METHOD AND APPARATUS FOR MANUFACTURING A STAPLE FIBER BASED ON NATURAL PROTEIN FIBER, A RAW WOOL BASED ON THE STAPLE FIBER, A FIBROUS YARN MADE OF THE STAPLE FIBER, A NON-WOVEN MATERIAL MADE OF THE STAPLE FIBER AND AN ITEM COMPRISING THE STAPLE FIBER.

Abstract

Disclosed embodiments describe a method for manufacturing a staple fiber based on natural protein fiber. The method may include: providing a protein suspension, the protein suspension comprising fibrils of the natural protein fiber; directing the protein suspension through a nozzle onto a surface for forming a protein based fiber; drying the protein suspension on the surface; extracting the fiber from the surface; and providing the staple fiber. Disclosed embodiments may further describe a fiber based raw wool. The raw wool may include staple fibers, wherein the staple fibers are reconstructed on the basis of protein fibrils and are mechanically subdivided from natural protein fibers, wherein the protein fibrils are interlocked by hydrogen bonds, and wherein the raw wool comprises an unoriented, entangled, fluffy network of staple fibers.

Claims

1. -48. (canceled)

49. A method for manufacturing a staple fiber based on natural protein fiber, the method comprising: providing a protein suspension, the protein suspension comprising fibrils of the natural protein fiber; directing the protein suspension through a nozzle onto a surface for forming a protein based fiber; drying the protein suspension on the surface; extracting the fiber from the surface; and providing the staple fiber.

50. The method of claim 49, wherein the natural protein fibers comprise collagen fibers.

51. The method of claim 49, wherein the natural protein fibrils are mechanically divided from a source of natural protein fibers.

52. The method of claim 49, wherein the protein suspension exits the nozzle in at least one of a round of elliptic cross-sectional shape.

53. The method of claim 49, wherein drying the protein suspension on the surface comprises drying via at least one of: radiation, blowing, and conduction.

54. The method of claim 49, wherein the surface comprises a hydrophobic external surface.

55. The method of claim 49, further comprising applying at least one of oil and wax to the surface.

56. The method of claim 49, wherein the protein suspension is dried on the surface to a dry concentration of at least 70% by weight for forming a fiber, and wherein the weight percent is given with reference to the weight of the formed and dried fiber.

57. The method of claim 49, wherein the staple fiber has a length of 6-80 mm.

58. The method of claim 49, wherein the staple fiber has a length of 40-60 mm.

59. The method of claim 49, further comprising combining the staple fibers into a raw wool.

60. The method of claim 59, further comprising processing the raw wool to form at least one of: a yarn strand and a non-woven material.

61. The method of claim 59, further comprising: processing the raw wool into a pre-yarn; and spinning the pre-yarn into a yarn.

62. The method of claim 49, further comprising processing the raw wool into a non-woven material.

63. The method of claim 49, wherein the suspension comprises collagen fibrils of natural fiber, and wherein the collagen content of the suspension is more than 50% of the total weight of natural protein fiber fibrils in the suspension.

64. A fiber based raw wool, the raw wool comprising staple fibers, wherein the staple fibers are reconstructed on the basis of protein fibrils and are mechanically subdivided from natural protein fibers, wherein the protein fibrils are interlocked by hydrogen bonds, and wherein the raw wool comprises an unoriented, entangled, fluffy network of staple fibers.

65. The wool of claim 64, wherein the staple fibers have a length of 6-80 mm.

66. The wool of claim 64, wherein the staple fibers have a length of 40-60 mm.

67. The wool of claim 64, wherein the wool has at least one of: a staple fiber yarn count of 1-20 dtex; a staple fiber diameter of 15-70 m; a staple fiber tensile strength of 15-25 cN/tex; and elongation at break of 5-15%.

68. The wool of claim 64, wherein the natural protein fibers comprise collagen fibers.

69. The wool of claim 64, wherein the natural protein fibrils comprise collagen fibrils obtained from natural collagen fibers.

Description

DESCRIPTION OF DRAWINGS

[0095] In the following embodiments of the invention are described with the accompanying figures of which

[0096] FIG. 1 illustrates a method for manufacturing a fiber based raw wool according to an embodiment.

[0097] FIG. 2 illustrates a method for manufacturing a fiber based raw wool according to an embodiment.

[0098] FIG. 3 illustrates an apparatus for manufacturing a fiber based raw wool according to an embodiment.

[0099] FIG. 4 illustrates a cylinder according to an embodiment.

