PLANT FIBER PILE FABRIC TEXTILE

Information

  • Patent Application
  • 20250034765
  • Publication Number
    20250034765
  • Date Filed
    July 25, 2024
    6 months ago
  • Date Published
    January 30, 2025
    a day ago
  • Inventors
    • Stuebler; Martin (San Francisco, CA, US)
  • Original Assignees
    • BioFluff Inc. (SAN FRANCISCO, CA, US)
Abstract
A plant fiber deep pile fabric is disclosed that closely resembles animal fur or wool manufactured via a method that includes extracting the plant fibers from the plant material and forming a yarn or sliver made from plant fibers and simultaneously attaching it to a scrim also made from plant fibers, where the fiber is attached and extends from the scrim to form a length of plant-fiber pile fabric having natural plant fibers on one side and the scrim on the opposite side. The method includes finishing the scrim side of the fabric with an adhesive agent to attach the fibers to the scrim and form a stable base. The method also includes finishing the plant fiber pile side of the fabric by applying fur-industry specific processing steps to alter the properties of the fibers resulting in an even closer resemblance of animal fur.
Description
FIELD OF THE INVENTION

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.


STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

No federal funds were used to develop or create the invention disclosed and described in the patent application.


BACKGROUND

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.


The present disclosure includes four different methods of assembling a plant fiber fur and two structures. A first plant fiber fur structure may include a continuous field of uniform fibers and a second plant fiber fur structure may include fibers at various configurations, as depicted in FIGS. 10 through 13. The methods of assembly may include blocking which may yield the first plant fiber first structure including a continuous field of uniform fibers. The methods of assembly may include knitting, weaving, and warp knit which may yield the second plant fiber first structure including fibers at various configurations.


One of ordinary skill in the art will understand that any of the described methods of manufacture, such as knitting, weaving, warp knit, and blocking, may be utilized in conjunction with one another, separately, or in various combinations and sub-combinations and still fall within the scope of this disclosure.


Other illustrative variations 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.





BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present variations and features thereof will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein:



FIG. 1 is a simplified diagram of a natural plant-fiber based pile fabric textile and method of manufacturing the same according to at least one embodiment described herein illustrating a process overview including the steps of raw material preparation, a pre-finishing process, a finishing process and a post finishing process.



FIG. 2 is another simplified diagram for a natural plant-fiber based pile fabric textile and method of manufacturing the same according to at least one embodiment described herein illustrating processing steps including raw material preparation and evaluation, a retting process, a bleaching process, a mercerization process, a dying process, a drying process, a quality assessment, a rejection of fibers, an assignment to substrate group, and labeling and storage of fibers.



FIG. 3 is another simplified diagram illustrating at least one embodiment of a natural plant-fiber based pile-fabric textile and method of manufacturing the same to at least one embodiment described herein illustrating processing steps including a pre-substrate preparation process, a combing process, a carding process, a slivering process and a storage of sliver.



FIG. 4 is another simplified diagram illustrating at least one embodiment of a natural plant-fiber based pile-fabric textile and method of manufacturing same illustrating the processing steps including a knitting preparation process, a sliver and yarn preparation process, an insertion into machine and calibration process, a process of forming the scrim and attaching sliver fibers, a process of cutting and labeling semi-finished fabric, a preparation of backside, an application of adhesive, a cleaning and drying of the base, and storage of semi-finished fabric.



FIG. 5 is a simplified diagram illustrating at least one embodiment of a natural plant-fiber based pile-fabric textile and method of manufacturing, the processing steps including a finished fabric preparation process, a steam treatment, a heat treatment, a mechanical treatment, an assessment process, applying of a finishing solution, a mechanical treatment, an assessment process, a step of final trimming, a step of combing and cleaning and a step of storage of post finished fabric.



FIG. 6 is a simplified diagram illustrating a natural plant-fiber based pile-fabric textile according to at least one embodiment described as exemplified by a cross section of a post-finished plant pile fabric with exposed plant fibers attached to a base.



FIG. 7 is a simplified diagram illustrating a natural plant-fiber based pile-fabric textile according to at least one embodiment described herein exemplified as an exploded cross-section view of the post-finished plant pile fabric with clearly exposed plant fibers attached to the base.



FIG. 8 is a simplified diagram illustrating a natural plant-fiber based pile-fabric textile according to at least one embodiment described herein exemplified as an exploded cross-section view of the plant pile fabric before being exposed to the pos-finishing process.



