METHOD FOR PRODUCING A VEGETABLE PLANAR TEXTILE STRUCTURE

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.

Claims

1. Process for the production of a non-synthetic textile surface structure, comprising the steps of: a) providing a pulp comprising at least one liquid, at least one non-synthetic fiber material, at least one binder, and at least one process additive; and b) producing a non-synthetic textile surface structure by at least partially separating the liquid, from the pulp, wherein the at least one binder comprises at least one natural latex.

2. The process according to claim 1, wherein step a) comprises one or more of the following sub-steps: a1) providing the non-synthetic fiber material, wherein the non-synthetic fiber material comprises or consists of shortened and/or un-shortened fibers; a2) adding the at least one liquid to the non-synthetic fiber material; a3) mechanically processing the non-synthetic fiber material; a4) cleaning the non-synthetic fiber material; a5) adding at least one binder; a6) adding at least one process additive; a7) adding at least one auxiliary agent; or a8) production of the pulp.

3. The process according to claim 1, wherein step b) comprises one or more of the following sub steps: b1) applying the pulp provided in step a) to a liquid-permeable carrier element for at least partial separation of the at least one liquid; b2) producing a pulp layer comprising the pulp from step a), wherein the at least one liquid is at least partially removed from the pulp layer; b3) drying the pulp layer; b4) carrying out a moulding process on the pulp layer to obtain the non-synthetic textile surface structure; or b5) adding at least one auxiliary agent.

4. The process according to claim 2, wherein the mechanical preparation in step a3) comprises splitting the non-synthetic fiber material into fibers, or fibrillating it.

5. The process according to claim 1, wherein the at least one process additive is selected from the group consisting of polysaccharides, starch, modified starch, cationically modified starch, cellulose or derivatives thereof, carboxymethylated cellulose, cellulose acetate, hydroxypropylmethylcellulose, aluminum sulphate, and mixtures thereof.

6. The process according to claim 1, wherein the at least one binder further comprises synthetic latex.

7. The process according to claim 1, 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.

8. The process according to claim 1, wherein the non-synthetic fiber material is selected from vegetable fiber material, natural fibers, cellulose, recycled cellulose, textiles made of natural fibers, recycled textiles made of natural fibers, or mixtures thereof.

9. The process according to claim 1, wherein the method further comprises the following step: c) carrying out a post-treatment on the non-synthetic textile surface structure produced in step b).

10. Use of cationic starch as a process additive in the process according to claim 1.

11. Non-synthetic textile surface structure obtainable by the process according to claim 1.

12. Non-synthetic textile surface structure comprising a non-synthetic fiber material, at least one process additive, and at least one binder, wherein the at least one binder comprises natural latex.

13. Non-synthetic textile surface structure according to claim 12, further comprising 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.

14. Use of the non-synthetic textile surface structure according to claim 12 as a leather substitute for the manufacture of fashion, furniture, car interiors, stationery covers, facade paneling, or floor coverings.

15. Leather substitute comprising the non-synthetic textile surface structure according to claim 12.

16. Leather substitute according to claim 15 further comprising decorations, engravings, embossings, embroideries, coatings, adhesions, or mixtures thereof.

17. The process according to claim 1, wherein the at least one liquid is water.

Description

[0095] 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.

[0096] FIG. 1 shows a photographic representation of a non-synthetic fiber material made from un-shortened fibers;

[0097] FIG. 2 shows a photographic representation of a partially dewatered pulp layer for sheet formation; and

[0098] FIG. 3 shows a photographic representation of a finished non-synthetic textile surface structure.

[0099] 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 FIG. 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.

[0100] 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 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.

[0101] 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.

[0102] 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-K?then sheet formers) or by hand, similar to paper scooping.

[0103] 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 FIG. 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.

[0104] 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.

[0105] In a continuous process, pressing and drying takes place via pairs of rollers and drying cylinders or via calenders.

[0106] The surface of the dried material can be further refined by embossing or pressing between metal plates or rollers.

[0107] 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 FIG. 3.

EXAMPLES

[0108] The present invention is explained again below with reference to the examples, but without being limited to these.

Example 1

[0109] 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.

[0110] A grey/black surface structure, haptically reminiscent of leather, is obtained. The surface structure is stiff after drying.

Example 2

[0111] 30 g of hemp fibers are cut to a length of 0.5 cm and mixed with water to a total weight 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 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.

[0112] The non-synthetic textile surface structure shown in FIG. 3 is obtained, which is reminiscent of leather in its feel and appearance.