Composite fabric comprising a bacterial biopolymer layer

Abstract

Provided is a composite fabric having a base fabric and at least one bacterial biopolymer layer. The base fabric is a woven fabric, and includes warp yarns and weft yarns. At least a first plurality of warp yarns and a first plurality of weft yarns form a base layer of the base fabric. A second plurality of warp yarns and/or a second plurality of weft yarns forms an additional layer of loop portions on at least one of the sides of the base fabric. The bacterial biopolymer layer is provided at least on part of the additional layer. Further provided is a process for the production of the composite fabric and a clothing article formed of the composite fabric.

Claims

1. A composite fabric comprising a base fabric and at least one biopolymer layer, said base fabric being a woven fabric comprising warp yarns and weft yarns woven together, said base fabric having a front side and a back side, at least a first plurality of said warp yarns and a first plurality of said weft yarns forming a base layer of said base fabric, and at least a second plurality of said weft yarns forming an additional layer of loop portions on one of said sides of said base fabric, said at least one biopolymer layer being obtained from microorganisms and being disposed on at least part of said additional layer, wherein said biopolymer layer is produced directly on said fabric, whereby said loop portions extend into said biopolymer layer, and wherein said biopolymer is selected from the group consisting of bacterial cellulose, bacterial collagen, bacterial cellulose/chitin copolymer, bacterial silk, and mixtures thereof, wherein the composite fabric comprising said at least one biopolymer layer is dyed.

2. The composite fabric according claim 1, wherein at least one of said warp yarns and said weft yarns are hydrophilic yarns.

3. The composite fabric according to claim 1, wherein said warp yarns and said first plurality of said weft yarns form said base layer of said base fabric and said second plurality of said weft yarns forms said additional layer of loop portions along said front side of said base fabric, said second plurality of weft yarns floating over three to twenty-four of said warp yarns of said base layer.

4. The composite fabric according to claim 3, wherein said second plurality of said weft yarns of said additional layer of loop portions float over at least seven said warp yarns.

5. The composite fabric according to claim 1, wherein said warp yarns and said first plurality of said weft yarns form said base layer of said base fabric and said second plurality of said weft yarns forms said additional layer of loop portions, said additional layer of loop portions disposed along said back side of said base fabric by floating under three to twenty-four of said warp yarns.

6. The composite fabric according to claim 5, wherein said second plurality of said weft yarns of said additional layer of loop portions float under at least seven said warp yarns.

7. The composite fabric according to claim 1, wherein said weft yarns are made of a different material than said warp yarns.

8. The composite fabric according to claim 1, wherein at least one of said warp yarns and said weft yarns comprise natural yarns, synthetic yarns or mixed yarns.

9. The composite fabric according to claim 1, wherein said base fabric is a denim fabric.

10. The composite fabric according to claim 9, wherein said denim fabric is an elastic denim fabric.

11. A clothing article comprising the composite fabric according to claim 1.

12. The clothing article according to claim 1, wherein said front side of said base fabric is an external, visible side of said clothing article when the clothing article is worn, said back side is an opposed internal side not visible when the clothing article is worn and wherein said at least one biopolymer layer and said additional layer of loop portions are disposed on said front side.

13. The clothing article according to claim 11, wherein said front side of said base fabric is an external, visible side of said clothing article when the clothing article is worn, said back side is an opposed internal side not visible when the clothing article is worn and wherein said at least one biopolymer layer and said additional layer of loop portions are disposed on said back side.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further aspects and advantages of the present invention will be discussed more in detail with reference to the enclosed drawings, illustrating embodiments of the invention and that are provided by way of non-limiting example, wherein:

(2) FIG. 1 is a perspective view of an embodiment of the base fabric according to the invention;

(3) FIG. 2 is a perspective view of an embodiment of the composite fabric of the invention;

(4) FIG. 3 is a cross-sectional view of a portion of a composite fabric according to the invention;

(5) FIG. 4 is a perspective view of another embodiment of the base fabric according to the invention;

(6) FIG. 5 is a perspective view of another embodiment of the composite fabric of the invention;

(7) FIG. 6 is a cross-sectional view of a portion of an embodiment of the composite fabric of the invention; and

(8) FIG. 7 shows a weaving report of an embodiment of a base fabric according to the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(9) FIG. 1 is a schematic perspective view of a portion of an exemplary embodiment of the base fabric according to the invention.

