Patent Application
20250011982
The invention generally relates to artificial fur including raised natural plant fibers attached to a plant-based or biodegradable base-construction and a process for making the same.
No federal funds were used to develop or create the invention disclosed and described in the patent application.
This summary is provided to introduce a variety of concepts in a simplified form that is further disclosed in the detailed description of the embodiments. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended to determine the scope of the claimed subject matter.
The present disclosure relates to a plant deep pile fabric, velvet or fleece that closely resembles and can be used in lieu of animal or synthetic fur to make a variety of products including but not limited to clothing, apparel, footwear, and interior design objects.
The disclosed plant deep pile fabric, velvet or fleece may provide for a low-environmental impact product including complete biodegradability without animal-product manufacturing.
The present disclosure relates to a method of developing a fabric from one plant fiber or a blend of natural plant fibers from different plants. Plant fibers may be chosen and combined according to their physical properties and the properties of the animal fur they should resemble.
The present disclosure relates to a method of developing a fabric utilizing mechanical, chemical, and thermal processing steps to prepare the fibers for successful assembly into fabric. These processing steps differ from existing processing steps commonly employed in synthetic fur manufacturing as natural fibers are more diverse in form, shape, and chemical composition than synthetic fibers. The final material differs from existing synthetic fur in a way, as it is completely based on natural plant material that is completely biodegradable as an end-of-life cycle scenario. The final material differs from existing synthetic fur in a way, as it does not use manmade fibers which are energy intensive to produce while preserving the structural integrity of the natural fibers.
Other illustrative embodiments within the scope of the invention will become apparent from the detailed description provided hereinafter. The detailed description and enumerated embodiments, while disclosing optional variations, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
A complete understanding of the present embodiments and features thereof will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein:
The drawings are not necessarily to scale, and certain features and certain views of the drawings may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness and should not be considered limiting.
The specific details of the single embodiment or variety of embodiments described herein are to the described system and methods of use. Any specific details of the embodiments are used for demonstration purposes only and no unnecessary limitations or inferences are to be understood from there. It is noted that the embodiments reside primarily in combinations of components and procedures related to the system. Accordingly, the system components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
As used herein, the term “plant based fiber” and variations of that term refer to fibers that May or may not be processed by industrial processes that include creating a pulp of the initial fibers such as commonly seen for wood or bamboo-derived fibers or any biodegradable fibers, or similar. The term “plant fiber” refers to a natural plant staple fiber, which may be used as a raw material, and obtained from a plant or several different plants including, but not limited to, cotton (Gossypium arboreum L.) or a similar plant from this plant family, hemp (Cannabis sativa ssp.) or a similar plant from this plant family, stinging nettle (Urtica dioica L. convar. fibra) or a similar plant from this plant family, linen (Linum usitatissimum) or a similar plant from this plant family, jute (Corchorus capsularis) or a similar plant from this plant family, banana (Musa spp. fibra) or a similar plant from this plant family, ramie (Bochmeria nivea) or a similar plant from this plant family, coir (Cocos nucifera) or a similar plant from this plant family, pineapple (Ananas comosus), sisal (Agave sisalana) or a similar plant from this plant family, raffia palm (R. taedigera) or a similar plant from this plant family, kenaf (Hibiscus cannabinus) or a similar plant from this plant family, abacá (Musa textilis) or a similar plant from this plant family or gomuti (Arenga pinnata) or a similar plant from this plant family. The term “biodegradable” and variations of that term refer to the ability of the fibers and/or material to be broken down physically and/or chemically by microorganisms resulting in the production of basic natural elements, including carbon dioxide, methane, water, minerals, and new microbial cellular constituents (biomass).
The present disclosure relates to a method of making plant deep pile fabric, velvet or fleece that closely resembles animal or synthetic fur and can be used in lieu of animal or synthetic fur to make a variety of products including but not limited to clothing, apparel, footwear, or design objects.
