. Leaf formation can take place in both a
continuous
and a discontinuous process. Continuous sheet formation requires large
screening
machines with vacuum suction (similar to a paper machine). Discontinuous sheet
formation can be carried out using laboratory equipment (e.g. Rapid-Kothen
sheet
formers) or by hand, similar to paper scooping.
During sheet formation, the water is separated from the other solids in the
pulp. The pulp
is placed on a sieve (water-permeable carrier element) for this purpose. Such
a pulp
layer is shown photographically in Figure 2. In the manual process, a sieve
box is used
for this purpose. The water can drain through the sieve while the solids are
retained. On
a sieving machine, the process can be accelerated by applying a vacuum.
The partially dewatered pulp layer in the form of a fiber mat is then
transferred from the
screen to a felt by inverting the screen box (only temporarily). For further
dewatering, the
fiber mat is pressed between two nonwovens in a press. The remaining liquid
must be
pressed out as slowly as possible to not damage the three-dimensional
structure. After
pressing, the formed sheet is already so tear-resistant that it is easy to
handle. The sheet
must now be dried further with room air until equilibrium is reached. Drying
takes place
in an oven at moderate temperatures or in the air.
In a continuous process, pressing and drying takes place via pairs of rollers
and drying
cylinders or via calenders.
The surface of the dried material can be further refined by embossing or
pressing
between metal plates or rollers.
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In this way, the non-synthetic textile surface structure according to the
invention is
obtained. A specific embodiment of this non-synthetic textile surface
structure is shown
photographically in Figure 3.
EXAMPLES
The present invention is explained again below with reference to the examples,
but
without being limited to these.
Example 1
200 g fibers (hemp, long wool fiber) are added to 18 liters of water in a
Hollander. The
subsequent grinding process is carried out for 30 minutes under standard
weight. 10 g
carbon black (as color pigment) and 60 g latex (binding agent) are added while
stirring.
30 g of cationic starch (process additive) are dissolved in 3 liters of water,
which is then
also added. The pulp is stirred and the pulp precipitates while stirring. This
pulp is then
placed in a sieve box for dewatering. After dewatering, the generated
partially dewatered
pulp layer is placed between two layers of felt, pressed, and then air-dried.
A grey/black surface structure, haptically reminiscent of leather, is
obtained. The surface
structure is stiff after drying.
Example 2
g of hemp fibers are cut to a length of 0.5 cm and mixed with water to a total
weight
25 of 300 g. The mixture is placed in a PFI mill and ground at
normal weight for 3 minutes.
The fiber suspension is then mixed with 1.5 liters of water and whipped in a
whipping
device. The pulp is then produced by adding 1 g of sulphated sunflower oil
(plasticizer),
10 g of latex (binder), 2 g of kaolin (filler) and 1 liter of water. 0.01 to
0.02 M aluminum
sulphate (process additive) is added under stirring until a pH value of 5 is
reached, to
30 precipitate or fix the pulp. The pulp obtained in this way is
placed in a sieve box for
dewatering. After dewatering, the generated, partially dewatered pulp layer is
placed
between two layers of felt, pressed, and then air-dried.
The non-synthetic textile surface structure shown in Figure 3 is obtained,
which is
reminiscent of leather in its feel and appearance.
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