[0100] FIG. 5 illustrates an apparatus for manufacturing a fiber based raw wool according to an embodiment.

[0101] FIG. 6 illustrates a belt according to an embodiment of the invention.

[0102] FIG. 7 illustrates a staple fiber according to an embodiment of the invention.

[0103] FIG. 8 illustrates a staple fiber according to an embodiment of the invention.

[0104] FIG. 9 illustrates a fiber based raw wool.

[0105] FIG. 10 illustrates a tensile strength graph.

DESCRIPTION OF EMBODIMENTS

[0106] FIG. 1 illustrates a method for manufacturing a natural fiber based raw wool according to an embodiment. A protein suspension is provided 101. The protein suspension comprises aqueous suspension of mechanically divided protein fibrils. In other words, the protein fibrils as such are to be regarded as natural fibril. The protein suspension may comprise water, divided protein fibrils and at least one rheology modifier. Fibrils of the protein suspension may originate from mechanically shortened protein fibers. In a preferred embodiment of the invention, the protein fibrils are collagen fibrils originating from tanned hide-based material. The collagen fibrils may thus originate from e.g. wet-blue, i.e. hides which has been tanned and where the collagen fibers used as a basis for the reconstructing of a collagen based filament has been pretreated e.g. by chromium salts according to conventional and well-known tanning methods.

[0107] The protein suspension is directed through a nozzle 102. The nozzle feeds the protein suspension to a surface. The surface may be a surface of a belt or of a cylinder. The protein suspension is dried on the surface 103. Drying removes water from the protein suspension. The dried protein suspension is arranged to form a reconstructed fiber on the surface. The reconstructed fiber may be arranged in a form of a continuous reconstructed fiber. The continuous reconstructed fiber is extracted from the surface 104. The reconstructed fiber extracted from the surface is cut or shortened in order to form staple fibers 105. The stable fibers are arranged to form an inhomogeneous network comprising fiber concentrations of varying density and orientation. The inhomogeneous fluffy material of staple fibers is called a natural fiber based raw wool 106.

[0108] The above process is described as a process using collagen fibers as a source for the manufacture of staple fibers. The process may be repeated with another protein fiber base, such as elastin or resilin.

[0109] FIG. 2 illustrates a method for manufacturing a natural fiber based raw wool according to an embodiment. A protein suspension is provided 201. The protein suspension comprises aqueous suspension of divided protein fibrils. The protein suspension may comprise water, at least one rheology modifier and divided protein fibrils. Divided protein fibrils may originate from tanned hides, which has been mechanically subdivided into pulp. The protein suspension is directed through a nozzle 202. The nozzle feeds the protein suspension to a surface, for example on a surface of a belt or of a cylinder. The protein suspension is arranged to be shortened and dried on the surface 203. The dried and shortened protein suspension is arranged to form staple fibers. This is enabled by grooves (not shown) arranged on a surface. In following embodiments grooves refer to structures enabling a formation of staple fibers having a length defined by the distance between the groove. Those grooves, including grooves 401 and 601 may generally alternatively be made as ridges performing the same function, i.e. weakening strength of the reconstructed filament at positions where the filament may divide or break into the desired reconstructed staple fibers. The shortened fibers are extracted from the surface 204. The stable fibers are arranged to form an inhomogeneous network comprising fiber concentrations of varying density and orientation. The inhomogeneous fluffy material of staple fibers is called a natural fiber based raw wool 206.

[0110] A protein suspension could comprise collagen fibrils. Collagen fibrils are natural fibrils originating from shavings, leather waste, pulp and/or tanned hides including the hazardous waste material from the tanning process. The collagen fibrils are thus originating from different animals, typically skin. This may include wet blue and wet white shavings or leather shavings or tanned hide shavings.

[0111] Collagen may have macromolecular structure repeating amino acid sequences (GPX)n and glycine(G)-X-hydroxyproline(HYP). (GPX)n is the most common amino acid sequence in collagen. In the sequence X refers to any amino acid other than glycine, proline or hydroxyproline. The amino acid composition of collagen is atypical for proteins, particularly with respect to its high hydroxyproline content. Collagens are the most abundant proteins found in tissues of animals. Collagen is main structural protein in extracellular space in the connective tissues including tendons, ligaments and skin. There are several types of collagen. Type I (skin, tendon, bone), II (hyaline cartilage), III (reticulate), V (cell surfaces, hair, placenta) and XI (cartilage) being fibrillar. A single collagen molecule, tropocollagen, is used to make up larger collagen aggregates, such as fibrils. A collagen fibril is approximately 10 micrometers long and a diameter around 10 to 500 nm. It is made up of three polypeptide strands (called alpha peptides), each of which has the conformation of a left-handed helix. These three left-handed helices are twisted together into a right-handed triple helix or super helix, a cooperative quaternary structure stabilized by many hydrogen bonds. With type I collagen and possibly all fibrillar collagens, if not all collagens, each triple-helix associate into a right-handed super-super-coil referred to as the collagen microfibril. Each microfibril is interdigitated with its neighboring microfibrils.