FIG. 9 is a simplified diagram illustrating a natural plant-fiber based pile-fabric textile according to at least one embodiment described herein exemplified as individual types of fibers such as guard hair and underfur as well as the width dimensions and length of the fabric.



FIG. 10A-10B is a schematic drawing illustrating two different ways of fixing fibers in the backing for at least one embodiment of the natural plant-fiber based pile-fabric textile.



FIG. 10A illustrates a knitting, weaving, or warp knit using a scrim as the base according to at least one embodiment of the disclosed natural plant-fiber based pile-fabric textile.



FIG. 10B illustrates a blocking using vegan leather or any similar material as the base according to at least one embodiment of the disclosed natural plant-fiber based pile-fabric textile.



FIG. 11 illustrates simplified processing steps used during blocking according to at least one embodiment of the disclosed natural plant-fiber based pile-fabric textile.



FIGS. 12A-12B are schematic drawings illustrating the production of plant fiber pile-fabric textile via blocking according to at least one embodiment of the disclosed natural plant-fiber based pile-fabric textile.



FIGS. 13A-13E are schematic drawings illustrating fiber distribution within the pile-fabric textile according to at least some variations described herein.



FIGS. 14A-14B illustrate examples of different plant fiber thicknesses being obtained within the same type of plant according to least one embodiment of the natural plant-fiber based pile-fabric textile disclosed herein.



FIG. 15 illustrates a cross-section of an illustrative embodiment of a pile-fabric textile having a mixture of different types of plant fibers of a plant fiber according to least one embodiment of the natural plant-fiber based pile-fabric textile disclosed herein.



FIG. 16. illustrates examples of potential variations of a natural plant-fiber based pile-fabric textile.



FIG. 17. illustrates additional examples of potential variations of a plant-fiber based pile-fabric textile.





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.


