Environmentally friendly process for the production of a textile by spraying

Abstract

Environmentally friendly process for the production of a textile by spraying. Process for producing a textile comprising the following successive steps: supply E01 comprising the following substeps: supply E02 of at least one liquid composition comprising a water-soluble binder and a water-based solvent in which the binder is dissolved, the binder comprising a water-soluble polymer representing 30 to 70% by weight of the liquid composition, and the solvent comprising water representing 30 to 70% by weight of the liquid composition; supply E03 of a filler consisting of loose fibers and / or a powder, at least 5% by weight of the filler being of bio-based origin; supply E04 of a support having a deposition surface; formation E05 on the deposition surface of a composite layer consisting of a liquid composition and a filler, comprising the following substeps: spraying E06 on the deposition surface of a liquid composition;spraying E07 onto the deposition surface of a filler; the substep of spraying a filler E07 being simultaneous with or subsequent to the substep of spraying the liquid composition E06; drying E08 of the composite layer and polymerization of the water-soluble polymer by evaporation of water at atmospheric pressure; repetition E09 at least once of the steps of forming E05 and drying E08 of a composite layer, and formation of a textile on the deposition surface; removal E13 of said textile from the deposition surface. Figure to be published with the abbreviation: None;

Description

Title of the invention: Environmentally friendly process for the production of a textile by spraying. TECHNICAL FIELD OF THE INVENTION

[0001] The technical field of the invention is that of the production of a textile by spraying.

[0002] The present invention relates to a method of producing a textile by spraying, as well as a textile obtained by this method and an article obtained from this textile. TECHNOLOGICAL BACKGROUND OF THE INVENTION

[0003] From documents EP1511577B1, EP1904598A1 and EP1910600B1, a process for manufacturing textiles by spraying fibers onto a support element is known, as well as a mixture of fibers, binder and solvent to be used in the process.

[0004] These processes make it possible to supply textiles by flexible and practical methods, allowing personalized or made-to-measure creations, quickly and at low cost thanks to a very fine control of thickness, shape and color, while minimizing losses.

[0005] They allow textiles to be formed quickly and easily from a variety of different materials and in a variety of different shapes. Consequently, these spray-based textile manufacturing processes are of interest to several industrial sectors, particularly in the fashion and furniture industries.

[0006] However, the composition used in these processes and the processes themselves are extremely polluting, toxic, and environmentally unfriendly. Indeed, these textile manufacturing processes using spray technology utilize, in particular, polymers and solvents based on hydrocarbons and other fossil resources. Furthermore, they require raw materials that are generally difficult to produce locally and are therefore imported, resulting in additional pollution during transport.

[0007] Nowadays, however, there is an urgent and growing need to reduce the environmental and ecological impact of industrial manufacturing processes.

[0008] The object of the invention is therefore to improve the production processes of a textile by spraying in order to meet these needs. Summary of the invention

[0009] The invention offers a solution to the problem of reducing the environmental and ecological impact of textile production processes by spraying by providing a new process for producing a textile by spraying that meets, as far as possible, all of the following requirements: • use environmentally friendly and ecologically sound materials; • use materials derived from renewable natural raw materials; • use non-toxic materials, especially by contact and / or inhalation; • use as little as possible of materials obtained from fossil resources; • use recyclable and / or biodegradable materials; • use recycled materials; • use locally produced materials; • use a production process that generates little waste, this waste being reusable, recyclable and / or biodegradable.

[0010] In order to meet these requirements, following numerous studies, including feasibility studies, the applicant chose to primarily use bio-based fillers in the form of powder and / or fibers, a water-soluble binder, and a water-based solvent, and to adapt the spray manufacturing process accordingly. A bio-based material is defined as a material derived from renewable, non-fossil, natural organic raw materials of plant or animal origin.

[0011] One aspect of the invention relates to a method for producing a textile, comprising the following steps: • supply E01 of a support, at least one liquid composition and at least one charge to be sprayed onto said support, this supply step E01 comprising the following sub-steps: • supply E02 of at least one liquid composition comprising a water-soluble binder and a water-based solvent in which the binder is dissolved, the binder comprising one or more water-soluble polymers, which represent 30 to 70% by weight of the liquid composition, and the solvent comprising water representing 30 to 70% by weight of the liquid composition; • supply E03 of a filler consisting of loose fibers and / or powder, at least 5% by weight of the filler being of bio-based origin; • supply E04 of a support having a deposition surface; • E05 formation on the deposition surface of a composite layer consisting of a liquid composition and a filler resulting from the supply step E01, this E05 formation step comprising the following sub-steps: • spraying E06 onto the deposition surface of a liquid composition resulting from the supply step E01; and • spraying E07 onto the deposition surface of a charge consisting of loose fibers and / or a powder resulting from the supply step E01; • the spraying substep E07 of a charge being simultaneous with or subsequent to the spraying substep E06 of the liquid composition; • drying E08 of the composite layer resulting from the formation step E05 and polymerization of the water-soluble polymer by evaporation of water at atmospheric pressure; • repetition E09 at least once of the formation steps E05 and drying steps E08 of a composite layer, and formation of a textile on the substrate deposition surface; and • removal E13 of said textile from the substrate's deposit surface.

[0012] The expression "spraying onto a layer or surface" means spraying onto the outer face of a layer or surface.

[0013] By "loose fibers" we mean loose fibers that are not bound together, or compacted, or oriented in any way, so that when sprayed, they are randomly arranged on the surface on which they are sprayed.

[0014] It should also be noted that the term "textile" used here can refer to a non-woven textile material when it contains fibers. When it does not contain fibers but only powder, the term "textile" is used somewhat loosely because it contains neither yarns nor fibers, but it remains appropriate because the material of the invention behaves substantially like a conventional textile and is intended for similar applications.

[0015] The textile obtained by the process of the invention is essentially two-dimensional, as it can be either completely flat when manufactured on a flat substrate, or have hollows, protrusions, slightly concave parts, or slightly convex parts when manufactured on a substrate having these same shapes. The textile obtained by the process of the invention thus takes the form of a curved surface, that is to say, a piece that is essentially flat, but with possible variations in relief. Overall flat but able to exhibit gentle or irregular curves as illustrated in [Fig. 7], the textile obtained by the process of the invention can be flat (see a), slightly parabolic (see b), slightly wavy (see c), slightly domed (see d), slightly twisted (see e), slightly paraboloid (see f), It may have one or more curved edges (see g and h), etc. It may also have some low-height reliefs or hollows when manufactured on a textured substrate.

[0016] The textile obtained by the process of the invention is not three-dimensional in the classical sense of the term, since it develops primarily in two-dimensional space and does not delimit a closed volume. Indeed, the textile obtained by the process of the invention is not closed upon itself, for example, as would be a tubular, conical, frustoconical, polyhedral, spherical, toroidal, ellipsoidal, or any other object with a similar shape or a combination thereof. Thus, the textile obtained by the process of the invention is not a self-enclosed object; that is to say, none of its cross-sections is in the form of a closed line.

[0017] Spraying thin, water-based liquid layers onto or into which bio-based fibers or powders adhere not only significantly reduces the process's carbon footprint but also allows for rapid drying of each layer, without necessarily requiring heating and / or a vacuum, and without the release of toxic or hazardous fumes. Similarly, this process enables the local, on-demand production of textiles with precisely controllable shape and thickness, while generating very little waste.