A pile side of the fabric may include a first group of pile fibers, such as guard hair, including fibers of one plant or a mixture of different plants which form a first group of longer hair similar to guard hair in animal fur and a second group of shorter pile fibers, such as an underlayer, including fibers of the same plant or a mixture of different plants which form a layer similar to underlayer in animal fur, wherein each fiber of the first group is provided with a flat, tapered, pointed, beveled, or round free end portion and a second end portion firmly held by a base. The guard hair and the underlayer can be a different length or the same length.
The term “base” as used herein refers to the backside of a pile fabric including scrim or an adhesive agent or both. The base or scrim may include raw material such as, but not limited to, cotton, tencel, rayon, hemp, linen, jute, as a knitted and/or woven material. The base can also be a plant fiber, plant based or any bio-based type of leather, and adhesive or leather-like material i.e. a material made from renewable, carbon-based biological resources, such as, but not limited to, agricultural, bacterial, mycelium, or forest materials. The base can also be any type of biodegradable kitted/woven fiber.
The pile fibers of the first group may be longer than the pile fibers of the second group, while the diameter of each fiber within the first group may be thicker than the thickness of the second group. The pile fibers of the guard hair may be the same length as the pile fibers of the underlayer, while the diameter of each fiber within the first group may same or different.
The ratio of underlayer to guard hair can range from 1:1 in weight to 9:2. The ratio of underlayer to guard hair may include ranges such as 1:2, 2:1, 1:3, 3:1, 1:4, 4:1, 1:5, 5:1, 1:6, 6:1, 1:7, 7:1, 1:8, 8:1, 1:9, and 9:1, The individual fibers range in thickness from 20 um to 50 um for the underlayer. The individual fibers range in thickness from 25-50 um, 30-50 um, 35-50 um, 40-50 um, 45-50 um, 25-30 um, 25-35 um, 25-40 um, 25-45 um, and 25-50 um for the underlayer. The individual fibers range in thickness from 30 um to 120 um for the guard hair. The individual fibers range in thickness from 25-50 um, 30-50 um, 35-50 um, 40-50 um, 45-50 um, 25-30 um, 25-35 um, 25-40 um, 25-45 um, and 25-50 um for the guard hair. There is also a possibility to use exclusively underlayer or guard hair for the product, this is especially true when the product should imitate a plugged fur such as otter or mink fur or a velvet which only uses the underlaying fur.
The individual fiber length protruding from the backing can range from 6 mm to 70 mm for all fibers. For underlayer, the average fiber length is between 10-35 mm and for guard hair the average length ranges from 10-70 mm. Alternatively, the average fiber length for the underlayer and guard hair may be 10-20 mm, 10-30 mm, 10-40 mm, 10-50 mm, 10-60 mm, 10-70 mm, 20-70 mm, 30-70 mm, 40-70 mm, or 50-70 mm.
Fiber volume per square centimeter of backing may range from about 1.5 cubic centimeters to about 7 cubic centimeters per 1 square centimeter of base of combined guard hair and underlayer. Fiber volume per square centimeter of backing may range from 1.5-2 cubic centimeters, 1.5-2.5 cubic centimeters, 1.5-3.0 cubic centimeters, 1.5-3.5 cubic centimeters, 1.5-4.0 cubic centimeters, 1.5-4.5 cubic centimeters, 1.5-5.0 cubic centimeters, 1.5-5.5 cubic centimeters, 1.5-6.0 cubic centimeters, 1.5-6.5 cubic centimeters, or 1.5-7.0 cubic centimeters per 1 square centimeter of base of combined guard hair and underlayer.
Measured fiber volume to surface ratio (cubic centimeters of fiber per square centimeter) of traditional towels ranges from about 0.4 cm3/cm2 to about 0.8 cm3/cm2. Measured fiber volume to surface ratio of traditional carpets ranges from about 0.5 cm3/cm2 to about 1.3 cm3/cm2. Measured fiber volume to surface ratio of the present embodiments may range from about 1.5 cm3/cm2 to about 2.5 cm3/cm2 to about 6 cm3/cm2 for short, medium, and long fibers, respectively.