DETAILED DESCRIPTION—LISTING OF ELEMENTS












Element Number
Element description
















200
Raw material preparation


201
Raw material preparation and evaluation


202
Retting process


203
Bleaching process


204
Mercerisation process


205
Drying process


206
Drying process


207
Quality assessment


208
Rejection of fibers


209
Assignment to substrate group


210
Labeling and storage of fibers


300
Pre-finishing process


301
Pre-substrate preparation


302
Combing process


303
Carding process


304
Slivering process


305
Storage of fibers sliver


400
Finishing process


401
Knitting process preparations


402
Sliver and yarn preparations


403
Insertion into machine and calibration


404
Simultaneously forming the scrim and



knitting the yarn to the scrim


405
Cutting and labeling semi-finished fabric


406
Preparation of backside


407
Application of adhesive agent on backside



of drying


408
Cleaning and drying of the base


409
Storage of semi-finished fabric


500
Post finishing process


501
Finished fabric preparations


502
Steam treatment


503
Heat treatment


504
Mechanical treatment


505
Assessment process


506
Applying of finishing solutions


507
Mechanical treatment


508
Assessment process


509
Final trimming


510
Combing and cleaning


511
Storage of post-finished fabric


900



901



902
Guard hair


904
Underlayer


906
Width of fabric


908
Length of fabric


910
Dimension of fabric


1000
Natural plant fiber pile (processed)


1001
Fiber length


1003
Guard hair


1004
Underlayer


1005
Base


1006
Base


1007



1008



1100
Natural plant fiber pile fabric textile


1101
Exploded cross-section view


1102
Base


1110
Selecting fiber slivers


1113
Securing the frames


1114
Trimming of the fibers


1116
Removing top and bottom frames


1118
Fiber thinning, softening or cutting


1120
Pretreating of fibers


1122
Secure fibers to backing material


1124
Removal of frame


1201
Pre-finished fabric


1300
Framing assembly


1302
First frame (top)


1304
Second frame (center)


1306
Third frame (bottom)


1308
Attachment mechanisms


1310
Nut


1312
Bolt


1314
Frame side


1316
Frame side


1320
Angle of fiber attached to backing









DETAILED DESCRIPTION

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 (Boehmeria 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 10 um to 100 um for the underlayer. The individual fibers range in thickness from 10-20 um, 20-50 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, 25-50 um, and 50-100 um for the underlayer. The individual fibers range in thickness from 20 um to 300 um for the guard hair. The individual fibers range in thickness from 20-50 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, 25-50 um, 50-100 um, 100-150 um, 150-200 um, and 200-300 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 density, the amount of fibers protruding from the backing per square centimeter can range from 1000 fibers to 30000 fibers. Fiber density per square centimeter of backing may range from 1000-2000 cm2, 1000-3000 cm2, 1000-4000 cm2, 2000-3000 cm2, 2000-4000 cm2, 3000-4000 cm2, 3000-5000 cm2, 4000-5000 cm2, 4000-6000 cm2, 4000-7000 cm2, 5000-6000 cm2, 5000-7000 cm2, 5000-8000 cm2, 5000-9000 cm2, 6000-7000 cm2, 6000-8000 cm2, 6000-9000 cm2, 7000-8000 cm2, 7000-9000 cm2, 7000-10000 cm2, 8000-9000 cm2, 8000-10000 cm2, 8000-11000 cm2, 900-10000 cm2, 9000-11000 cm2, 9000-12000 cm2, 10000-12000 cm2, 10000-14000 cm2, 12000-14000 cm2, 12000-16000 cm2, 12000-18000 cm2, 14000-16000 cm2, 14000-18000 cm2, 14000-20000 cm2, 16000-20000 cm2, 20000-25000 cm2, 25000-30000 cm2.


The plant fiber content in the pile fabric, pile and the base, can range from 10-100 wt. %. Plant fiber composition of the pile fabric may range 10-20 wt. %, 10-30 wt. %, 10-40 wt. %, 20-30 wt. %, 20-40 wt. %, 20-50 wt. %, 30-40 wt. %, 30-50 wt. %, 30-40 wt. %, 40-50 wt. %, 40-60 wt. %, 40-70 wt. %, 50-60 wt. %, 50-70 wt. %, 50-80 wt. %, 60-70 wt. %, 60-80 wt. %, 60-90 wt. %, 70-80 wt. %, 70-90 wt. %, 70-100 wt. %, 80-90 wt. %, 80-100 wt. %, 90-95 wt. %, 90-100 wt. %


The individual fiber length protruding from the backing can range from 5 mm to 80 mm for all fibers. For underlayer, the average fiber length is between 5-35 mm and for guard hair the average length ranges from 10-100 mm. Alternatively, the average fiber length for the underlayer and guard hair may be 5-10 mm, 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, 50-70 mm, or 70-100 um.


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 variations 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. Measured fiber volume to surface ratio of the present embodiments may range from about 0.5 cm3/cm2 to about 3 cm3/cm2 to about 7 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.


In yet another embodiment, the method may include knitting, weaving, warp knit, or blocking. Knitting may include a process for forming fabric or cloth by interlocking loops of thread or fiber. Weaving may include a process for forming fabric or by interlacing two sets of thread or fiber, such as a warp and a weft. Warp knitting may include a process for forming fur fabric or cloth by interlocking parallel yarns, known as the warp, using multiple needles simultaneously. Blocking may include a process for forming fibers or cloth by wetting or steaming the fibers and then carefully stretching and pinning it into the desired shape and fixing it into a backing with adhesives.


Knitting process can be performed in a manual, semi-automatic or fully-automated knitting process. In yet another embodiment, the creation of plant-pile fabric with a circular knitting machine is described. In the present embodiment, the process includes loading and calibrating the knitting machine with plant fiber yarns and plant fiber sliver followed by a calibration process. During the knitting process, the yarn or double twisted yarn and sliver are simultaneously attached to the scrim.


In the yarn knitting process, the yarn is used in a circular knitting-process in which the yarn is knitted simultaneously with a base material made of natural fibers. In this process, the knitting is cast on and a circle of stitches is joined to form a circular, seamless knit material. Depending on the fibers used to make up the base material, the base material can be made to have different physical properties, including directional stretch and drape.


The method described a knitting machine where each of the knitting machines has a plurality of knitting feed devices to feed the yarn into the machines attached to it. It should be appreciated that the present method may employ one or a plurality of knitting machines each having a suitable number of feed devices.


Each of the feed devices is properly configured to receive one yarn spool. It should be appreciated that the number of yarn spools loaded on the machine depends on the size of the plant pile fabric produced. During the knitting process, the strands forming the scrim and the yarn are simultaneously knit together in the knitting step to produce a tubular knit pile fabric. It should be appreciated that scrim or base material may be made of any suitable plant material. When the knitting process has been completed the piece of the finished substrate is cut by the operator from the machine.