[0112] If collagen is irreversibly partially hydrolyzed (e.g., by heat and chemicals), it is termed gelatin. Gelatin is modified protein.

[0113] Collagen fibrils may be in native form, which have not undergone any chemical modification. Natural collagen fibers and natural collagen fibrils may be non-regenerated. Thus, natural collagen fibers/fibrils have not undergone chemical regeneration or physical modification of the collagen polymer structure. It should nevertheless be noted that the collagen fibrils may have been chemically or at least physically affected when the source of collagen fibrils are tanned hides of animals.

[0114] Mechanical disintegration into protein fibrils from protein raw material, protein pulp, or refined pulp is carried out with suitable equipment such as a refiner, grinder, homogenizer, colloider, friction grinder, ultrasound sonicator, fluidizer such as microfluidizer, macrofluidizer or fluidizer-type homogenizer.

[0115] In particular and advantageously mechanical disintegration into collagen fibrils from collagen raw material, collagen pulp, or refined collagen pulp is carried out with suitable equipment such as a refiner, grinder, homogenizer, colloider, friction grinder, ultrasound sonicator, fluidizer such as microfluidizer, macrofluidizer or fluidizer-type homogenizer.

[0116] Protein fibers, such as collagen fibers may be isolated from any relevant protein containing raw material using chemical-, mechanical-, bio-, thermo-mechanical-, or chemi-thermo-mechanical pulping process. Mechanically shortened, divided or cut fibers may comprise chemically or physically modified derivative of collagen micro fibrils or fibril bundles.

[0117] A protein suspension may comprise 80-98 wt-% of water and 2-20 wt-% of protein. The protein suspension may comprise 85-98 wt-% of water and 2-15 wt% of protein. In addition, the protein suspension may comprise 0-5 wt-% of rheology modifier.

[0118] A collagen suspension may comprise 80-98 wt-% of water and 2-20 wt-% of collagen. The collagen suspension may comprise 85-98 wt-% of water and 2-15 wt% of collagen. In addition, the collagen suspension may comprise 0-5 wt-% of rheology modifier.

[0119] The mechanically divided protein fibril may be pure protein structures, or comprise chemically modified or chemically treated protein fibrils. Thus, the protein suspension comprises mechanically divided or shortened protein fibers. According to a preferred embodiment of the invention, the applied protein source is collagen.

[0120] Fiber product may include additives like rheology modifier(s), binder(s), cation active reagent(s), crosslinking agent(s), dispersion agent(s), pigment(s), and/or other modifier(s).

[0121] Fiber and staple fibers may comprise additives such as alginate, alginic acid, pectin, carrageenan, cationic polyacrylamide (CPAM), anionic polyacrylamide (APAM), cationic polyacrylamide (CPAM) i, cationic starch, chitosan, polyethylene oxide (PEO), carboxymethyl cellulose (CMC), starch, enzymes (such as laccase, transglutaminase), polyphenols, glutaraldehyde, gelatine, casein, glucose, Tris-HCl, phosphate or a combination of such.

[0122] Rheology modifier comprises a compound or agent arranged to modify the viscosity, yield stress and/or thixotropy of the suspension. Rheology modifier may comprise high molecular weight polymers. Rheology modifier is arranged to modify protein suspension rheology by adjusting gel strength and yield point of the protein suspension.

[0123] FIG. 3 illustrates an apparatus for manufacturing natural fiber based raw wool according to an embodiment. A protein suspension 310 is fed to a nozzle 320. The refined fibrils of the protein suspension align in a nozzle. The aqueous suspension of water and fibrils of the protein suspension form an oriented fibril network in a nozzle 320.

[0124] The protein suspension 310 is directed onto a cylinder 300 via the nozzle 320. The protein suspension exiting the nozzle 320 is shaped according to the nozzle outlet opening. The nozzle outlet opening may be shaped as a round or as elliptic, for example. The protein suspension exits the nozzle 320 in a form of a continuous strand having a cross-sectional shape corresponding to that of the nozzle outlet opening. The protein suspension exiting the nozzle 320 may have round or elliptic cross-sectional shape.