[0018] In addition to being non-toxic, inexpensive and abundant, water has numerous and obvious advantages for the environment and ecology compared to organic solvents

[0019] Thus, the process according to the invention has a considerably reduced environmental and ecological impact compared to previous processes of textile production by spraying.

[0020] If the sub-steps of spraying E06 of the liquid composition and spraying E07 of the charge are simultaneous, this makes it possible in particular to reduce the duration of the production process.

[0021] In the case where a liquid composition and a filler are sprayed simultaneously, they may each be sprayed by a separate spraying unit or by the same spraying unit. In the latter case, the liquid composition and the filler may be mixed together before being introduced into the spraying unit, or be mixed within it.

[0022] If the E07 spraying substep of the filler is carried out after the E06 spraying substep of the liquid composition, this allows in particular better control of the composition of each composite layer.

[0023] According to one aspect of the invention, during the drying step E08, the support is subjected to vibrations, which in particular improves the mechanical properties of the textile obtained and accelerates drying.

[0024] According to another aspect of the invention, prior to the textile removal step E13, it comprises a finishing layer formation step E10 on the composite layer resulting from the repetition step E09, this finishing layer formation step E10 comprising the following successive sub-steps: • spraying Eli onto the deposition surface of a liquid composition resulting from the E02 supply step of at least one liquid composition; and • drying E12 of the liquid composition sprayed during the previous spraying substep El 1 and polymerization of the water-soluble polymer thereof by evaporation of water at atmospheric pressure.

[0025] This E10 formation step of a finishing layer makes it possible in particular to cover the external face of the textile with polymer in order to give it a smooth and uniform aesthetic appearance and to protect the lower layers.

[0026] According to a further aspect of the invention, at least one drying step E08, E12 is carried out at room temperature, thereby reducing the cost and carbon footprint of the process. "Room temperature" refers to the temperature of the room where the process is implemented. This temperature depends on the geographical region and the season, but is usually between 10 and 30 °C, more commonly between 15 and 25 °C, and even more commonly between 18 and 22 °C. The process of the invention is thus designed to be carried out at a temperature at which most people are accustomed to working indoors.

[0027] According to one aspect of the invention, at least one drying step E08, E12 is carried out at a temperature between 50 and 90 °C, which in particular makes it possible to accelerate drying and promote the polymerization of the water-soluble polymer.

[0028] According to another aspect of the invention, after a drying step E08, E12, the process includes a stabilization step E14 of the textile material, this stabilization step E14 comprising at least one of the following sub-steps: • a heat treatment; • plasma therapy; and / or • crosslinking by irradiation.

[0029] According to a further aspect of the invention, at least a part of the substrate's deposition surface is textured in relief or intaglio, which makes it advantageous in particular to generate a texture intaglio or intaglio on at least a part of the inner face of the textile obtained, i.e. its face in contact with the substrate before its removal from the latter.

[0030] According to one aspect of the invention, during the E05 formation step of a composite layer, the filler represents 30 to 60% by weight of said composite layer, this which advantageously reduces the environmental and ecological impact of the process.

[0031] According to another aspect of the invention, during the E05 formation step of a composite layer, the weight-filler ratio in said composite layer is in the range of 2:1 to 1:2, which advantageously reduces the environmental and ecological impact of the process while providing a textile with characteristics suitable for its subsequent use. The choice of this ratio makes it possible, in particular, to adapt the flexibility and strength of the resulting textile for a given final thickness, with a high binder content generally favoring flexibility, while a high filler content generally favoring rigidity of the resulting textile.

[0032] According to a further aspect of the invention, during the E05 formation step of a composite layer, a bio-based filler represents 5 to 50%, preferably 10 to 40% and more preferably 15 to 30% by weight of said composite layer, which advantageously reduces the environmental and ecological impact of the process.

[0033] According to one aspect of the invention, during the E03 feed supply step, 5 to 70%, preferably 10 to 60% and more preferably 20 to 50% by weight of the feed is of bio-based origin.

[0034] According to another aspect of the invention, during the feed supply step E03, 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the bio-based feed consists of viscose fibers, cotton fibers, wool fibers, silk fibers, cashmere fibers, flax fibers, fur fibers, mammal hair, mycelium fibers, cellulose fibers, wood fibers, hemp fibers, mycelium powder, rice powder, wheat powder, wood powder, starch powder, alginate powder, carbon black powder, wheat flour, corn flour, millet flour, hemp flour, rapeseed flour, soybean hull powder, walnut hull powder, olive kernel powder, cellulose nanofiber powder, or powder or bio-based polyamide fibers, powder or bio-based polypropylene fibers,of bio-based polyethersulfone powder or fibers or bio-based polyurethane powder or fibers, used alone or in mixtures, which notably reduces the carbon footprint of the process.

[0035] According to a further aspect of the invention, during the feed supply step E03, 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the bio-based feed consists of at least one bio-based material comprising at least 5% by weight of calcium, preferably at least 10% in weight of calcium, which notably improves the tensile strength, compression strength and / or water absorption capacity of the resulting textile.

[0036] According to one aspect of the invention, at least one bio-based material comprising at least 5% by weight of calcium is gypsum powder, limestone powder, bone powder, calcium carbonate powder or chalk powder, which advantageously reduces the environmental and ecological impact of the process.

[0037] Indeed, calcium carbonate increases the tensile and compressive strength of the resulting textile. Magnesium sulfate increases both the tensile and compressive strength of the resulting textile, as well as its water absorption capacity. Gypsum, on the other hand, only increases the tensile strength of the resulting textile, while sodium sulfate increases the water absorption capacity of the resulting textile.

[0038] According to another aspect of the invention, during the supply step E02 of at least one liquid composition, the water-soluble binder comprises at least 10%, preferably at least 30% and more preferably at least 60% by weight of bio-based and / or biodegradable polymer, which in particular makes it possible to reduce the carbon footprint of the process.

[0039] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition, the water-soluble binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of elastomer, which makes it possible in particular to produce a textile having elastic properties.

[0040] According to one aspect of the invention, during the supply step E02 of at least one liquid composition, the water-soluble binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of natural latex of plant origin, latex of plant origin treated to reduce its protein content, bio-based polylactic acid, bio-based thermoplastic polyurethane, bio-based polyurethane dispersion, rosin dispersion of plant origin, terpene dispersion of plant origin, bio-based acrylic polymer or polymer matrix hydrogel, taken alone or in mixture, which advantageously reduces the environmental and ecological impact of the process.

[0041] According to another aspect of the invention, during the supply step E02 of at least one liquid composition, the water-soluble binder comprises at least 10%, preferably at least 20% and more preferably at least 30% by weight of electrically conductive polymer, which notably allows the resulting textile to be instrumented.

[0042] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition, the liquid composition comprises from 1 to 30% in weight of magnesium sulfate and / or sodium sulfate, which notably improves the tensile strength, compression strength and / or water absorption capacity of the resulting textile.

[0043] According to one aspect of the invention, during the supply step E02 of at least one liquid composition or during the supply step E03 of a filler consisting of loose fibers and / or a powder, the liquid composition or the filler includes a water-soluble bridging agent capable of forming ionic and / or covalent bonds with a water-soluble polymer of the binder, which makes it possible in particular to improve or modify the physical properties of the textile, in particular its mechanical resistance and / or its elasticity.