After the knitting process, the base of the material is brought into contact with an agent to attach the plant fibers to the scrim or to build the base itself. Followed by a drying step and a visual control step the bases can get trimmed, grinded and if necessary polished.


Pile weave or high pile fabric weaving can be performed on a semi-automated, automated loom or a substantially continuous process on the length of the fabric traveling at a defined speed through the machinery.


It shall be appreciated here that the previously mentioned yarn can be any kind of yarn as long as it is predominately based on plant fibers. It can be appreciated that the warp yarn, the weft yarn, as well as the pile yarn can be predominately based on plant fibers.


After the yarn is attached to the warp beam and the harnesses put in place the weaving process is started and the shuttle moved across the full or part of the length of the warp lines to create two fabrics simultaneously. After the weaving process the two parts of fabric are cut and two pieces of pile fabric are created from a single pile weave process. After the base fabric was woven and cut with a rotating or static blade into two separate pieces of pile fabric the backside of the material is brought into contact with an adhesive agent to attach the plant fibers to the scrim or to build the base itself.


Blocking as a method of natural plant-fiber based pile-fabric textile production may include first selecting fiber slivers and bundling of fiber slivers as needed. Fibers may be positioned vertically within a framing device. According to some embodiments, the frame may be constructed and arranged to securely hold fibers in the first frame. The frames may include tightening mechanisms to securely hold fibers within the frame. A second top frame may be positioned above the first frame. A third lower frame may be positioned below the first frame. The blocking method may include securing the frames to one another, such as via a locking mechanism. The method may include trimming of the fibers, using the second and third frames as guides for limiting how much of each fiber is trimmed from the top or bottom of each fiber. The second top frame and third lower frame may be removed, post-fiber trimming. Additional fiber thinning, softening, or trimming may then be performed on the fibers. Fibers may then be pretreated to facilitate attachment of the fibers to a backing material, such as the base. Pretreated fibers may then be attached to the backing material, such as via an optional adhesive or by mechanical press. The first frame may then be removed. Further brushing, trimming, or post-finishing may occur. The disclosed method allows for adjusting fiber orientation (the angle at which a fiber attaches to the backing) to simulate various fur arrangements such as fox fur, cow hide, mink fur or the like. For example, fiber orientation may be adjusted to simulate fur such as cowhide, by adjusting fiber orientation approximately 15-35 degrees from perpendicular to the base or backing. Similarly, fiber orientation may be adjusted to simulate fur, such as fox fur, by adjusting fiber orientation approximately 75-90 degrees perpendicular to the base or backing.


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. The impregnation process may include subjecting the impregnation liquid to high pressures. In at least one embodiment, the impregnation liquid could be placed 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 at least one embodiment disclosed herein, 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 6-55% 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 variations. 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.



FIG. 1 depicts a simplified flowchart showing an overview of steps for processing natural plant fibers into a pile fabric. The disclosed method may include the following processing steps: fiber preparation 200, pre-finishing process 300, finishing process 400, and post-finishing process 500.



FIG. 2 depicts a simplified flowchart showing the steps for the raw material intake and initial quality check. As shown, in at least illustrative embodiment the method is comprised of the following processing steps: a raw material preparation and evaluation 201, retting process 202, bleaching process 203, mercerisation process 204, dying process 205, drying process 206, quality assessment 207, rejection of fibers 208, assignment to substrate group 209, labeling and storage of fibers 210.


Raw plant material used for the disclosed process may be harvested soon after reaching maturity or at the end of the plant's life cycle depending on the plant used for the individual process 201. Processing steps include, but are not limited to, a retting process 202 such as, but not limited to, dew retting, water retting, enzymatic or chemical retting, decortication process, hackling process, selection process and baling, or a combination of all the above-mentioned techniques.


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. This process may also work at room temperature and atmospheric pressure.


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, 8-10, 9-11, 8-11, or about 10-12 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 6-55% 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.



FIG. 3 is a simplified flowchart showing the steps for the substrate preparation process. For at least one illustrative embodiment, the substrate preparation process may be comprised of the pre-substrate preparation at step 301, fiber combing process at step 302, carding process at step 303, and slivering process at step 304. The slivering process 304 may be conducted according to standard industry practices with some variations. 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. The method may further include storing fiber sliver 305.