(10) FIG. 1 shows a portion of an exemplary base fabric 1, which comprises a plurality of warp yarns 2, a plurality of first weft yarns 3 and a plurality of second weft yarns 4. Warp yarns 2, first weft yarns 3, and second weft yarns 4, are woven together in a pattern, to form a base layer 1a of the base fabric 1. The base fabric 1 has a front side 5 and a back side 6.

(11) According to an aspect, first weft yarns 3 of base fabric 1 are woven together with the warp yarns 2 to from a base layer 1a of the base fabric 1, and second weft yarns 4 form an additional layer 1b of the base fabric 1.

(12) In particular, in the embodiment of FIG. 1 second weft yarns 4 form an additional layer 1b of the base fabric 1 in the form of loop portions 7, on the front side 5 of the base fabric 1.

(13) The base layer 1a and the additional layer 1b, which are not indicated in FIG. 1, are illustrated e.g. in FIG. 3.

(14) In the exemplary embodiment shown in FIG. 1, second weft yarns 4 form loop portions 7 when they pass over the warp yarns 2, on the front side 5 of the base fabric 1.

(15) In the embodiment shown in FIG. 1, second weft yarns 4 form loop portions 7 by floating over seven warp yarns 2.

(16) In the embodiment of the base fabric 1 shown in FIG. 1, warp yarns 2 and weft yarns 3,4 are not dyed.

(17) FIG. 2 shows a schematic perspective view of a composite fabric 10 according to the invention. FIG. 2 shows a base fabric 1 coupled with a bacterial biopolymer layer 20.

(18) For example, the base fabric 1 of FIG. 2 can be the same base fabric 1 illustrated in FIG. 1. In this case, the bacterial biopolymer layer 20 is provided on the base fabric 1 on its front side 5. In particular, the bacterial biopolymer layer 20 is coupled with the additional layer 1b of loop portions 7; in other words, the base fabric 1 is coupled with the layer of bacterial biopolymer 20 through the additional layer 1b, i.e., through the loop portions 7. The loop portions 7 act as “securing means” to maintain the bacterial biopolymer layer 20 attached to the front side 5 of the base fabric 1.

(19) FIG. 3 is a schematic cross-sectional view of a portion of a composite fabric 10 according to the invention, comprising a base fabric 1 and a bacterial biopolymer layer 20.

(20) FIG. 3 shows a base fabric 1, having warp yarns 2 and weft yarns 3,4 woven together, having a front side 5 and a back side 6.

(21) First weft yarns 3 of base fabric 1 are woven together with the warp yarns 2 to form a base layer 1a of the base fabric 1; the second weft yarns 4 form an additional layer 1b of the base fabric 1.

(22) In particular, second weft yarns 4 form an additional layer 1b of the base fabric 1 in the form of loop portions 7, on the front side 5 of the base fabric 1. FIG. 3 shows an embodiment of the composite fabric 10 of the invention wherein the bacterial biopolymer layer 20 is coupled with the base fabric 1 by means of the additional layer 1b of the base fabric 1. Loop portions 7, which form the additional layer 1b of the base fabric 1, are, as shown in FIG. 3, “immersed” into the bacterial biopolymer layer 20. The bacterial biopolymer layer 20 is thus “anchored” (i.e. “attached” or “secured”) to the base fabric 1 through the loop portions 7.

(23) Embodiments of the composite fabric 10 of the invention, where the loop portions 7 of the base fabric 1 are “immersed” into the bacterial biopolymer layer 20, can be advantageously obtained by growing (i.e. “producing”) the bacterial polymer directly on the base fabric 1.

(24) For example, the composite fabric 10 illustrated in FIG. 3, can be obtained by contacting the front side 5 (i.e., the same side of the base fabric 1 where second weft yarns 4 form the additional layer 1b in the form of loop portions 7) of the base fabric 1, with a culture of bacterial biopolymer-producing microorganisms, e.g. bacterial biopolymer-producing bacteria, and culturing the bacterial biopolymer-producing microorganisms. The loop portions 7 allow the bacterial biopolymer-producing microorganisms to pass through the additional layer 1b on the front side 5 of the base fabric 1, reaching and contacting the surface of the base layer 1a on the front side 5 of the base fabric 1. In various embodiments, bacterial biopolymer-producing microorganisms do not penetrate deeply into the base layer 1a, but they substantially settle on the surface of the base layer 1a on the front side 5 of the base fabric 1. Bacterial biopolymer-producing microorganisms are then cultured, allowing them to produce a layer of bacterial biopolymer 20 (i.e. a bacterial biopolymer layer 20) which can have a thickness that is, for example, smaller, equal or greater than the thickness of the additional layer 1b. For example, a bacterial biopolymer layer 20, e.g. a layer of bacterial cellulose, according to the invention, is grown on the fabric, in about 10 to 23 hours, e.g. 14-18 hours.