[0044] According to another aspect of the invention, the bridging agent mainly comprises mushroom spores, mushroom mycelium, silicate derivatives or magnesium chloride derivatives, taken alone or in mixture, which advantageously reduces the environmental and ecological impact of the process.

[0045] According to a further aspect of the invention, during a formation step E05 of a composite layer, the weight ratio of bridging agent in said composite layer is in the range between 1:100 and 1:1, preferably between 1:10 and 1:4, and more preferably between 2:10 and 3:10, which in particular makes it possible to improve or modify the physical properties of the textile in a satisfactory manner.

[0046] According to one aspect of the invention, during the supply step E02 of at least one liquid composition, the charge includes a coalescing agent whose quantity represents from 0.1 to 10%, preferably 1 to 5% by weight of the liquid composition.

[0047] According to another aspect of the invention, the coalescing agent is 2,2,4-trimethyl-1,3-pentane diol monoisobutyrate, glycol acetate, butyl glycol, fatty acid ester, propylene glycol or ethyl acetate, taken alone or in mixture.

[0048] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition, said liquid composition includes at least one pigment, which advantageously makes it possible to produce a textile with at least one layer dyed in the mass.

[0049] According to one aspect of the invention, during the supply step E02 of at least one liquid composition, said liquid composition comprises a water-soluble viscosity-modifying agent, which advantageously allows the viscosity of the liquid composition to be adjusted, for example, to thicken or thin it, particularly to ensure that it adheres to the substrate without excessive dripping, for example, when the application surface is not entirely flat and horizontal. Viscosity here also refers to the rheological properties of the liquid composition.

[0050] According to another aspect of the invention, the viscosity agent is polylactic acid, sugar, polysaccharide derivative, alginate, potato dextrose, agar, glucose, malt, peptone or yeast extract, taken alone or in mixture, which advantageously reduces the environmental and ecological impact of the process.

[0051] According to a further aspect of the invention, during the supply step E02 of at least one liquid composition, said liquid composition has a dynamic viscosity between 0.1 and 10,000 mPa.s at 20 °C, which provides a wide viscosity range suitable for the different spraying conditions and the different applications envisaged.

[0052] According to one aspect of the invention, during the supply step E02 of at least one liquid composition, said liquid composition includes a water-soluble adhesive agent, which makes it possible in particular to improve the bond between the different layers of the textile if necessary. Indeed, the bond between layers can be made by the polymers themselves present in each layer, in particular when they are of the same chemical family.

[0053] According to another aspect of the invention, the adhesive agent is an aqueous dispersion of rosin and terpene, both of plant origin, which advantageously reduces the environmental and ecological impact of the process.

[0054] According to a further aspect of the invention, during a substep E06 of spraying the liquid composition, said liquid composition completely covers a filler comprising fibers, at least 80% of these fibers having a length between 3 and 7 mm, preferably between 3 and 5 mm, and more preferably between 3 and 4 mm, which in particular makes it possible to reinforce the textile obtained.

[0055] According to one aspect of the invention, during a substep E06 of spraying the liquid composition, said liquid composition does not completely cover a filler comprising fibers, at least 80% of these fibers having a length between 0.1 and 2 mm, preferably between 0.5 and 1.5 mm, and more preferably between 0.5 and 1 mm, which in particular makes it possible to improve the feel of the textile obtained, with average counts of 1.7 Dtex for fibers of length 0.5 mm and 3.3 Dtex for fibers of length 1 mm.

[0056] One aspect of the invention also relates to a textile comprising alternating layers of water-soluble polymer-based material and a filler comprising a powder and / or fibers, said textile being a product resulting from the process according to the invention as previously described. By its composition and production process, this textile advantageously presents an environmental impact and significantly reduced environmental impact compared to previous spray-produced textiles.

[0057] According to one aspect of the invention, the textile has an average thickness of between 0.1 and 3 mm.

[0058] In addition, an aspect of the invention also relates to a textile article made from a textile according to the invention as described above, also exhibiting a considerably reduced environmental and ecological impact compared to previous textile articles.

[0059] Finally, an aspect of the invention also relates to a spraying system for implementing the process as described above, which spraying system comprises the following equipment: • at least one spraying unit equipped with one or more spray nozzles; • at least one fluid displacement device; • at least one tank containing: • a liquid composition comprising a water-soluble binder and a water-based solvent, • a powder charge, • a load in the form of loose fibers, taken alone or in blend ; • supply pipes connecting at least one reservoir to at least one fluid displacement device and to at least one spray nozzle; • at least one support having a deposition surface on which a textile can be manufactured by spraying at least one fluid contained in a reservoir and supplied by a fluid displacement device to a spraying unit.

[0060] The invention and its various applications will be better understood by reading the following description and examining the accompanying figures. BRIEF DESCRIPTION OF THE FIGURES

[0061] The figures are presented for illustrative purposes only and are not intended to limit the invention.

[0062] [Fig. 1] is a schematic representation of an example of a method according to the invention in which a liquid composition is sprayed before a charge.

[0063] [Fig.2] is a schematic representation of an example of a process according to the invention in which a liquid composition and a charge are sprayed simultaneously.

[0064] [Fig.3] is a schematic view of an example of a device comprising two units spraying units, each mounted on a separate robotic arm, enabling the implementation of the process according to the invention for the production of a flat textile.

[0065] [Fig.4] is a schematic view of an example of a device comprising two units spraying units mounted on the same robotic arm and enabling the implementation of the process according to the invention for the production of a flat textile.

[0066] [Fig.5] is a schematic view of an example of a device comprising a single spraying unit mounted on a robotic arm and enabling the implementation of the process according to the invention for the production of a slightly curved textile.

[0067] [Fig.6] is a schematic view of an example device comprising three units spraying units mounted on the same robotic arm, enabling the implementation of the process according to the invention for the production of a textile in the shape of a shoe outsole.

[0068] [Fig.7] is a schematic perspective view illustrating different forms for a flat or curved textile obtained by the process of the invention. DETAILED DESCRIPTION

[0069] Unless otherwise specified, the same element appearing on different figures has a unique reference.

[0070] The process according to the invention uses at least one liquid composition and at least one filler intended to be sprayed onto a support 1 in order to produce a textile 2.

[0071] A liquid composition according to the invention comprises a water-soluble binder and an aqueous solvent in which the binder is dissolved.

[0072] The aqueous solvent is preferably entirely composed of water. It represents 30 to 70% by weight of the liquid composition.

[0073] The binder comprises a water-soluble polymer representing 30 to 70% by weight of the liquid composition.

[0074] Although the binder can be supplied in the form of an aqueous solution, the percentages given here are in dry weight of binder or water-soluble polymer.

[0075] The binder preferably comprises one or more water-soluble bioplastics or one or more recyclable water-soluble polymers. Bioplastics are understood to mean polymers derived from renewable sources (bio-based polymers) and biodegradable polymers. Thus, a bioplastic can be bio-based but not biodegradable, bio-based and biodegradable, or derived from fossil resources (often petrochemicals) and yet biodegradable. Bioplastics should not be confused with biocompatible plastics.

[0076] Thus, the water-soluble binder comprises at least 10%, preferably at least 30% and more preferably at least 60% by weight of bio-based and / or biodegradable polymer.

[0077] In order to enable the production of a textile 2 exhibiting elastic properties, the water-soluble binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of elastomer.