FIG. 4 depicts a simplified flowchart showing the steps for the pre-finishing process. For at least one illustrative embodiment, the pre-finishing process may be comprised of the following processing steps including a knitting preparation process 401, a sliver and yarn preparation process 402, an insertion into machine and calibration 403 step, the step of forming the scrim and attaching the sliver fibers 404, cutting and labeling semi-finished fabric 405, preparation of backside 406, application of adhesive 407, cleaning and drying of the base 408, and or storage of semi finished fabric 409. The knitting process preparations 401 may also include the preparation of a carding band or sliver preparations 402 and insertion into the machine and calibration at step 403, simultaneously forming the base and forming the scrim and knitting the double twisted yarn to the scrim at step. The yarn may contain fibers from cotton, linen, flax, bamboo, Tencel, rayon, or other suitable plant fibers or plant-derived fibers 404. In the scrim and yarn knitting process 404, the yarn is used in a circular knitting process in which the yarn is knitted simultaneously with a base material made of natural fibers. In this process, the knitting is cast on and a circle of stitches is joined to form a circular, seamless knit material. Alternatively, during the knitting process, the strands forming the scrim are simultaneously knit together in the knitting step to produce a tubular knit pile fabric. The method may further include cutting and labeling semi-finished fabric at step 405 and subsequent preparation of the backside 406. The method may further include the application of an adhesive agent 407 on the prepared backside. The adhesive agent may be cured (temperature, UV, or other) and mechanically pressed by rollers or dried. The method may further include cleaning and drying of base 408 and storage of the semi-finished fabric 409.



FIG. 5 depicts a simplified flowchart showing the steps for the post-finishing process including a multitude combing, cutting, roughening, trimming, straightening, shearing, and polishing steps, steaming, heating, tumbling or spraying steps with a finishing solution. In at least embodiment as disclosed herein the method is comprised of the following processing steps including a finished fabric preparation process 501, a steam treatment 502, a heat treatment 503, a mechanical treatment 504, an assessment process 505, applying of finishing solution 506, a mechanical treatment 507, an assessment process 508, a final trimming 509, a combing and cleaning 510, and storage of post finished fabric 511, without limitation or restriction, unless so limited by the claims herein.


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 secondary 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 at least one illustrative embodiment of the methods disclosed 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., 60-90 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 80-200 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.



FIG. 6 depicts a cross-sectional of the post-finished plant pile fabric with guard hair and an underlayer attached to the base. The individual layers are pile fibers including guard hair and underlayer, scrim, and adhesive agent. FIG. 6 depicts an illustrative plant pile fabric 1100 that may have fibers 1000 having length 1001, underlayer 1004, guard hair 1003, applied and reacted sealing agent 1005, and scrim base 1006 of the pile fabric 1100.



FIG. 7 depicts an exploded cross-sectional view of the post-finished plant pile fabric depicting the individual layers of the fabric according to at least one embodiment disclosed herein. The three individual layers are pile fibers, scrim, and adhesive agent. The figure may include the section view of plant pile fabric 1100 having a plurality of fibers 1000, having fiber length 1001, the section of the pile fabric imitation longer guard hair 1003, applied and reacted sealing agent 1005, scrim base 1006 of the pile fabric 1100, the combination of pile fabric 1100 and base 1101, and the combination of scrim and an agent to connect the fibers to the base 1102.



FIG. 8 depicts a cross-section of the finished plant pile fabric before being exposed to the post-finishing process. The figure may include the section view of plant pile fabric 1100 having fibers 1000 with fiber length 1001, the scrim base of the fabric 1006, and the pre-finished fabric 1201.



FIG. 9 depicts a perspective view of the post-finished plant pile fabric with guard hair 902 and an underlayer 904 attached to the base. The individual layers are pile fibers including guard hair and underlayer, scrim, and adhesive agent. FIG. 9 depicts plant pile fabric 1100 that may have fiber length 910, applied and reacted sealing agent 1005, and scrim base 1006 of the pile fabric 1100. The plurality of pile fibers 1000 includes a fiber volume (906, 908) per square centimeter ranging from about 1.5 cubic centimeters to about 7 cubic centimeters per 1 square centimeter of base.



FIG. 10A illustrates a simplified diagram of natural plant-fiber based pile-fabric textile production including guard hair 902 and an underlayer 904 attached to a base 1102 via knitting, weaving, warp knitting, or, as in FIG. 10B, blocking.