(25) In the embodiment of FIG. 3, the bacterial biopolymer layer 20 has a thickness that is greater than the thickness of the additional layer 1b.

(26) For example, a garment comprising the composite fabric 10 of FIG. 3, has the bacterial biopolymer layer 20, which is on the front side 5 of the base fabric 1, that is visible when the garment is worn; i.e., the bacterial biopolymer layer 20 is on the external visible side of the garment. The back side 6 of the base fabric 1, on the contrary, is on the internal side of the garment and is not visible when the garment is worn.

(27) FIG. 4 is a schematic perspective view of an exemplary embodiment of the base fabric 1 according to the invention.

(28) FIG. 4 shows a base fabric 1, having a front side 5 and a back side 6.

(29) Base fabric 1 of FIG. 4 comprises warp yarns 2, first weft yarns 3 and second weft yarns 4. Warp yarns 2 and first weft yarns 3 form the base layer 1a of the base fabric 1.

(30) The second weft yarns 4 form loop portions 7, by floating under a determined number of warp yarns 2. Loop portions 7 form the additional layer 1b on the back side 6 of the base fabric 1.

(31) In the exemplary embodiment of FIG. 4, the second weft yarns 4 form loop portions 7 by floating under eleven warp yarns 2.

(32) FIG. 4 shows a base fabric 1 which comprises two pluralities of second weft yarns 4, form the additional layer 1b on the back side 6 of the base fabric 1 in the form of loop portions 7.

(33) FIG. 5 shows a schematic perspective view of a composite fabric 10 according to the invention. FIG. 5 shows a base fabric 1 coupled with a bacterial biopolymer layer 20.

(34) The base fabric 1 of the exemplary embodiment of the composite fabric 10 according to the invention represented in FIG. 5 can be, e.g., the same base fabric 1 illustrated in FIG. 4.

(35) Base fabric 1 of FIG. 5 comprises warp yarns 2, first weft yarns 3 and second weft yarns 4, and has a front side 5 and a back side 6. Warp yarns 2 and first weft yarns 3 form the base layer 1a of the base fabric 1.

(36) The second weft yarns 4 form the additional layer 1b, in the form of loop portions 7, on the back side 6 of the base fabric 1.

(37) The bacterial biopolymer layer 20 is provided to the base fabric 1 on the back side 6 of the base fabric 1. In other words, the layer of bacterial biopolymer 20 is coupled with the additional layer 1b of the base fabric 1, i.e. is coupled with the loop portions 7 on the back side 6 of the base fabric 1. FIG. 5 shows an embodiment of the composite fabric 10 of the invention wherein the base fabric 1 is coupled, through its additional layer 1b, i.e., through the loop portions 7, with a bacterial biopolymer layer 20, on its back side 6. The loop portions 7 act as “securing means” to maintain the bacterial biopolymer layer 20 attached to the back side 6 of the base fabric 1.

(38) FIG. 5 schematically represents an embodiment of the composite fabric 10 of the invention wherein the bacterial biopolymer layer 20 has a thickness that is equal to the thickness of the additional layer 1b.

(39) FIG. 6 is a schematic cross-sectional view of a portion of an exemplary composite fabric 10 according to the invention.

(40) FIG. 6 shows a base fabric 1, having warp yarns 2 and weft yarns 3,4 woven together, and a front side 5 and a back side 6.

(41) First weft yarns 3 of base fabric 1 are woven together with the warp yarns 2 to from a base layer 1a of the base fabric 1; the second weft yarns 4 form an additional layer 1b of the base fabric 1.

(42) More in detail, second weft yarns 4 form an additional layer 1b of the base fabric 1 in the form of loop portions 7, on the back side 6 of the base fabric 1.

(43) FIG. 6 shows an embodiment of the composite fabric 10 of the invention wherein the bacterial biopolymer layer 20 is coupled with the additional layer 1b of the base fabric 1; i.e., in other words, the base fabric 1 is coupled, through its loop portions 7, with the bacterial biopolymer layer 20, the loop portions 7 forming the additional layer 1b of the base fabric 1, on the back side 6 of the base fabric 1.