[0125] The nozzle 320 may be arranged to move back and forth along the longitudinal direction C, i.e. direction of the rotational axis A, of the cylinder 300, along horizontal plane. The protein suspension 310 is directed to a certain horizontal level along the longitudinal cylinder surface. Due to rotation of the cylinder 300 and movement of the nozzle 320, the fed protein suspension 310 circles around the cylinder surface forming a round next to a round, or partly overlapping with adjacent rounds. The continuously injected protein suspension 310 moves on the surface of the cylinder 300 with the rotating cylinder 300. While the cylinder 300 rotates around its rotational axis A, the nozzle 320 is arranged to move to an adjacent place along longitudinal cylinder surface C.

[0126] Alternatively, two or more nozzles may be arranged adjacent, parallel along longitudinal cylinder surface C. The two or more nozzles are united, forming an integrated unit, and arranged to move concurrent along longitudinal cylinder surface C. The distance between two adjacent nozzles may be in order of centimeters, for example 1 cm. The nozzle(s) are oscillating along the longitudinal dimension of the cylinder. In case of two or more nozzles arranged at 1 cm distance from each other, the time that the nozzles take to move 1 cm corresponds to drying time of the protein suspension injected on the cylinder surface. Moving speed of nozzles is arranged such that time for a length of the dimension between the two adjacent nozzles is arranged to correspond to drying time of the protein suspension.

[0127] During drying water is removed and fibrils star forming hydrogen bonds. Thereby fiber is formed. Dried protein suspension or fiber forming or fiber refer to dry content of at least 70 wt-%. Fiber yarn count comprises 1-20 dtex. Fiber diameter may be 15-70 m. Fiber tensile strength may be 10-25 cN/tex, preferably 15-20 cN/tex, and comprise stretch or elongation break of 10-30%, preferably 15-25%.

[0128] In case of multiple nozzles along the longitudinal dimension of the cylinder, the multiple nozzles may be placed next to each other along the whole longitudinal dimension of the cylinder. Thus, there is no need for movement of nozzles, but those may be fixed in their places. In this case the drying time of the protein suspension corresponds to time of rotation of the cylinder.

[0129] With two or more nozzles, the cylinder is covered with protein suspension and fiber is formed faster than in case of one nozzle. Accordingly extracting fibers, providing oil or wax and other relating functions shall be accomplished at corresponding pace.

[0130] The protein suspension exit from a nozzle and/or injection onto a surface may be controlled hydraulically or pneumatically. Velocity of the protein suspension exiting the nozzle may be controlled by pressure applied on the protein suspension at the nozzle.

[0131] An oil or wax supply 330 may be arranged relative to a surface of the cylinder 300. The oil or wax supply 330 is arranged to move, in an oscillating manner, as the nozzle 320, along longitudinal dimension of the cylinder 300, parallel with the axis of rotation A of the cylinder 300, at certain vertical level. In case of oscillating nozzle(s) 320 the oil or wax supply 330 is arranged to oscillate simultaneously with the nozzle(s) 320.

[0132] Rotation of a cylinder may be controlled externally, for example by an electric motor, whose rotational speed is adjustable. A cylinder or a curved belt may generate a centripetal acceleration of 1-1000 g, preferably 100-500 g. Diameter of a cylinder may be 1-6 m. Rotational speed of the surface of the cylinder may be 5-25 m/s. The centripetal force (Fcp) acting on suspension (m) is dependent on radius (r) of the cylinder and its rotational surface speed (v). The centripetal force (Fcp) acting on suspension (m) is dependent on radius (r) of curvature of a belt and its rotational surface speed (v). Mathematically: Fcp=ma=mv2/r; wherein a=v2/r.

[0133] The protein suspension is dried on the surface of the cylinder 300. This may be effected internally and/or externally. Heating internally may be effected via electric heating resistor, heating steam or air. Heating externally may be effected via irradiation, heating and/or air blow. The dried protein suspension forms a fiber 350 onto surface of the cylinder 300. The fiber 350 is extracted from the surface of the cylinder 300.