The present disclosure relates to a process and finishing method that achieves a natural plant deep-pile fabric that closely approximates animal fur. The disclosed product may include a soft, dense fiber that exhibits the same performance characteristics as natural animal fur.
The present disclosure relates to a process and finishing method wherein a natural plant pile fabric that closely resembles natural animal fur, includes extracting the plant fibers from the natural leaf, fruit, or bast fiber bundles, cleaning fibers or fiber bundles, and aligning fibers or fiber bundles, and assembling bundles into hanks, carding band, yarn, sliver, or other fiber structures for processing.
The present disclosure relates to a process and finishing method including finishing the scrim side of the fabric with a sealing agent to improve the adherence of the natural fibers to the scrim and finishing the pile side of the fabric with a mixture of synthetic fur processing steps and traditional fur processing steps.
In yet another embodiment, the method further includes treating the deep pile side of the fabric with a multitude of combing, cutting, roughening, trimming, straightening, shearing, and polishing steps, steaming, heating, tumbling or spraying steps.
An impregnation process may include the placement of the purified raw fiber into an impregnation liquid. The impregnation mixture can be gaseous, liquid, or molten solids as long as the solids do not exceed 200 degrees C. in melting temperature. Fibers can be impregnated with flame retardants, biopolymers, strengthening agents, stabilizing agents, pigment, softeners, and other protective agents by being put in a chamber of high pressure. The high-pressure chamber may range in pressure from about 101.325 kPa (ambient pressure) up to about 1013.250 kPa and at a temperature of about 40 degrees C. to about 145 degrees C. to force the surrounding liquid phase which covers the fibers completely into the first few micrometers of the surface.
According to some embodiments, the high-pressure chamber may range in temperature from about 70-80 degrees C., 70-90 degrees C., 70-100 degrees C., or the like. Alternatively, a combination of high pressure and vacuum cycles ranging from 101.324 kPa down to 1.333 kPa, 100-90 kPa, 90-80 kPa, 80-70 kPa, 70-60 kPa, 60-50 kPa, 50-40 kPa, 40-30 kPa, 30-20 kPa, 20-10 kPa, or 10-0 kPa can be applied to the chamber in which the material rests in an impregnation solution to force the solution into fibers or base or scrim. This process may also work at room temperature and ambient pressure.
Following the impregnation process, the raw material is transferred to a drying unit and dehydrated to about 13-55% relative moisture. During the drying process, the fibers are either hung in 0.1-1 kg bundles in a 15-80 degrees C. oven or dehydrated in a continuous drying mode at 15-80 degrees C. According to some embodiments, continuous drying may occur at 15-20 degrees C., 15-30 degrees C., 15-40 degrees C., 15-50 degrees C., 15-60 degrees C., 15-70 degrees C., or 15-80 degrees C. The drying process can be repeated to achieve the desired outcome. The raw fiber is inserted in a carding machine with stainless steel carding teeth of about 0.5-3 inches in length. The carding wheels run at around 10-200 rpm depending on their diameter and fiber length.
The creation of sliver is conducted according to standard industry practices with some embodiments. Combining the fibers removes the short fibers and arranges the remaining fibers in a flat bundle, with all the fibers going in the same direction i.e., arranged parallel to each other, in the combed plant fiber slivers. After the fibers are aligned, the silver is created using standard industry slivering equipment.
Raw materials may include raw material obtained from a plant, or several different plants, including, but not limited to, cotton, hemp, stinging nettle, linen, jute, banana, ramie, coir, pineapple, lotus, or sisal. The raw material entry and inspection process includes the raw materials receiving 201, quality control process which may include industry standard raw material selection process including processability evaluation and possible rejection of raw material. The method may include assignment to a quality group based on plant origin and fiber type and labeling and storage at step.
A bleaching process 203 may remove any color or pigments inherent to the plants and give a brighter, whiter color to the fibers to accept dyes at a later stage. Bleaching can be done with sodium hypochlorite, hydrogen peroxide or standard bleaching agents from the textile industry. Bleaching may also be performed enzymatically.