FIG. 11 illustrates the processing steps used during blocking according to at least one embodiment of the method of natural plant-fiber based pile-fabric textile production including, in a first step 1110, selecting fiber slivers and bundling of fiber slivers as needed. Step 1110 may include positioning fibers vertically within a framing device. According to some embodiments, the frames may be constructed and arranged to securely hold fibers in the first frame. The frames may include tightening mechanisms to securely hold fibers within the frame. A second top frame may be positioned above the first frame. A third lower frame may be positioned below the first frame. Step 1113 may include securing the frames to one another as previously described. Step 1114 may include trimming of the fibers, using the second and third frames as guides for limiting how much of each fiber is trimmed from the top or bottom of a fiber. Step 1116 may include removing the second top frame and third lower frame. Step 1118 may include performing additional fiber thinning, softening, or trimming as described herein. Step 1120 may include pretreating fibers to facilitate attachment of the fibers to a backing material, such as base 1102. Step 1122 may include attaching the fibers to the base 1102, such as via an optional adhesive. In step 1124, the first frame may be removed. Further brushing, trimming, or post-finishing may occur. The disclosed method allows for adjusting fiber orientation (the angle at which a fiber attaches to the backing) to simulate various fur arrangements such as fox fur, cowhide, or the like.



FIGS. 12A-12B illustrates a method of natural plant-fiber based pile-fabric textile production including selecting fiber slivers and bundling of fiber slivers 902, 904 as needed. A framing assembly 1300 may include a first frame 1302, second top frame 1304, and bottom third frame constructed and arranged to be assembled via attachment mechanisms 1308 including, for example, a nut 1310 and bolt 1312 arrangement. Each of the frames may include frame sides 1314, 1316 which may be disassembled. Fiber slivers 902, 904 may be arranged vertically within the framing assembly including the first frame 1302, second top frame 1304, and bottom third frame 1306. Frames 1302, 1304, and 1306 may be secured to one another as previously described. Subsequently, the second top frame 1304 and bottom third frame 1306 may be detached and removed such that the fiber slivers 902, 904 remain within the first frame 1302.


Referring to FIG. 12B, fiber slivers 902, 904 within the first frame 1302 may be attached to a base 102, such as vegan leather backing. The method and system disclosed in FIGS. 12A-12B allows for adjusting fiber orientation (the angle 1320 at which a fiber attaches to the backing) to simulate various fur arrangements such as fox fur, cow hide, or the like.



FIGS. 13A-13E illustrate various types of natural plant-fiber based pile-fabric textile patterns of fibers attached to the backing produced weaving or knitting fibers (902, 904) to backing 1102 according to at least one embodiment of the plant pile textile disclosed herein. FIGS. 13A-13E depict blocked fibers in spatial arrangements to simulate various furs, such as, but not limited to, dispersed (illustrated by FIG. 13A), rows (illustrated by FIG. 13B and FIG. 13D), “checkerboard” (illustrated by FIGS. 13C), whole coverage (FIG. 13E), and the like. Each image in FIGS. 13A-13E represents approximately 10×10 mm of the plant fiber pile fabric textile. FIG. 13E illustrates the types of natural plant fiber based pile fabric textile produced by blocking according to at least one embodiment of the natural plant-fiber based pile-fabric textile disclosed herein.



FIGS. 14A-14B illustrate various examples of different plant fiber thicknesses being obtained within the same type of plant at least one embodiment of the plant fiber based pile fabric textile. FIG. 14A illustrates a thicker fiber (a conglomerate of thinner fibers) being split into thinner fibers. FIG. 14B illustrates a thinner single fiber which cannot be further split.



FIG. 15. illustrates an example of a plant fiber cross-section within a final product according to at least one embodiment of the plant fiber based pile fabric textile disclosed through-out. FIG. 15 illustrates how a mixture of different types of plant fibers may be combined. As shown, thin fibers are positioned as underfur and thicker fibers are positioned as guard hair. Additionally, FIG. 15 illustrates a plant fiber with hollow fibers. Configuring a product with plant fibers having different densities across the fiber cross-section allows for replication of animal fur as it is common for animal fibers to have different densities across the fiber cross-section.



FIGS. 16A-16F illustrate examples of potential variations of a final product according to at least one embodiment of the plant fiber based pile fabric textile 1100 disclosed throughout. FIGS. 17A-17D illustrate additional examples of potential variations of a final product according to at least one embodiment of the plant fiber based pile fabric textile 1100 disclosed throughout.