[0134] Extracting may be based on blowing, suction, vacumization, scraping or dropping fibers from the surface based on gravitation. The fiber 350 may be extracted mechanically or using vacuum or pressurized air. The extraction may be implemented manually or automatically. An extractor may be placed on a side of the cylinder 300 opposite to the nozzle 320. The extractor may have a fixed place, or the extractor may be arranged to move, in an oscillating manner, as the nozzle 320, along longitudinal dimension of the cylinder 300, parallel with the axis of rotation A of the cylinder 300, at certain vertical level. The extractor is arranged to oscillate simultaneously with the nozzle. The extractor may be integrated with the oil or wax supply 330 and move with it. Oil or wax is supplied on a cylinder surface after the fiber has been extracted from the cylinder surface.

[0135] The extracted fiber 360 is in form of unoriented and entangled fiber based raw wool, which may comprise uneven clumps among fluffy fiber based raw wool. When the fiber based raw wool comprises continuous fiber, the length of fiber is arranged to be cut or shortened to form staple fibers. After shortening fiber based raw wool comprising staple fibers is formed.

[0136] The fiber comprises linear mass density of 1-20 dtex, which relates to an amount of mass per unit length (1 tex=1 g/1000 m; and 1 decitex=1 dtex=1 g/10000 m). Tenacity of the fiber comprises 10-25 cN/tex, preferably 15-20 cN/tex. Stretch to break the fiber is 10-30%, preferably 15-25%. Some of the oil from the drying surface is present in the fiber surface. The oil or wax on the fiber surface has effect on further processing of the fiber based raw wool, for example to the friction and adhesion between fibers of the raw based wool.

[0137] FIG. 4 illustrates a cylinder according to an embodiment of the invention. FIG. 4 shows axis of rotation A of the cylinder 400. Cylinder may comprise an even, flat external surface or a grooved surface, as illustrated in the FIG. 4. Grooves 401 are arranged onto external surface of the cylinder 400 parallel with the axis of rotation A of the cylinder 400. The injected protein suspension is in contact with ridges 402 between the grooves 401 of the cylinder surface. Grooves 401 form a weak point for the protein suspension and have effect of forming a discontinuity for the continuously injected protein suspension. The continuously injected protein suspension has a break at each groove. Thereby the protein suspension forms separate parts of length of ridges 402 between the grooves 401. After extensive water is dried, staple fiber is formed onto the cylinder, on the ridges 402 between the grooves 401. Length of formed staple fibers is determined by the length between grooves 401 on the cylinder surface.

[0138] In case of grooved cylinder, the fiber based raw wool extracted from the cylinder comprises staple fibers. No additional refining, shorting or cutting means or phases are needed. The staple fiber based raw wool is processable. The fiber based raw wool comprises staple fibers, which have been shortened to a predefined length with the aid of grooves. The spacing between the grooves on the cylinder surface determine length of the staple fibers.

[0139] FIG. 5 illustrates an apparatus for manufacturing natural fiber based raw wool according to an embodiment. A protein suspension 510 is fed to a one or more nozzle 520. The refined fibrils of the protein suspension align in a nozzle. The fibrils of the protein suspension form an oriented fibril network in a nozzle 520.

[0140] The protein suspension 510 is directed onto a belt 500 via the nozzle(s) 520. The protein suspension exiting the nozzle 520 is shaped according to the nozzle outlet opening. The nozzle outlet opening may be shaped as a round or as elliptic, for example. The protein suspension exits the nozzle 520 in a form of a continuous strand having a cross-sectional shape corresponding to that of the nozzle outlet opening. The protein suspension exiting the nozzle 520 may have round or elliptic cross-sectional shape.

[0141] Two or more nozzles may be arranged adjacent, parallel along cross-sectional or transverse belt surface. Cross/transverse dimension refers to a width dimension of the belt; perpendicular to a longitudinal dimension of the belt, which corresponds to the moving direction of the belt. The two or more nozzles may be united, form an integrated unit. The distance between two adjacent nozzles may be in order of 0.5-50 mm, or 0.5-20 mm, for example 1 mm. The multiple nozzles may be placed next to each other along the whole cross dimension of the belt. In such case the whole cross dimension of the belt is covered with injected protein suspension at the same time via multiple nozzles.

[0142] During drying water is removed and fibrils star forming hydrogen bonds. Thereby fiber is formed. Hydrogen bonds are formed when dry content is from 70 wt-% to 100 wt-%. Dried protein suspension or fiber forming or fiber refer to dry content of at least 70 wt-%.

[0143] The protein suspension exit from a nozzle and/or injection onto a surface may be controlled hydraulically or pneumatically. Velocity of the protein suspension exiting the nozzle may be controlled by pressure applied on the protein suspension at the nozzle.