The solution may contain water-soluble substances such as natural plant derivatives, minerals, dyes, salts, natural flame retardants, and the like into a pressurized chamber. The process May include increasing the pressure and temperature in the chamber from ambient pressure to about 10-20 PSI, 10-15 PSI, or 15-20 PSI and increasing the temperature to about 120-130 degrees C., 120-125 degrees C., or 125-130 degrees C. The process may include maintaining the pressure for a duration of 30 min to 90 min, 30-40 minutes, 30-50 minutes, 30-60 minutes, 30-70 minutes, or 30-80 minutes to fully impregnate the raw fibers.
A mercerization process 205 may include applying a finishing treatment for fabric and yarn which improves dye uptake and tear strength, reduces fabric shrinkage, and provides a silk-like luster. Treatment with sodium hydroxide destroys the spiral form of the cellulose with the formation of alkali cellulose, which is changed to cellulose hydrate on washing out the alkali. Caustic soda concentrations of 20-26%, 21-22%, 22-23%, 23-24%, 24-25%, or 25-56% and a pH of about 5-8, 5-6, 6-7, 7-8, 8-9, 9-10, or about 8-10, may be utilized to further treat fabric and yarn, including untwisting (deconvolution) of the cotton hair.
Dying process 206 may include applying various dyes or coloring agents to adjust the appearance of the fibers. These dying agents can be plant-derived, mineral-derived, or a mixture of plant and mineral dyes.
Drying process 207 may include transferring raw material to a drying unit and dehydrating to about 13-55% relative moisture. During the drying process, the fibers may be hung in 0.1-1 kg bundles in a 15-80 degrees C. oven or dehydrated in a continuous drying mode at 15-80 degrees C. The drying process can be repeated to achieve the desired outcome.
The method may further include a quality assessment at step 208, optional rejection of substrate at step 209, assignment to a substrate group at step 209, and labeling and storage of substrate at step 211.
The finishing solution may include natural plant latexes, proteins, plant resins, lignin, plant protein or a mixture of natural plant derivatives. Parts of the agent can also contain other plant-derived polymers that improve its ability to bind to plant fibers. All primary or sedentary plant products can be considered as agents and added in solid, liquid, or emulsion form to the agent solution.
The finishing solution may improve individual fiber qualities such as luster, surface roughness, softness, color, alignment, and spring as well as the overall appearance of the fabric. The finishing solution can further include a coloring agent, flame-retardant agent, softening agent, surface lubrication agent, stiffening agent, humectant agent, moisturizing agent, degreasing agent, or cleaning agent. All primary or secondary plant metabolites and products derived from them can be considered agents and added in solid, liquid, or emulsion form to the finishing solution.
According to yet another embodiment of the present invention, the adhesive agent can be applied to the fabric by a roller or a multitude of spray nozzles fed from pressure lines or hand-held spray bottles. The roller will be covered in adhesive and transferred parts or all of the adhesive to the base while the base is moving over the rotating roller. The adhesive agents can be applied in one step or in several different steps, followed by a drying step at room temperature or at less than 200 degrees C., throughout the post-finishing process and repeated as often as necessary.
The post-finishing process may include the finished fabric preparation at step 501, steam treatment at step 502, heat and pressure treatment at step 503, mechanical treatment at step 504, and assessment process at step 505 with an optional repetition of steps 503-504 of N1=(1-10), applying of finishing solution at step 506, mechanical treatment at step 507, assessment process at step 508 with an optional repetition of step 506-507 of N2=(1-10), final trimming at step 509, combing and cleaning at step 510, and storage of post finished fabric at step 511. The steam treatment 502 may include exposing fibers to steam of at least 80 degrees Celsius in a static way with individual pieces in an enclosed or partially enclosed chamber that is then filled with steam at a higher pressure than the ambient pressure or at ambient pressure. The heat treatment 503 may include heating fibers to a temperature between 80 degrees C. up to 200 degrees C., 80-90 degrees C., 80-100 degrees C., 80-110 degrees C., 80-120 degrees C., 80-130 degrees C., 80-140 degrees C., 80-150 degrees C., 80-160 degrees C., 80-170 degrees C., 80-180 degrees C., or 80-190 degrees C. to straighten the fibers and give them a specific direction. This heat treatment process is responsible for giving the fabric a natural animal-like grain, as the heat is affecting the basis of each individual fiber changing each fibers protrusion angle in a way that natural animal hair is usually grown by natural hair follicles ranging from 45 to 85 degrees, 45-55 degrees, 55-65 degrees, 65-75 degrees, or 75-85 degrees between the base and the individual fiber.