[0078] According to one embodiment, the water-soluble binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of natural latex of vegetable origin, latex of vegetable origin treated to reduce its protein content, bio-based polylactic acid, bio-based thermoplastic polyurethane, bio-based polyurethane dispersion, rosin dispersion of vegetable origin, terpene dispersion of vegetable origin, bio-based acrylic polymer or polymer matrix hydrogel, taken alone or in mixture.

[0079] Natural latex of plant origin is extracted in liquid form from several plants and trees, primarily the rubber tree (Hevea brasiliensis), and forms rubber after polymerization. It is advantageous because it is bio-based, biodegradable, compostable, recyclable, and elastic. A plant-based latex treated to reduce its protein content was Vytex® from VYSTAR, which yielded excellent results with the process for producing a textile 2 according to the invention.

[0080] Polylactic acid (PLA) is a homopolymer of lactic acid. It is advantageous because it is biodegradable, compostable, recyclable and can be bio-based, notably being obtained primarily from corn.

[0081] Thermoplastic polyurethanes (TPUs) are thermoplastic elastomers (TPEs) of isocyanate block polyurethane. They are advantageous in that they are recyclable and can be bio-based, biodegradable and elastic.

[0082] Very satisfactory tests were obtained with a bio-based polyurethane dispersion based on one of the following products: Impranil® DL 1545, Impranil® DL 1126, Impranil® DL 2611 / 1, Impranil® DLP, Impranil® 43031 and Impranil® DL 1380 from COVESTRO.

[0083] Very satisfactory tests were also obtained with a rosin dispersion based on Dermulsene A 7510® (Brookfield viscosity at 20 °C, 50 min-1, mPa.s: 600) and from a rosin solution based on Dermulsene TR 602® (Brookfield viscosity at 20 °C, 50 min-1, mPa.s: 800) from LES DERIVES RESINIQUES ET TERPENIQUES (DRT).

[0084] Among the bio-based water-soluble polymers that can be used, the following binders can also be mentioned: • the natural polymer, 100% bio-based and biodegradable from LACTIPS, which can provide water-soluble properties to the textile; • vinyl ethylene acetate (VAE), a water-soluble thermoplastic polymer that can be derived from bio-based sources; • Polyvinyl alcohol (PVA), a water-soluble polymer that can be produced from renewable raw materials; • polyethylene glycol (PEG), also known as polyethylene oxide (PEO) and poly(oxyethylene) (POE), a water-soluble linear polyether polymer that can also be used as a thickening agent and can be derived from renewable resources; • polyvinylpyrrolidone (PVP), a water-soluble polymer that can be used as an emulsifier and stabilizer and can be produced from bio-based sources; • ExpertGel®, a water-soluble thermogelling polymer developed by PolymerExpert, derived from natural oils; and • EstoGel® Green, a bio-sourced rheology modifier also developed by POLYMEREXPERT, a biodegradable oily gelling and shear-thinning agent, 100% of origin, which allows great versatility in terms of textures and visuals and flexibility in its use.

[0085] According to one embodiment, the water-soluble binder comprises at least 10%, preferably at least 20% and more preferably at least 30% by weight of electrically conductive polymer.

[0086] The process according to the invention also uses a filler consisting of loose fibers and / or a powder. At least 5% by weight of the filler is bio-based. Depending on the sprayed layers and the materials chosen, 5 to 70%, preferably 10 to 60%, and more preferably 20 to 50% by weight of the filler is bio-based.

[0087] The filler improves the texture and consistency of the final textile, increasing its durability. It can also provide additional properties, particularly when it includes a bridging agent. When bio-based, it is environmentally friendly.

[0088] In addition to adding flexibility and durability to the textile by increasing its resistance to wear, a filler made of fibers can provide a soft and pleasant texture to the textile 2.

[0089] According to one embodiment, 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the bio-based filler, consists of viscose fibers, cotton fibers, wool fibers, silk fibers, cashmere fibers, flax fibers, fur fibers, mammal hair, mycelium fibers, cellulose fibers, wood fibers, hemp fibers, powder of mycelium, rice powder, wheat powder, wood powder, starch powder, alginate powder, carbon black powder, wheat flour, corn flour, millet flour, hemp flour, rapeseed flour, soybean seed hull powder, walnut shell powder, olive kernel powder, cellulose nanofiber powder, bio-based polyamide powder or fibers, bio-based polypropylene powder or fibers, bio-based polyethersulfone powder or fibers or bio-based polyurethane powder or fibers, taken alone or in mixtures.

[0090] According to one embodiment, the liquid composition and / or the filler comprises a water-soluble bridging agent capable of forming ionic and / or covalent bonds with a water-soluble polymer of the binder. Preferably, the bridging agent comprises mainly mushroom spores, mushroom mycelium, silicate derivatives, or magnesium chloride derivatives, alone or in mixtures. The bridging agent preferably represents an amount such that, during the E05 formation step of a composite layer, before drying, the weight ratio of bridging agent to binder in said composite layer is in the range of 1:100 to 1:1, preferably between 1:10 and 1:4, and more preferably between 2:10 and 3:10.

[0091] For the mushroom mycelium, preferred mushroom species include the following: Pleurotus and subspecies o stratus and eryngii (king oyster mushroom), Ganoderma and subspecies lucidum (reishi) and resinceum, Trametes and subspecies versicolor (Turkish mushroom) and m ulticolor, Cordyceps, Lentinus, Lentinula, Agaricus (for example Agaricus bisporus, known as the button mushroom), Hericium, Schizophylium commune (saw fungus), Fomes fomentarius (birch fungus) and Lentinula edodes (shiitake).

[0092] Bridging agents in powder form are preferentially present in the feedstock, while bridging agents in liquid form are preferentially present in the liquid composition. Of course, if a feedstock is mixed with a liquid composition before spraying, a bridging agent can be added to this mixture.

[0093] According to one embodiment, 5 to 70%, preferably 30 to 65%, and more preferably 40 to 60% by weight of the bio-based filler, consists of at least one bio-based material comprising at least 5% by weight of calcium, preferably at least 10% by weight of calcium. Such a material improves the rigidity and strength of the material, while being a natural product. This bio-based material comprising at least 5% by weight of calcium is preferably gypsum powder, limestone powder, bone meal, calcium carbonate powder, or chalk powder.

[0094] When the charge includes powder, this powder preferentially has a narrow particle size distribution in the range of 20 to 100 pm, with an average particle size distribution for example of about 50 pm.

[0095] A liquid composition according to the invention may also comprise from 1 to 30% by weight of an additive suitable for improving the tensile strength, compressive strength and / or water absorption capacity of the resulting textile. This additive may, for example, be magnesium sulfate and / or sodium sulfate.

[0096] A liquid composition according to the invention may also include a coalescing agent that lowers the minimum film formation temperature (MFT) of aqueous dispersions, allowing the polymers to react more readily at lower temperatures. It acts by reducing the surface tension between the particles, thus facilitating their coalescence.

[0097] Some examples of usable coalescing agents are given in the table below, with preferred concentrations given for each as a percentage by weight relative to the total mass of the liquid composition.