[0144] An oil or wax supply 530 may be placed before the nozzle(s) 520 in relation to the moving direction of the belt 500. The oil or wax supply 530 may be arranged to move, in an oscillating manner along cross dimension of the belt 500, perpendicular with direction of movement of the belt 500. The oil or wax supply 530 is arranged after fiber extraction phase. Oil or wax is supplied on the surface of the belt 500. The protein suspension is injected on an oily belt surface.

[0145] The protein suspension is dried on the surface of the belt 500. This may be effected internally and/or externally. Heating internally may be effected via the belt, e.g. by an electric heating resistor, heating steam or air. Heating externally may be effected via irradiation, heating and/or air blow. The dried protein suspension forms a fiber 550 onto surface of the belt 500. The fiber 550 is extracted from the surface of the belt 500. Extracting may be based on blowing, suction, vacumization, scraping or dropping fibers from the surface based on gravitation. The fiber 550 may be extracted mechanically or using vacuum or pressurized air. The extraction may be implemented manually or automatically. An extractor may be placed on any part of the belt 500, where the dryness of the fiber is at a desired level, for example over 70 wt-%. The extractor may be placed at end of the belt, or at either external side of the belt, wherein upper external side of the belt is arranged to move at opposite direction than the lower external side of the belt. It is possible to convey protein suspension or fiber on another belt for further drying.

[0146] Oil or wax is supplied on a belt surface before the protein suspension is injected onto the surface.

[0147] The extracted fiber 560 is in form of unoriented and entangled fiber based raw wool, which may comprise uneven clumps among fluffy fiber based raw wool. When the fiber based raw wool comprises continuous fiber, the length of fiber is arranged to be cut, shortened or refined to form staple fibers. After shortening fiber based raw wool comprising staple fibers is formed.

[0148] The fiber comprises linear mass density of 1-20 dtex, which relates to an amount of mass per unit length (1 tex=1 g/1000 m; and 1 decitex=1 dtex=1 g/10000 m). Tenacity of the fiber comprises 10-25 cN/tex, preferably 15-20 cN/tex. Stretch to break or elongation break of the fiber comprises 10-30%, preferably 15-25%. Some of the oil or wax from the drying surface is present in the fiber surface. The oil or wax on the fiber surface has effect on further processing of the fiber based raw wool, for example to the friction and adhesion between fibers of the raw based wool.

[0149] FIG. 6 illustrates a belt according to an embodiment of the invention. FIG. 6 shows belt 600 comprising curved and grooved surface. FIG. 6 shows a belt for forming staple fibers, while in case of even, flat, non-curved belt a continuous fiber is formed on the belt. The curved surface of the belt comprises a radius of curvature of 0.25-4 m.

[0150] Grooves 601 are arranged onto external surface of the belt 600. The grooves 601 are arranged along a transverse direction of the belt 600, perpendicular to the longitudinal dimension or direction of movement of the belt 600. The injected protein suspension is in contact with ridges 602 between the grooves 601 of the belt surface. Grooves 601 form a weak point for the protein suspension and have effect of forming a discontinuity for the continuously injected protein suspension. The continuously injected protein suspension has a break at each groove. Thereby the protein suspension forms separate parts of length of ridges 602 between the grooves 601. After extensive water is dried, Length of formed staple fibers is determined by the length between grooves 601 on the belt surface.

[0151] In case of grooved belt, the fiber based raw wool extracted from the belt comprises staple fibers. No additional refining, shorting or cutting means or phases are needed. The staple fiber based raw wool is processable. The fiber based raw wool comprises staple fibers, which have been shortened to a predefined length with the aid of grooves. The spacing between the grooves on the belt surface determine length of the staple fibers.

[0152] When the continuous fiber is shortened as staple fibers, cut end of a staple fiber is sharp, or at least substantially sharp. Sharp cut end is illustrated in a FIG. 7. When staple fiber is formed on a curved, grooved surface by the grooves, the end of the staple fiber is uneven or irregular in comparison to the sharp cut end of a staple fiber. FIG. 8 shows end of a staple fiber, which has been formed by a curved, grooved surface.

[0153] Groove causes interruption to the applied continuous protein suspension, thereby forming separated portions of certain length, which, after dried, form staple fibers. Such interrupted surface of a staple fiber may show fibrils or smaller portions. In an extended view, uneven end surface of interruption shows irregular shape.

[0154] FIG. 9 shows a fiber based raw wool arranged on a conveyor belt. Staple fibers are extracted from cylinder to a moving conveyor belt where they are arranged in a random, bulky network.