The mechanical treatment 504 may include a cold brushing process performed with unheated rollers. After cold brushing, the fabric is inspected by the operator in an assessment process 505 for factors such as fiber straightness, fiber orientation, and fiber length are considered when deciding if the step should be repeated. Repetition of steps 503-504 of N1=(1-10) may occur as desired. The finishing solution 506 can be applied to the fibers and may further contain, an adhesion agent, coloring agent, flame retardant agent, softening agent, surface lubrication agent, stiffening agent, humectant agent, moisturizing agent, degreasing agent, or cleaning agent. All primary or secondary plant metabolites and products derived from them can be considered agents and added in solid, liquid, or emulsion form to the finishing solution.
The finishing solution 506 with and/or without an adhesion agent, coloring agent, flame retardant agent, softening agent, surface lubrication agent, stiffening agent, humectant agent, moisturizing agent, degreasing agent, or cleaning agent. All primary or secondary plant metabolites and products derived from them can be considered agents and added in solid, liquid, or emulsion form to the finishing solution, which could require none or several further processing steps such as fixing and curing steps, including but not limited to pH changes, coating, polymerizing, temperature fixing/curing, pressure change, drying between individual processing steps, fixing by condensation.
According to yet another embodiment, the finishing solution can be applied to the fabric by one or a multitude of spray nozzles fed from pressure lines or hand-held spray bottles. The finishing solutions can be applied in one step or in several different steps throughout the post-finishing process and repeated as often as necessary. The mechanical treatment 507 may include a cold brushing process performed with unheated rollers. After cold brushing, the fabric is inspected by the operator in an assessment process 508 for factors such as fiber straightness, fiber orientation, and fiber length are considered when deciding if the step should be repeated. Repetition of steps 506-508 of N2=(1-40) may occur as desired.
The process may further include applying a hot rotational ironing at about 60-120 degrees C. and about 60-1500 RPM to straighten the fibers. The hot rotational ironing may occur at 60-70, 70-80, 80-90, 90-100, 100-110, or 110-120 degrees C. and at about 60-100, 100-200, 200-300, 400-500, 500-600, 600-700, 700-800, 800-900, 900-1000, 1000-1100, 1100-1200, 1200-1300, 1300-1400, or 1400-1500 RPM.
In the present method, the plant pile fabric may be finished with an unconventional textile finishing process that may be more similar to natural fur than to synthetic fur. However, unlike natural fur processing steps, where the equipment to finish the length of pile fabric in a high speed, efficient manner, are not commonly used in European tanneries. In the present method, each pelt may be finished one at a time by automated or continuous processing machinery in sheets or in rolls using a textile finishing process or/and natural fur processing machinery.
Final trimming 509 may occur to achieve desired fiber lengths and textures followed by combing and cleaning 510. The completed plant-fiber-based pile-fabric textiles may be stored 511.
While a number of embodiments have been described, it will be appreciated by a person skilled in the art that numerous variations and/or modifications may be made in the invention without departing from the spirit or scope of the invention as broadly described. The following description of variants is only illustrative of components, elements acts, products, and methods considered to be within the scope of the invention and are not in any way intended to limit such scope by what is specifically disclosed or not expressly set forth. The components, elements, acts, products, and methods as described herein may be combined and rearranged other than as expressly described herein and are still considered to be within the scope of the invention.
According to embodiment 1, pile-fabric textile may include a base; a plurality of pile fibers including plant fibers affixed to the base at a first end of each fiber, and wherein the plurality of pile fibers include a fiber volume per square centimeter ranging from about 1.5 cubic centimeters to about 7 cubic centimeters per 1 square centimeter of base.