[0098] [Tables 1] Coalescing Agent Operating Conditions Concentration Eastman's TEXANOL® (2,2,4-trimethyl-1,3-pentanediol monoisobutyrate) Used in water-based spray solutions. 1% to 5% Glycol Acetates Used as a coalescing agent in aqueous spray solutions. 0.1% to 10%, preferably 1% to 2% Butyl glycol Used in water-based spray solutions. 1% to 5% Fatty acid ester Used in spray solutions to reduce the minimum layer formation temperature. 2% to 4% Propylene glycol Used to improve the adhesion and durability of sprayed layers. 1% to 3% Ethyl acetate Used in spray solutions to facilitate drying. 2% to 6%

[0099] Among preferred glycol acetates, examples include ethylene glycol monoethyl ether acetate, 2-hexyl-1,3-dioxolane-4-methanol, 2-hexyl-1,3-dioxane-5-ol, 2-hexyl-2-methyl-1,3-dioxolane-4-methanol and 2-hexyl-2-methyl- 1,3-dioxane-5-ol. Ethylene glycol monoethyl ether acetate is a particularly suitable choice due to its favorable properties for atomization and its compatibility with water-based formulations.

[0100] A liquid composition according to the invention may also include at least one pigment. This pigment is preferably water-soluble. It may, for example, be an organic or inorganic pigment, for example, of chemical, mineral, or natural origin. It may also be pigments extracted from fungi or algae. Finally, it may also be disperse, azo, acid, or reactive dyes.

[0101] Some examples of usable pigments are given in the table below.

[0102] [Tables2] Pigment Type / Source Description Iron Oxide Inorganic Used to produce yellow, red, brown, black, and orange pigments. Titanium Dioxide Inorganic Common white pigment, widely used in paints, inks, and plastics. Carbon Black Inorganic Used in black printing inks; highly pigmented and lightfast. Zinc White Inorganic Solid white pigment, valued for its opacity and lightfastness. Prussian Blue Mineral Highly pigmented blue pigment, used in oil and acrylic paints. Cadmium Red Mineral Bright red pigment, known for its durability and lightfastness. Indigo Organic Blue pigment derived from the indigo plant, used for centuries for dyeing. Burnt Sienna Natural Reddish-brown pigment, used in oil and acrylic paints. Vermilion Mineral Bright red pigment, made from mercury sulfide; highly opaque and luminous.Organic pyrrole orange: A synthetic pigment offering a beautiful range of bright reds and oranges. Ganoderma lucidum mushroom pigment: Offers natural hues, including reds, yellows, whites, blacks, and purples, and is biodegradable. Also known for its antibacterial properties. Pigment from Lentinula edodes Fungus Pigments offering brown and beige shades. Pigment from Fornes fomentarius Fungus Known for its polysaccharides and phenolic compounds, this fungus can be used to obtain natural dyes. Pigment from Trametes versicolor Fungus Known for its medicinal properties, this fungus produces pigments that can be used in textile dyes. Pigment from Schizophyllum commune Fungus Contains polysaccharides and proteins; this fungus can also provide natural dyes for textiles. Phycoerythrin Red algae such as Porphyridium cruentum Fluorescent red pigment Phycocyanin Cyanobacteria and certain red algae Blue pigment Chlorophyll Algae Green pigment Carotenoid Algae Yellow, orange, or red pigment

[0103] It should be noted that other algae extracts can be used in the invention in combination with pigments: • Agar: A polysaccharide extracted from certain red algae such as Gelidium and Gracilaria. It can be used as a natural mordanting agent to fix dyes onto cellulosic and protein fibers. • Alginates: Polysaccharides found in brown algae such as Laminaria and Macrocystis. They can be used as thickeners and binders for natural dyes in textile applications. • Carrageenans: Sulfated polysaccharides extracted from red algae such as Chondrus crispus. They improve the fixation and durability of natural dyes on fibers. • Fucoidans: Sulfated polysaccharides found in brown algae. They possess properties similar to carrageenans for textile dyeing.

[0104] A liquid composition according to the invention may also include a water-soluble viscosity-modifying agent. This water-soluble viscosity-modifying agent is preferably polylactic acid, sugar, a polysaccharide derivative, alginate, potato dextrose, agar, glucose, malt, peptone, or yeast extract, taken alone or in mixtures.

[0105] According to one embodiment, the liquid composition has a dynamic viscosity ranging from 0.1 mPa·s at 20 °C for very dilute solutions to several thousand mPa·s at 20 °C, for example, 10,000 mPa·s at 20 °C for solutions concentrated in viscosity-enhancing agents (up to 20% or more), depending on the type of polymer used. For example, polyacrylamides and polyethylene glycols (PEGs) can have specific viscosities of up to 10 mPa·s or more in certain formulations, such as 500 mPa·s or 10,000 mPa·s at 20 °C.

[0106] A liquid composition according to the invention may also include a water-soluble adhesive agent. The adhesive agent may be in the form of an aqueous dispersion of rosin and terpene, both of plant origin. Other examples of water-soluble adhesive agents are given below. Advantageously, most of them are compatible with mycelium-based materials.

[0107] [Tables3]Adhesive Agent Description Pullulan Water-soluble, biodegradable polysaccharide produced by the fermentation of tapioca starch by the fungus Aureobasidium pullulans and compatible with mycelium-based materials. Xanthan Gum Water-soluble polysaccharide produced by the fermentation of the bacterium Xanthomonas campestris and compatible with mycelium-based materials. Can be used as a thickener and stabilizer. Agar Polysaccharide extracted from algae and compatible with mycelium-based materials. Can also be used as an adhesive agent. Polyvinylpyrrolidone (VP) Biocompatible water-soluble polymer that can be used as a binder and stabilizer. Its compatibility with mycelium-based materials has yet to be confirmed. Dextrin Polysaccharide derived from the hydrolysis of starch, used as an adhesive agent and can be used as a thickening agent. Compatible with mycelium-based materials, readily soluble in water, and biodegradable..

[0108] The process according to the invention comprises several steps, notably spraying at least one liquid composition and at least one filler according to the invention onto a support 1 to form a composite layer, and repeating this operation after drying of said composite layer in order to superimpose several of them, these superimposed composite layers constituting the textile 2. It should be noted that the liquid composition and / or the load may be identical or different for each composite layer.

[0109] The process according to the invention therefore comprises a preliminary supply step E01 of certain essential means of the invention. This supply step E01 comprises a supply substep E02 of at least one liquid composition as described above, a supply substep E03 of a filler as described above, and a supply substep E04 of a support 1.

[0110] This support 1 can have any shape and dimensions. By way of example, it can have at least one surface on which the textile 2 is produced by spraying. This surface is designated as the deposition surface 101. It can be the external or internal surface of a support 1.

[0111] The deposition surface 101 can be totally two-dimensional (see [Fig.3] and [Fig.4]), for example for the formation of a completely flat textile 2 or be slightly curved (see [Fig.5]), for example for the formation of a textile 2 with slightly curved edges.

[0112] At least part of the deposition surface 101 of the support 1 can be textured in relief or in intaglio, for example for the formation of a mainly flat textile 2 with a textured face (cf. [Fig.6]).

[0113] Indeed, although the support 1 only has a role as a temporary support 1, it is the shape of the deposition surface 101 onto which the liquid composition and the filler according to the invention are sprayed that substantially determines the shape adopted by the resulting textile 2.

[0114] The support 1 is preferably rigid, but it may be at least partially flexible or elastic. It is preferably made of steel, aluminum, thermoplastic polyurethane (TPU), thermoplastic polyamide elastomer (TPA), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polycarbonate (PC), polyamide (nylon), polystyrene (PS), polypropylene (PP) or acrylonitrile butadiene styrene (ABS).