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.


LISTING OF EMBODIMENTS

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 10 micrometers to approximately 300 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 10 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 10 micrometers to approximately 300 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 1000 fibers per square centimeter to approximately 30000 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 a 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 a 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 a 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 32 may include a method of any of embodiments 27 through 31, 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 33 may include a method of any of embodiments 27 through 32, wherein the finishing process includes applying a hot rotational ironing at about 60-175 degrees C. and about 60-1500 RPM to straighten the knitted material.


Embodiment 34 may include a method of any of embodiments 27 through 33, wherein the finishing process includes trimming of a plurality of guard fibers and a plurality of underlayer fibers.


Embodiment 35 may include a method of any of embodiments 27 through 34 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 36 may include the method of any of embodiments 27 through 35, wherein the knitting process includes at least one of knitting, weaving, or warp knitting.


Embodiment 37 may include the method of any of embodiments 27 through 36, wherein the knitting process includes blocking.


Embodiment 38 may include the method of any of embodiments 27 through 37, wherein the plant-fiber based pile-fabric textile includes a fiber density per square centimeter of base ranging from about 1000 fibers per square centimeter to approximately 30000 fibers per square centimeter of base surface.


Embodiment 39, 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, the plant-fiber based pile-fabric textile including a fiber density per square centimeter of base ranging from about fibers per square centimeter to approximately 30000 fibers per square centimeter of base surface.


Embodiment 40 may include the method of embodiment 39 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 41 may include the method of any of embodiments 39 through 40, 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 42 may include the method of any of embodiments 39 through 41, 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 43 may include the method of any of embodiments 39 through 42, 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 44 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.


Embodiment 45 may include the method of any of embodiments 39 through 44, wherein the knitting process includes at least one of knitting, weaving, or warp knitting.


Embodiment 46 may include the method of any of embodiments 39 through 45, wherein the knitting process includes blocking.


Embodiment 47 may include a method of any of embodiments 27 through 35 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 48 may include the method of any of embodiments 27 through 37 further including enzymatic thinning on both ends of the pile fiber.


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.