Embodiment 2 may include the pile-fabric textile as in embodiment 1, wherein the plurality of pile fibers are devoid of synthetic or man-made fiber material.
Embodiment 3 may include the pile-fabric textile as in embodiment 1 or 2, wherein the plurality of pile fibers are biodegradable.
Embodiment 4 may include the pile-fabric textile as in any of embodiments 1 through 3, wherein the plant-derived fibers includes at least one of cotton, hemp, stinging nettle, linen, jute, banana, ramie, coir, pineapple, silk, lotus, or sisal.
Embodiment 5 may include the pile-fabric textile as in any of embodiments 1 through 4, wherein the plurality of pile fibers include a first guard hair group of pile fibers having a first average length and a second underlayer group of pile fibers having a second average length.
Embodiment 6 may include the pile-fabric textile as in any of embodiments 1 through 5, wherein the first guard hair group of pile fibers and the second underlayer group of pile fibers include the same plant fiber.
Embodiment 7 may include the pile-fabric textile as in any of embodiments 1 through 6, wherein the first guard layer group of pile fibers and the second underlayer group of pile fibers include different plant fibers.
Embodiment 8 may include the pile-fabric textile as in any of embodiments 1 through 7, wherein the first guard hair group of pile fibers and the second underlayer group of pile fibers have the same average length.
Embodiment 9 may include the pile-fabric textile as in any of embodiments 1 through 8, wherein the first guard hair group of pile fibers and the second underlayer group of pile fibers have different average lengths.
Embodiment 10 may include the pile-fabric textile as in any of embodiments 1 through 9, wherein the average length of each fiber within the first guard hair group of pile fibers is approximately 5 millimeters to approximately 30 millimeters.
Embodiment 11 may include the pile-fabric textile as in any of embodiments 1 through 10, wherein the average length of each fiber within the second underlayer group of pile fibers is approximately 20 millimeters to approximately 40 millimeters.
Embodiment 12 may include the pile-fabric textile as in any of embodiments 1 through 11, wherein the plurality of pile fibers have an average diameter between approximately 20 micrometers to approximately 120 micrometers.
Embodiment 13 may include the pile-fabric textile as in any of embodiments 1 through 12, wherein each fiber within the first guard hair group of pile fibers and the second underlayer group of pile fibers have approximately the same diameter.
Embodiment 14 may include the pile-fabric textile as in any of embodiments 1 through 13, wherein each fiber within the first guard hair group of pile fibers have a diameter different from the second underlayer group of pile fibers of the second underlayer group.
Embodiment 15 may include the pile-fabric textile as in any of embodiments 1 through 14, wherein the diameter of the first guard hair group is approximately 20 micrometers to approximately 50 micrometers.
Embodiment 16 may include the pile-fabric textile as in any of embodiments 1 through 15, wherein the diameter of the first guard hair group of pile fibers is approximately 30 micrometers to approximately 120 micrometers.
Embodiment 17 may include the pile-fabric textile as in any of embodiments 1 through 16, wherein a ratio of the first guard hair group of pile fibers to the second underlayer group of pile fibers is approximately 1:1-9:2.
Embodiment 18 may include the pile-fabric textile as in any of embodiments 1 through 17, wherein a ratio of the first guard hair group of pile fibers to the second underlayer group of pile fibers is approximately 9:2.
Embodiment 19 may include the pile-fabric textile as in any of embodiments 1 through 18, wherein the base includes a scrim.
Embodiment 20 may include the pile-fabric textile as in any of embodiments 1 through 19, wherein the scrim includes plant fiber or plant-derived material.
Embodiment 21 may include the pile-fabric textile as in any of embodiments 1 through 20, wherein at least one of the first guard hair group of pile fibers or the second underlayer group of pile fibers are affixed to the base with an adhesive agent.
Embodiment 22 may include the pile-fabric textile as in any of embodiments 1 through 21, wherein at least one of the first guard hair group of pile fibers or the second group of pile fibers are affixed to the base by stitch knitting.