[0115] The process according to the invention comprises a formation step E05 on the deposition surface 101 of a composite layer consisting of a liquid composition and a filler resulting from the supply step E01. This formation step E05 comprises the following substeps: • spraying E06 onto the deposition surface 101 of a liquid composition resulting from the supply step E01; and • spraying E07 onto the deposition surface 101 of a charge consisting of loose fibers and / or a powder resulting from the supply step E01; • the spraying substep E07 of a charge being simultaneous with or subsequent to the spraying substep E06 of the liquid composition;

[0116] These two spraying substeps E06, E07 can be carried out one after the other (see [Fig. 1]), or simultaneously (see [Fig. 2]). If these two substeps are carried out simultaneously, the liquid composition and the filler can be sprayed by a single spraying unit 4 in which they are in a composite mixture state, or be sprayed at the same time by a separate spraying unit 4 for each.

[0117] It will be noted that it is technically easier to spray a composite mixture with a single spraying unit 4 when the filler preferably comprises a powder and / or very short fibers, because it is difficult to obtain a satisfactory spray quality when spraying a composite mixture comprising both a liquid composition and a filler containing long fibers.

[0118] The two spraying sub-steps E06, E07 can be carried out at a pressure between 0.5 and 100 bar.

[0119] During the spraying step E06 of a liquid composition according to the invention on the deposition surface 101, a thin layer of liquid composition is deposited on the deposition surface 101.

[0120] During the spraying step E07 of a charge according to the invention on the deposition surface 101, a thin layer of charge is deposited on the deposition surface 101.

[0121] For these spraying steps E06, E07, by thin layer means a layer of liquid composition having an average thickness of between 0.1 and 2 mm, preferably between 0.2 mm and 1.5 mm, and more preferably between 0.2 and 0.8 mm.

[0122] If the liquid composition and the filler are sprayed simultaneously or one after the other, the liquid composition being sprayed before the filler, the liquid composition and the filler form a composite layer.

[0123] In a composite layer, the distribution of the filler within the liquid composition is not necessarily homogeneous and may vary throughout the thickness of said composite layer. The textile may therefore exhibit different physical and / or chemical characteristics in certain areas and / or throughout its thickness.

[0124] Masks can be used during these spraying steps E06, E07 to control the shape and dimensions of the deposition surface 101. The liquid composition and the charge deposited on these masks can be recovered and used in order to limit waste.

[0125] According to one embodiment, during the E05 formation step of a composite layer, the filler represents 30 to 60% by weight of said composite layer. bio-based filler of the filler represents 5 to 50%, preferably 10 to 40% and more preferably 15 to 30% by weight of said composite layer.

[0126] According to one embodiment, the quantity of filler and the quantity of liquid composition sprayed into a composite layer are such that the weight-to-filler ratio in said composite layer is in the range between 2:1 and 1:2.

[0127] During a substep E06 of spraying a liquid composition, this spraying E06 can be arranged so that said liquid composition completely covers a filler comprising so-called long fibers, i.e., at least 80% of these fibers have a length between 3 and 7 mm, preferably between 3 and 5 mm, and more preferably between 3 and 4 mm. This has the effect of strengthening the resulting textile.

[0128] During a substep E06 of spraying a liquid composition, this spraying E06 can also be arranged so that said liquid composition does not completely cover a filler comprising so-called short fibers, i.e., at least 80% of these fibers have a length between 0.1 and 2 mm, preferably between 0.5 and 1.5 mm, and more preferably between 0.5 and 1 mm. This has the effect of improving the feel of the resulting textile.

[0129] Once these two spraying steps E06 and E07 have been carried out, the process according to the invention includes a drying step E08 during which the composite layer solidifies. During this drying step E08, the water-based solvent evaporates and the water-soluble polymer polymerizes. Due to the thinness of the liquid composition layer, this drying can be quite rapid, for example, on the order of 1 to 10 minutes, preferably 2 to 8 minutes, and more preferably 3 to 5 minutes. By polymerizing, the water-soluble polymer binds the filler, which forms a textile 2.

[0130] A drying step E08 can be carried out at room temperature, or with heating, for example at a temperature between 50 and 90°C.

[0131] The drying steps are preferably carried out at atmospheric pressure.

[0132] According to one aspect of the invention, during the drying step E08, the support 1 can be subjected to vibrations, for example by means of a vibrator.

[0133] The spraying steps E06, E07, which allow obtaining a composite layer, and the drying step E08, which allows solidifying said composite layer, can be repeated at least once in order to increase the thickness of textile 2 obtained on the deposition surface 101 of the support 1. The process according to the invention thus comprises at least one repetition step E09, which includes a spraying step E06 of a liquid composition and a spraying step E07 of a filler, followed by at least one drying step E08 of the composite layer obtained.

[0134] The spraying and drying steps E08 are preferably repeated one to five times, more preferably twice, so as to superimpose three composite layers in total. This makes it possible, for example, to obtain a textile 2 having an average thickness of between 0.1 and 3 mm, preferably between 0.2 and 2 mm for the manufacture of clothing and preferably between 1 mm and 3 mm for the manufacture of footwear.

[0135] During a repetition step E09 for layering composite materials, the liquid composition and / or filler according to the invention used for each composite material layer may be identical to those of the preceding composite material layer or different. In the latter case, the composition of the resulting textile 2 is not homogeneous throughout its thickness. This makes it possible, in particular, to combine the characteristics of several polymers and / or fillers within the same textile 2, and thus said textile 2 may have internal and external faces 201 with a different feel and / or appearance.

[0136] Similarly, during a spraying step E06, E07, it is possible to simultaneously spray liquid compositions and / or fillers according to the invention which are locally different, in different places on the deposition surface 101, which makes it possible to obtain a textile 2 whose composition is not homogeneous over its entire surface.

[0137] Finally, during a spraying step E06, E07, it is possible to locally spray more liquid composition and / or more filler onto the deposition surface 101, or to repeat the spraying steps E06, E07 in order to spray liquid composition and / or filler locally only onto a specific part of the deposition surface 101. This makes it possible in particular to vary locally the thickness of the textile 2 obtained.

[0138] After drying E08 of the different composite layers, a step E13 consists of removing the textile 2 obtained from the deposition surface 101 of the support 1.

[0139] Optionally, the process according to the invention may also include a formation step E10 of a finishing layer provided before the removal step E13 of the textile 2. This formation step E10 of a finishing layer includes a substep of spraying El 1 of a liquid composition according to the invention on the last composite layer followed by a substep of drying said liquid composition E12.

[0140] This drying substep E12 for the polymerization of the water-soluble polymer by evaporation of water has the same characteristics as the drying step E08 previously described for a composite layer resulting from the formation step E05 of a composite layer.

[0141] This E10 formation step of a topcoat makes it possible, for example, to ensure that the last filler to have been sprayed adheres well to the polymer, or is even completely embedded in it.

[0142] This E10 formation step of a topcoat can also be carried out by adding glass beads, in particular of micron dimensions, to the liquid solution in addition to the usual fillers to enhance abrasion resistance, on all or part of the external surface.

[0143] The advantages provided by adding glass beads to the liquid solution are given in the table below.