[0155] The surface, of e.g. a belt or a cylinder, may comprise hydrophobic surface material. External surface of a cylinder or a belt may be covered with a nonporous hydrophobic polymer coating. The polymer coating has effect of forming a hydrophobic surface. The hydrophobic polymer coating may be covered with oil or wax. The coating and oil or wax coverage of the surface enable to achieve a hydrophobic, low friction and low contact angle hysteresis external surface. The oil or wax effects on protein suspension remaining in contact with the external surface via the oil or wax. The polymer coating and oil or wax on the surface and/or centripetal force of a rotating cylinder enable controlling and maintaining round cross-sectional shape of the protein suspension injected on the surface. Oil or wax and low contact angle hysteresis on the outer surface of the cylinder or the belt have effect on maintaining the round cross-sectional shape of the protein suspension during drying. Oil has effect of reducing risk of the protein-solution adhering to the surface. Oil or wax has effect of providing stable cross-sectional shape fiber and/or avoid formation of unwanted wide, thin and/or weak ribbons on the surface. Part of the oil or wax remains with the fiber and acts as finishing agent. Oil may be used for example to control friction between fibers and/or between fibers and metal during processing. These are desired parameters for processing the fiber based raw wool during further processing and formation of products, like yarn, non-woven or other.

[0156] The protein suspension directed through a nozzle onto a surface is dried on the surface. Drying is accomplished via heat and, in case of a cylinder, a rotating motion of a cylinder. Rotation of the cylinder and/or heating enable drying of provided protein suspension on the surface. A continuous fiber may be formed on the surface. Alternatively, stable fibers may be formed on the surface. The protein suspension may be dried externally and/or internally via the surface of a cylinder or of a belt. The cylinder or the belt may comprise a heating element. The cylinder or the belt may comprise an internal heater. The internal heater may implement heating electronically, via a resistor, or via hot steam. The cylinder or the belt may comprise an external heater. The external heater may provide irradiation or air blow or steam blow towards the surface in order to dry the protein suspension on the surface. The heater(s) enable drying protein suspension applied on the surface. Heater or heating elements are arranged to dry the protein suspension by removing water.

[0157] Oil or wax is applied on the surface. Oil or wax on the surface has effect of reducing surface tension, friction and/or surface contact angle hysteresis. Oil or wax may comprise, but is not limited to, fiber finishing oils to reduce fiber-fiber friction or fiber-metal friction, or a vegetable oil or a non-immiscible fluid.

[0158] The surface is arranged to move and convey the injected protein suspension. The surface may comprise grooves. Staple fibers may be formed on a curved and grooved surface. The surface may comprise a curver or round cylinder surface, or a curved belt surface. The grooves are aligned transverse to the direction of movement of a surface. Grooves are arranged transverse to the direction of movement of a belt. The grooves extend along transverse direction of the belt, which is perpendicular to the longitudinal dimension, or direction of movement of the belt. Grooves are arranged transverse to the direction of rotation of a cylinder. The grooves extend along length direction of the cylinder, being in parallel with the axis of rotation of the cylinder. The surface comprises thin grooves, in comparison to wide ridges between the grooves. The ridges of the surface form support surface for injected protein suspension, while grooves form a discontinuation places. Grooves and the ridges between them enable forming staple fibers on the surface. Injected protein suspension is arranged to break at a groove. Spacing between the grooves is configured to define length of formed staple fibers.

[0159] Width of the grooves may be 0.5-5 mm, preferably 2-3 mm. Depth of the grooves may be 0.5-10 mm, preferably 2-3 mm.

[0160] Centripetal force of a moving surface, hydrophobic properties of a surface and oil properties have effect on preserving round cross section of the injected protein suspension and fiber, as its dried form, on the surface.

[0161] As free water is removed from the protein suspension during drying, hydrogen bonds start to appear.

[0162] The dried protein solution forms a continuous fiber (strand) onto a continuous surface. Grooved and curved surface enable forming of stable fibers without additional refining or shortening after drying. The staple fibers comprise length of 6-80 mm, preferably 30-70 mm.

[0163] Long fibers or staple fibers may be interlocked together in order to form a permanent network of fibers. Disintegration of the hydrogen bonds, may be done by exposing the staple fibers to water or aqueous solution. A minor mechanical or hydrodynamical force, like a pull or a twist or a hydrodynamic shear, disintegrates a wetted staple fiber composition or product. When exposed to water, the staple fibers will return into separate primary protein fibrils. This enables forming water disposable products.