(44) For example, a garment comprising the composite fabric 10 of FIG. 6, has the bacterial biopolymer layer 20, which is on the back side 6 of the base fabric 1, that is not visible when the garment is worn. The front side 5 of the base fabric 1, on the contrary, is on the external side of the garment and is visible when the garment is worn.

(45) Similarly to the embodiment of the composite fabric of the invention illustrated in FIG. 3, the composite fabric 10 of FIG. 6 has loop portions 7 (which form the additional layer 1b of the base fabric 1 on the back side 6 of the base fabric 1) that extent into the bacterial biopolymer layer 20. In other words, loop portions 7 are “immersed” into the bacterial biopolymer layer 20. The bacterial biopolymer layer 20 is thus “anchored” (i.e. “attached” or “secured”) to the base fabric 1, on its back side 6, through the loop portions 7.

(46) Embodiments of the composite fabric 10 as shown in FIG. 6 can be advantageously obtained by growing (namely “producing”) the bacterial biopolymer layer 20 directly on the base fabric 1. For example, a bacterial biopolymer layer 20 can be produced on a base fabric 1 by contacting the back side 6 (i.e., the same side of the base fabric 1 where the second weft yarns 4 form the additional layer 1b in the form of loop portions 7) of the base fabric 1, with a culture of bacterial biopolymer-producing microorganisms, and culturing the bacterial biopolymer-producing microorganisms directly on the base fabric 1.

EXAMPLES

(47) The following examples will better illustrate an exemplary process for the production of a composite fabric according to the invention.

(48) The following examples are to be interpreted as merely illustrative and they do not limit the scope of the invention.

Example 1

(49) A sample base fabric according to the invention is provided.

(50) The fabric has a plurality of warp yarns, a plurality of first weft yarns and a plurality of second weft yarns, according to the weaving report illustrated in FIG. 7.

(51) Warp yarns are 73,875 tex (Ne 8/1), Ring slub cotton

(52) First weft yarns (“1”) are 84,43 tex (Ne 7/1), Ring cotton

(53) Second weft yarns (“2”) are 11,82 tex (Ne 50/1) Combed cotton

(54) Warp density of the fabric is 29.5 threads/cm

(55) Weft density of the fabric is 42.0 picks/cm

(56) Warp yarns and first weft yarns form the base layer of the base fabric.

(57) The second weft yarns form an additional layer, in the form loop portions that float over 7 warp yarns, on the front side of the base fabric.

(58) The ratio first weft yarns to second weft yarns is 1:1.

Example 2

(59) 0.06 m.sup.2 of the base fabric of Example 1 is contacted on its front side, where the second weft yarns form the additional layer, with 25 ml a culture of Gluconacetobacter hansenii having a concentration of 2×10.sup.4 cells/ml.

(60) The culture used is a culture of Gluconacetobacter hansenii, in Hestrin-Schramm (HS) medium containing 2% (w/v) glucose, 0.5% (w/v) peptone, 0.5% (w/v) yeast extract, 0.27% (w/v) Na.sub.2HPO.sub.4 and 1.15 g/L citric acid, and it is applied on the front side of the base fabric, i.e. on the same side on which the loop portions are present. For example, the culture of bacterial-biopolymer producing microorganisms (in this case, bacteria) can be applied by spraying it on the base fabric, or it can be pipetted on the base fabric.

Example 3

(61) After the application of the bacterial culture of Example 2 on the base fabric, the base fabric is incubated for 16 hours, at temperature 28° C.

(62) After 16 hours, at temperature 28° C., a layer of bacterial cellulose is obtained on the front side of the fabric, i.e. a composite fabric is obtained.

Example 4

(63) The composite fabric obtained in Example 3 is washed with 0.1M NaOH at 80° C. temperature, for 20 minutes, to remove the residual bacteria from the composite fabric.

Example 5

(64) The washed composite fabric is dyed, by impregnating the composite fabric with a solution of indigo dye.

(65) The fabric including a dyed biopolymer layer, particularly a bacterial cellulose indigo dyed biopolymer layer, may undergo finishing processes as disclosed in co-pending application having title “A process of preparing a dyed fabric including a bacterial biopolymer and having unique appearance” in the name of the present applicant. The finishing processes may impart the dyed fabric with a “multi-shaded” appearance and/or “vintage” or worn-out look.

(66) Although the invention has been described in terms of various embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the disclosure, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.