[0144] [Tables4] Advantages Details Improved Abrasion Resistance Glass beads increase the surface's abrasion resistance, extending the product's lifespan. Lightweight Glass beads are lightweight, preventing the material from becoming heavy while improving its mechanical properties. Chemical Resistance Excellent resistance to many chemicals and solvents, preserving the coating's integrity. Aesthetics Glass beads are transparent or slightly opaque, not altering the bag's appearance. Anti-slip Properties They can improve surface grip and safety, reducing the risk of slipping. Environmentally Friendly The glass bead process is environmentally friendly and recyclable. Cost-Effective Glass beads are relatively inexpensive and can be recycled multiple times (up to 30 times).

[0145] The technical characteristics of the glass beads are given in the table below.

[0146] [Tables5] Technical characteristics Details Bead size Generally between 0.05 mm and 1 mm (in accordance with the possible size of the spray nozzles), depending on the desired application (smaller for a smooth finish, larger for a rough texture). Spherical shape, which allows for uniform distribution within the material and reduces localized stress points. Density: Approximately 2.5 g / cm³, which is relatively light compared to other materials used for reinforcement. Wear resistance: Glass beads are wear-resistant and maintain their effectiveness over the long term. Compatibility: Compatible with various types of resins and coatings, including paints and epoxy resins.

[0147] The size of the beads can be adjusted according to the specific needs of the final product: • Microbeads (0.05 mm - 0.5 mm): For a softer finish and better integration into the material. • Medium beads (0.5 mm - 1 mm): Ideal for concealing imperfections while providing texture. • Large beads (1 mm - 2 mm): Used for applications requiring a rougher texture.

[0148] With a spray pressure of up to 100 bar, it is essential that the beads are sufficiently strong so as not to break during the application process.

[0149] Optionally, the process according to the invention may also include a stabilization step E14 of one or more layers of the textile material 2, for example carried out after a drying step E08, E12.

[0150] This stabilization step E14 comprises at least one of the following substeps: • a heat treatment; • plasma therapy; and / or • cross-linking by UV irradiation.

[0151] This E14 stabilization step of the textile material can, in particular, render inert the organic components of the filler that are liable to mineralize or degrade over time. This step can also be used to treat a surface of the textile in order to functionalize it or modify its physicochemical properties, for example to waterproof it, to activate it, to clean it, to improve its adhesion, to control its final shrinkage or to impregnate it with an odorant, coloring, antifungal, antimicrobial or other substance.

[0152] A heat treatment consists, for example, of subjecting the textile to a temperature between 50 and 90 °C for a period of between 5 and 30 minutes, depending on the nature and thickness of the layer being treated. This allows for control of the final shrinkage of the material in order to stabilize its dimensions. Indeed, a layer of the Textile 2 is likely to absorb moisture after its manufacture, and this heat treatment is therefore intended to carry out a short drying of textile 2 in order to ensure that it is free of moisture before its use or packaging.

[0153] Plasma treatment can, for example, be carried out using an atmospheric pressure plasma or a low-pressure plasma. An atmospheric pressure plasma operates at pressures close to atmospheric pressure, allowing for rapid and efficient treatment. It is preferentially used for continuous applications, while a low-pressure plasma is generally operated below 0.1 to 1 Torr, offering precise control over the treatment conditions. It requires longer exposure times but can use higher power levels.

[0154] The power used for plasma treatment varies depending on the type of plasma and the treatment objectives. It can range from a few watts to several kilowatts depending on the equipment and application, and is adjusted according to the type of material and the desired properties. For example, it ranges from 10 to 200 watts for atmospheric pressure plasma and from 100 to 1000 watts for low-pressure plasma. High power can improve the cleaning and functionalization of the treated textile surface, but it must be balanced to avoid damaging the material. Indeed, excessive power can lead to thermal degradation of the load.

[0155] Just as with the applied power, the duration of exposure and the type of gas used (nitrogen, argon, etc.) for plasma treatment are crucial to optimizing results.

[0156] The exposure time is for example between 10 seconds and 10 minutes, while the gas used is chosen according to the desired effect and its chemical reactivity with the textile.

[0157] The gases that can be used are as follows: • Oxygen (O2): used to improve the hydrophilicity of the filler fibers (e.g. polyester fibers). • Argon (Ar): used to increase the hardness of the fibers in the filler. • a fluorinated gas (e.g. CF4): makes surfaces hydrophobic, similar to PTFE. • a mixture of ethylene and propylene: used to obtain an oleophilic textile. • Nitrogen (N2): used for specific treatments and to create an inert atmosphere.

[0158] Plasma treatment can be combined with the incorporation of a liquid, powder, microparticles, or nanoparticles. For example, hydrophobic treatment of a textile surface can be achieved by combining plasma treatment with The addition of hydrophobic agents creates a waterproof textile. Similarly, plasma treatment can be combined with the incorporation of nanoparticles or antimicrobial agents to enhance the antibacterial and antifungal properties of the textile.

[0159] Plasma treatment can modify the texture of a textile surface, for example to prepare said surface before printing or bonding. In this case, plasma treatment can be used to increase the specific surface area available for adhesion, thereby improving the performance of the applied coatings.

[0160] Plasma treatment is advantageous because it reduces the use of water and chemicals compared to traditional methods. Indeed, plasma treatment requires little or no water and reduces the use of organic solvents, thus minimizing the environmental impact of the process.

[0161] UV irradiation crosslinking consists of irradiating a layer with ultraviolet rays. This crosslinking can, for example, be achieved by free radicals or by cationic means. In both cases, UV protection is necessary to protect the skin and eyes.

[0162] Free radical crosslinking is based on the decomposition of a photoinitiator, releasing free radicals. It allows for a very rapid polymerization rate, on the order of a few seconds, but is sensitive to inhibition by oxygen. It generally promotes good adhesion of the treated layer, but its effectiveness depends on the composition of the photoinitiator and can be limited by the thickness of the layer. Thus, longer exposure times are necessary for thick materials. Free radical crosslinking uses a UV radiation power preferably between 200 and 400 mW / cm², for a duration preferably between 1 and 10 seconds, depending on the formulation and the thickness of the treated layer.

[0163] Cationic crosslinking is based on the formation of positive ions by UV irradiation. It allows for a polymerization rate that is slightly slower than free radical crosslinking, on the order of a few minutes, but is less sensitive to inhibition by oxygen. It generally promotes good chemical and thermal resistance of the treated layer, and its effectiveness is less affected by thickness than free radical crosslinking. Cationic crosslinking uses a UV radiation power preferably between 100 and 300 mW / cm², for a duration preferably between 10 and 60 seconds, depending on the formulation and thickness of the treated layer.

[0164] In the process according to the invention, crosslinking by free radicals is preferred because it is faster and suitable for the small thicknesses of the layers obtained during each spraying step.

[0165] Optionally, the method according to the invention may also include a step of applying pressure to the textile material 2, for example before the stabilization step E14, to increase the mechanical properties of the composite layers and prevent their delamination. This pressure may, for example, be applied to the textile material 2 by means of a counter-mold substantially conforming to the shape of the support 1, while respecting the surface design of the part.

[0166] The invention also relates to the textile 2 obtained by the process, as well as any textile article made from this textile 2. The textile 2 obtained is particularly distinguished in that it comprises an alternation of layers of water-soluble polymer-based material and filler.

[0167] Depending on the nature of the liquid compositions used, these different layers of material may be more or less bound to each other. They may also form a substantially homogeneous whole such that it is not possible to distinguish them.