Claims
  • 1. A pile-fabric textile comprising: a) a plant-based base;b) a plurality of pile fibers comprising plant fibers affixed to the base at a first end of each fiber; and,c) wherein the plurality of pile fibers comprises a fiber density per square centimeter of base ranging from about 1000 fibers to about 30000 fibers per square centimeter of the base.
  • 2. The pile-fabric textile as in claim 1, wherein the pile fibers are at least 5% plant fibers.
  • 3. The pile-fabric textile as in claim 1, wherein the pile fibers are at least 90% plant fibers.
  • 4. The pile-fabric textile as in claim 1, wherein the pile fibers are biodegradable.
  • 5. The pile-fabric textile as in claim 1, wherein the pile
  • 6. The pile-fabric textile as in claim 1, wherein the plurality of pile fibers are devoid of fossil fuel based fiber material.
  • 7. The pile-fabric textile as in claim 1, wherein the plurality of pile fibers are processed plant fibers, the steps of processing further comprising: a) a retting process upon the plant fibers;b) a mercerizing process upon the plant fibers with sodium hydroxide; and,c) a treatment with pressure and heat to introduce a material into at least one microscopic crevasse in the plant fibers.
  • 8. The pile-fabric textile as in claim 1, wherein the plurality of plant fibers comprises at least one of a cotton, hemp, stinging nettle, linen, flax, jute, banana, ramie, coir, lotus, silk, pineapple, or sisal fiber.
  • 9. The pile-fabric textile as in claim 1, wherein the plurality of pile fibers comprises a guard hair group of pile fibers having a first average length and an underlayer group of pile fibers having a second average length.
  • 10. The pile-fabric textile as in claim 9, wherein the guard hair group of pile fibers and the underlayer group of pile fibers have different average lengths.
  • 11. The pile-fabric textile as in claim 9, wherein the average length of fibers within the first underlayer group of pile fibers is about 5 millimeters to about 25 millimeters.
  • 12. The pile-fabric textile as in claim 9, wherein the average length of each fiber within the second guard hair group of pile fibers is about 20 millimeters to about 100 millimeters.
  • 13. The pile-fabric textile as in claim 9, wherein each fiber within the first guard hair group of pile fibers and the second underlayer group of pile fibers have about the same diameter.
  • 14. The pile-fabric textile as in claim 9, wherein the fibers within the first guard hair group of pile fibers have a diameter different from fibers in the underlayer group of pile fibers.
  • 15. The pile-fabric textile as in claim 9, wherein the diameter of the fibers in the guard hair group is about 10 micrometers to about 50 micrometers.
  • 16. The pile-fabric textile as in claim 1, wherein the base comprises a scrim constructed of plant fibers.
  • 17. The pile-fabric textile as in claim 9, wherein at least one of the guard hair group of pile fibers or the underlayer group of pile fibers is affixed to the plant-based or biodegradable base with mechanical entanglement and an adhesive agent.
  • 18. The pile-fabric textile as in claim 9, wherein at least one of the guard hair group of pile fibers or the group of pile fibers are affixed to the plant-based and/or biodegradable base by at least one of stitching or knitting.
  • 19. The pile-fabric textile as in claim 9, wherein at least one of the guard hair group of pile fibers or the underlayer group of pile fibers further comprise 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, and a cleaning agent.
  • 20. The pile-fabric textile as in claim 19, wherein the agent is impregnated into at least one of the guard hair group of pile fibers or the underlayer group of pile fibers.
  • 21. The pile-fabric textile as in claim 19, wherein the guard hair group of pile fibers or the underlayer group of pile fibers is surface treated with the agent.
  • 22. A pile-fabric textile comprising: a) abase;b) a plurality of plant-derived processed pile fibers, wherein the plurality of plant-derived pile fibers have been processed via a retting process and then treated with heat and pressure in the presence of an impregnation material to introduce the impregnation material into at least one microscopic crevasse in each of the pile fibers; and,c) wherein a first end of each of the pile fibers is secured to the base.
  • 23. The pile-fabric textile according claim 22 wherein the impregnation material is selected from the group consisting of flame retardants, biopolymers, strengthening agents, stabilizing agents, pigments, and or softeners, alone or in any combination herein.
  • 24. The pile-fabric textile according to claim 22, wherein the plurality of pile fibers are biodegradable.
  • 25. The pile-fabric textile according to claim 22, wherein the plant-derived pile fibers are selected the group of plant fibers comprising cotton, hemp, stinging nettle, linen, jute, banana, ramie, coir, and or sisal, alone or in any combination herein.
  • 26. A method of making a plant-fiber based pile-fabric textile comprising: a) performing a raw material fiber preparation process on a plant material fiber to form a raw material fiber, wherein performing a raw material fiber preparation process further comprises: i. performing a dew retting process on the plant material fiber;ii. performing a mercerization process comprising treating the plant material fiber with sodium hydroxide; andiii. performing an impregnation process comprising treating the plant material fiber with pressure and heat in the presence of an impregnation liquid to introduce an impregnation material into at least one microscopic crevasse in the plant material fiber;b) performing a pre-finishing process on the raw material fiber to form a pre-finished material;c) performing a knitting process on the pre-finished material to form a knitted material;d) performing a finishing process on the knitted material to form a finished material; and,e) performing a post-finishing process on the finished material to form the plant-fiber based pile-fabric textile.
  • 27. The method of making a plant-fiber based pile-fabric textile according to claim 26 wherein the pressure during the impregnation process is between 101.325 kPa and 1013.250 kPa and the temperature is between 70 degrees C. and 120 degrees C.
  • 28. The method of making a plant-fiber based pile-fabric textile according to claim 26 wherein the impregnation material in the impregnation liquid is selected from the group consisting of flame retardants, biopolymers, strengthening agents, stabilizing agents, pigments, protective agents and or softeners, alone or in any combination herein.
CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of and claims the benefit of the non-provisional patent application filed on Jul. 25, 2024 and assigned Ser. No. 18/784,374, which was a continuation of the nonprovisional patent application filed on Jul. 24, 2024 and assigned Ser. No. 18/783,090 which entered into the National Phase in the United States 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. This application also claims the benefit of the U.S. provisional patent application filed on Jul. 25, 2023 and assigned Ser. No. 63/528,738. All of preceding applications are incorporated by reference herein in their entireties.

Provisional Applications (2)
Number Date Country
63302605 Jan 2022 US
63528738 Jul 2023 US
Continuations (1)
Number Date Country
Parent 18783090 Jul 2024 US
Child 18784374 US
Continuation in Parts (1)
Number Date Country
Parent 18784374 Jul 2024 US
Child 18784680 US