Embodiment 23 may include the pile-fabric textile as in any of embodiments 1 through 22, wherein at least one of the first guard hair group of pile fibers or the second underlayer group of pile fibers are affixed to the base at a density of approximately 100 fibers per square centimeter to approximately 5500 fibers per square centimeter.
Embodiment 24 may include the pile-fabric textile as in any of embodiments 1 through 23, wherein at least one of the first guard hair group of pile fibers or the second underlayer group of pile fibers further include an agent selected from the group consisting of a coloring agent, a flame-retardant, a softening agent, a surface lubrication agent, a stiffening agent, a humectant agent, a moisturizing agent, a degreasing agent, or a cleaning agent.
Embodiment 25 may include the pile-fabric textile as in any of embodiments 1 through 24, wherein the agent is impregnated into at least one of the first guard hair group of pile fibers or the second underlayer group of pile fibers.
Embodiment 26 may include the pile-fabric textile as in any of embodiments 1 through 25, wherein the first guard hair group of pile fibers or the second underlayer group of pile fibers is surface treated with the agent.
According to embodiment 27, a method of making a plant-fiber based pile-fabric textile May include performing a raw material fiber preparation process on a plant material fiber to form a raw material fiber; performing a pre-finishing process on the raw material fiber to form a pre-finished material; performing a knitting process on the pre-finished material to form a knitted material; performing a finishing process on the knitted material to form a finished material; and performing a post-finishing process on the finished material to form the plant-fiber based pile-fabric textile.
Embodiment 28 may include the method of embodiment 27, wherein the performing a raw material fiber preparation process further includes performing a retting process on the plant material fiber including at least one of dew retting, water retting, enzymatic retting, chemical retting, decortication process, hackling process, or baling; performing a mercerization process including treating the plant material fiber with sodium hydroxide; and performing an impregnation process including treating the plant material fiber with pressure and heat to introduce materials into at least one microscopic crevasse in the plant material fiber.
Embodiment 29 may include the method of embodiment 27 or 28, wherein performing a raw material fiber preparation process further includes dying the raw material fiber; and drying the raw material fiber.
Embodiment 30 may include the method of any of embodiments 27 through 29 wherein the pre-finishing process includes combing the raw material fiber; carding the raw material fiber; and slivering the raw material fiber.
Embodiment 31 may include the method of any of embodiments 27 through 30 wherein the knitting process includes simultaneously forming a base and forming a scrim and knitting a yarn including fixing the pre-finished material to the scrim in a circular knitting-process in which the yarn is knitted simultaneously with a base material made of natural fibers to form knitted material, wherein the knitted material includes a circular, seamless knit material.
Embodiment 32 may include a method of any of embodiments 27 through 31 wherein the knitting process includes simultaneously forming a base and forming a scrim and knitting a yarn including fixing the pre-finished material to the scrim in a circular knitting-process in which the yarn is knitted simultaneously with a base material made of natural fibers to form knitted material, wherein the knitted material includes a tubular knit pile fabric.
Embodiment 33 may include a method of any of embodiments 27 through 32 wherein the finishing process includes treating the knitted material with at least one of a steam treatment; treating the knitted material with a heat treatment at a temperature of greater than 70 degrees Celsius; treating the knitted material with a first cold brushing; applying at least one finishing solution; treating the knitted material with a second cold brushing; and trimming the knitted material.
Embodiment 34 may include a method of any of embodiments 27 through 33 wherein the finishing process includes applying a hot rotational ironing at about 60-120 degrees C. and about 60-1500 RPM to straighten the knitted material.
Embodiment 35 may include a method as in any of embodiments 27 through 34 wherein the finishing process includes trimming of a plurality of guard fibers and a plurality of underlayer fibers.
Embodiment 36 may include the method of any of embodiments 27 through 35 wherein the finishing process includes applying a post-trimming process to soften the tip of each of the fibers within the plurality of guard fibers and a plurality of underlayer fibers. The post-trimming process may be chemical, thermal, or mechanical to sufficiently soften or round off the tip of each fiber to achieve a more realistic faux fur.