[0164] The natural fiber based raw wool comprises large specific surface area and low density. It provides good filtering properties and a good insulator, while it's thermal conductivity is low. Due to uneven fiber surface, the natural fiber based raw wool comprises high friction, which is desired property for further processing, for example manufacturing non-woven material.

[0165] The fiber based raw wool may be processed as a raw wool sheared from a sheep. The fiber based raw wool comprises staple fibers. The fiber based raw wool comprises staple fibers in fluffy arrangement, in unorganized, unoriented order and forming clumps or conglomerates of different densities.

[0166] The fiber based raw wool may be carded. Generally carding orients, detangles and cleans raw wool towards oriented strands. Carding may be performed by a card, by a carding machine, by heckling machine. Carding machine may have surface covered with carding clothing or soft-bristled brush attachment. During carding the staple fibers orientate towards common fiber orientation and the staple fiber density becomes more even, while reducing clumps. Due to carding fibers tend to orient similarly, thereby having substantially similar orientation among longitudinal dimension of fibers. The carded fiber based raw wool comprises at least mainly oriented staple fibers and density variations or clumps are reduced. The structure tends to become more homogenous during carding.

[0167] Natural fiber based raw wool has properties desired during carding, like low friction between fibers and/or between fibers and metal (of cards).

[0168] The carded fiber based raw wool may be processed as a yarn or as a non-woven material. Yarn may be made from carded fiber based raw wool by forming a continuous pre-yarn and spinning several pre-yarns as a yarn. The yarn may be used for manufacturing textiles of different kind. A textile may be made of yarn using known textile manufacturing processes and equipment.

[0169] The non-woven material may be produced from the carded fiber based raw wool by a non-woven process, or felting, for example needle punch, hydro-entanglement or other suitable method. The non-woven process binds the staple fibers mechanically in order to produce continuous non-woven material or fabric. Adhesive may be added in order to enhance bonding.

[0170] Non-woven material may be used to manufacture hygiene products. The hygiene products may be disposed with water, whereby the product breaks down to protein fibrils. The hygiene products may comprise flushable products, which disintegrate into water. Hygiene products may comprise wipes or diapers. The products made of the staple fiber based raw wool have firm fabric and feel, when those are dry. However, underlying fibrils are small and locked together via hydrogen bonds, which become very weak at aqueous environment. Once in water, even a low shear will cause staple fibers to disintegrate back to sorter protein fibrils. In addition to disposability, the non-woven material made of staple fiber based raw wool has ability to absorb and retain water. This ability is desired for products like diapers and alike.

[0171] Yarn made of natural fiber based raw wool may have yarn count of 5-200 tex. The yarn comprises tenacity of 5-15 cN/tex; and elongation at break of 3-10%. Non-woven material made of natural fiber based raw wool comprises density of 10-100 kg/m3.

[0172] The manufacturing process enables providing yarn and/or non-woven material economically and environmentally friendly way. The provided fiber based raw wool is provided by compact manufacturing phase, even as a single process. The fiber based raw wool is processable with process and equipment known from raw wool processing and handling. The fiber based raw wool may be processed as yarn using yarn spinning equipment or as non-woven material using non-woven process and method.

[0173] The staple fiber based raw wool or products have effect on biodegradability. Discarding is ecological and use of natural based cellulosic fibers enables recycling and reuse.

[0174] A natural fiber based raw wool may be used as an insulator. It forms a usable insulator before or after carding.

[0175] FIG. 10 illustrates an example of fiber strength/breaking force (cN) and elongation (%) of collagen and cellulose respectively. Breaking force of collagen is less than cellulose, but the elongation and stretch is much higher for collagen.

[0176] FIG. 10 shows an example of the mechanical properties of a collagen based staple fiber product and a cellulose staple fiber product. Staple fiber product referred to as cellulose comprises 85% of fibrous elements of natural cellulose and 15% of additive(s). Staple fiber product referred to as collagen comprises 85% of fibrous elements of collagen and 15% of additive(s). Linear mass density of the fiber products is 7.5 dtex. Elongation of the cellulose staple fiber product is about 6%. Elongation of the fiber product of collagen is about 15%. Breaking force of the fiber product of cellulose is above 14 cN. Breaking force of the fiber product of collagen is above 8 cN.

[0177] The previously presented description is presented as illustrative of aspects of the invention. Parts or details may be replaced, changed, combined or omitted without departing from the scope of the invention as defined in the claims.