Embodiment 37 may include a method as in any of embodiments 27 through 36 further including enzymatic bio-polishing of fibers to remove smaller attached fibers from the main fibers by incubating the fibers in an enzymatic incubation bath.
Embodiment 38 may include a method as in any of embodiments 27 through 37 further including enzymatic thinning on both ends of the pile fiber.
Embodiment 39 may include a method as in any of embodiments 27 through 38 wherein the individual fibers of the scrim of the backside can be contracted by a mixture of thermal, enzymatic, and mechanical processes to increase the fiber density per surface of scrim.
According to embodiment 40, a method of making a plant-fiber based pile-fabric textile May include performing a raw material fiber preparation process on a plant material fiber to form a raw material fiber; performing a pre-finishing process on the raw material fiber to form a pre-finished material; performing a knitting process on the pre-finished material to form a knitted material; performing a finishing process on the knitted material to form a finished material; and performing a post-finishing process on the finished material to form the plant-fiber based pile-fabric textile a plurality of guard fibers and a plurality of underlayer fibers
Embodiment 41 may include the method of embodiment 40 wherein the performing a raw material fiber preparation process further includes performing a retting process on the plant material fiber including at least one of dew retting, water retting, enzymatic retting, chemical retting, decortication process, hackling process, or baling; performing a mercerization process including treating the plant material fiber with sodium hydroxide; and performing an impregnation process including treating the plant material fiber with pressure and heat to introduce materials into at least one microscopic crevasse in the plant material fiber.
Embodiment 42 may include the method of any of embodiments 39 through 41, wherein performing a raw material fiber preparation process further includes dying the raw material fiber; drying the raw material fiber; combing the raw material fiber; carding the raw material fiber; and slivering the raw material fiber.
Embodiment 43 may include the method of any of embodiments 40 through 42, wherein the knitting process includes simultaneously forming a base and forming a scrim and knitting a yarn including fixing the pre-finished material to the scrim in a circular knitting-process in which the yarn is knitted simultaneously with a base material made of natural fibers to form knitted material, wherein the knitted material includes a tubular knit pile fabric.
Embodiment 44 may include the method of any of embodiments 40 through 43, wherein the finishing process includes treating the knitted material with at least one of a steam treatment; treating the knitted material with a heat treatment at a temperature of greater than 70 degrees Celsius; treating the knitted material with a first cold brushing; applying at least one finishing solution; treating the knitted material with a second cold brushing; and trimming the knitted material.
Embodiment 45 may include the method of any of embodiments 39 through 43, further including applying a hot rotational ironing at about 60-175 degrees C. and about 60-1500 RPM to straighten the knitted material; trimming of a plurality of guard fibers and a plurality of underlayer fibers; and applying a post-trimming process to soften a tip of each of the fibers within the plurality of guard fibers and a plurality of underlayer fibers.
Many different embodiments have been disclosed herein, in connection with the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to describe and illustrate every combination and subcombination of these embodiments. Accordingly, all embodiments can be combined in any way and/or combination, and the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and subcombinations of the embodiments described herein, and of the manner and process of making and using them, and shall support claims to any such combination or subcombination.
An equivalent substitution of two or more elements can be made for any one of the elements in the claims below or that a single element can be substituted for two or more elements in a claim. Although elements can be described above as acting in certain combinations, and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can, in some cases, be excised from the combination and that the claimed combination can be directed to a subcombination or variation of a subcombination.
It will be appreciated by persons skilled in the art that the present embodiment is not limited to what has been particularly shown and described hereinabove. A variety of modifications and variations are possible considering the above teachings without departing from the following claims.
Applicant BIOFLUFF INC., a public benefit corporation formed under the laws of Delaware and the United States of America, requests entry into the National Phase in the United States by and through this application which is based on PCT Patent Application, assigned serial number PCT/US2023/01140 filed on Jan. 24, 2023, which claims priority from U.S. provisional App. No. 63/302,605 filed on Jan. 25, 2022, all of which applications are incorporated by reference herein in their entireties.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2023/011400 | 1/24/2023 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63302605 | Jan 2022 | US |