[0168] The implementation of the process of the invention requires in particular the use of at least one spraying system 3, comprising one or more spraying units 4. Any suitable spraying system 3 can be used within the framework of the present invention.

[0169] For spraying a liquid composition and / or a charge comprising powder and / or loose fibers according to the invention onto the support 1, a suitable spraying unit 4 may include, but is not limited to, an air-based, airless or electrostatic-based sprayer, and be for example in the form of a spray gun.

[0170] Besides the spraying unit 4, the spraying system 3 may also include one or more fluid displacement devices 5, tanks 6, flow and / or pressure regulators 7, supply pipes 8 and other components known in the art for spraying liquid products or bulk fibers.

[0171] A fluid displacement device 5 allows a liquid, powder, fibers, or composite material to be conveyed from a reservoir 6 to a spraying unit 4. In the case of a liquid or composite material, this is preferably a pump. In the case of a powder or fibers, this is preferably a compressor.

[0172] Each spray unit 4 is preferably variable flow to allow the creation of thicker bands or layers of product in the desired locations.

[0173] A spraying system 3 comprising several spraying units 4 makes it possible in particular to spray the desired quantities of product more quickly and / or to spray different products simultaneously.

[0174] The support 1 can be fixed or mobile.

[0175] For example, it may be a conveyor belt on which a textile 2 is continuously manufactured, with different spraying units 4 distributed along said conveyor belt, and where the speed of the conveyor belt and the spacing between the spraying units 4 are chosen so as to allow each sprayed composite layer to dry before the spraying of the next composite layer.

[0176] The spraying system 3 may also include one or more positioning devices 9, for example in the form of a fixed, mobile and / or articulated foot, a robotic arm, a cobot, or any other suitable known device, allowing a spraying unit 4 and / or the support 1 to be moved and oriented in space in a controlled and precise manner. If masks are used, each mask may also be associated with a positioning device 9.

[0177] The spraying system 3 may also include a controller 10 that adjusts, in particular, the position relationship between each spraying unit 4 and the support 1, and that adjusts in real time the flow rate of each spraying unit 4, notably in order to precisely control the position, arrangement, and thickness of the sprayed layers. An increase in thickness can be achieved by repeating the spraying on specific areas, by slowing down the movement on specific areas, or by increasing the flow rate of the sprayed product on specific areas.

[0178] The controller 10 can thus control each spraying unit 4, each fluid displacement device 5, each flow and / or pressure regulator 7, each positioning device 9 by means of control lines 12. It can also be connected to a probe provided in each of the tanks 6 in order to measure the quantity of material in each tank 6, and can in particular be provided to warn the operator when this quantity becomes low.

[0179] The controller 10 can also control the mask positioning device 9 if necessary.

[0180] In general, the controller 10 can be provided so as to automate or assist all or part of the process of producing a textile 2 by spraying.

[0181] The controller 10 can be a computer, a terminal, a control cabinet, a workstation or any other electronic device, preferably programmable, capable of controlling each device of the spraying system 3, for example individually and in a particular sequence.

[0182] Each spraying unit 4 may include a single spray nozzle 11 (see [Fig. 3] and [Fig. 5]) or several (see [Fig. 4] and [Fig. 6]), the latter being oriented in the same direction or in different directions, for example converging towards a point located at an ideal spraying distance. Each spray nozzle 11 may spray the same material or different materials.

[0183] Each spray nozzle 11 can be provided to spray a liquid composition, fibers, a powder or a composite mixture according to the invention, each spray nozzle 11 being in particular connected to a suitable product reservoir 6 via a supply pipe 8.

[0184] In [Fig. 3], given by way of example, two spraying units 4, each comprising a single spray nozzle 11, are provided on either side of a support 1 shaped as a flat plate for the production of a flat textile 2. The support 1 is mounted on a positioning device 9, articulated and rotatable about a vertical axis, so that the two spraying units 4, themselves mounted on an articulated positioning device 9, can spray their respective products over the entire deposition surface 101. In this example, having two spraying units 4 makes it possible, for example, to spray two different products, either simultaneously or one after the other, these two products each being a liquid composition, a filler, or a composite mixture of the two.

[0185] In [Fig. 4], also given by way of example, a single spraying unit 4 comprising two spray nozzles 11 is provided near a support 1 shaped as a flat plate for the production of a flat textile 2, each spray nozzle 11 being connected to its own reservoir 6. The support 1 and the spraying unit 4 are each mounted on an articulated positioning device 9. In this example, having two spray nozzles 11 makes it possible, for instance, to spray two different products with a single spraying unit 4, either simultaneously or one after the other, these two products each being a liquid composition, a filler, or a composite mixture of both.

[0186] Finally, in the example illustrated in [Fig. 5], a single spraying unit 4 comprising a single spray nozzle 11 is provided near a support 1 shaped into a predominantly flat surface with curved edges defining a footprint for the production of a textile 2 in the shape of a shoe sole. The support 1 and the spraying unit 4 are each mounted on an articulated positioning device 9. This assembly, comprising only a single spray nozzle 11, is preferably intended for spraying a composite mixture comprising a liquid composition and a filler.

[0187] The example illustrated on [Fig.6] will be described later in an example of implementation of the method of the invention.

[0188] It should be noted that the examples illustrated in [Fig. 3] to [Fig. 6] are very schematic and do not necessarily represent reality. In the examples illustrated in [Fig. 3] to [Fig. 6], each spray nozzle 11 is connected to a single reservoir 6 of its own. It is also possible to provide several reservoirs 6, each containing, for example, a different liquid composition and / or charge, and which can can be connected as needed to the same spray nozzle 11 by a quick-connect system. Each spray nozzle 11 can also be connected to several tanks 6, for example via a multi-port valve 13 as illustrated in [Fig. 6].

[0189] In order to control ambient air quality, temperature, and humidity, the means of the invention, in particular the spraying system 3 and the support(s) 1, can be housed in an enclosure 14. Due to the possible presence of robot(s), access to this enclosure 14 can be secured. EXAMPLES OF IMPLEMENTATION

[0190] Examples of liquid compositions

[0191] Six examples of liquid compositions according to the invention are given in the table below. The percentage of each component is given by weight relative to the total mass of the liquid composition.

[0192] [Tableauxô] % by weight LIQ1 LIQ2 LIQ3 LIQ4 LIQ5 LIQ6 Binder: bio-based polylactic acid 13% 45% 40% Binder: natural latex of plant origin 30% 40% 45% 40% Additive: magnesium sulfate 1% 5% 1% 24% 2% 1% Bridging agent 10% 10% 24% Pigment: azorubine dye El32 2% 5% 2% 1% 3% 5% Viscosity agent: potato dextrose 25% Adhesive agent: α-1,4-α-α,6-glucan (pullulane) 22% Aqueous solvent: water 44% 40% 30% 30% 30% 30% Total 100% 100% 100% 100% 100% 100%

[0193] Examples of loads

[0194] Six examples of loads according to the invention are given in the table below. The percentage of each component is given by weight relative to the total mass of the load.

[0195] [Tables?] % by weight CH1 CH2 CH3 CH4 CH5 CH6 Fur fibers (bio-based) 30% 55% 35% 40% 15% Limestone powder (bio-based) 40% 60% 30% 30% 35% Synthetic polyurethane fibers 30% 40% 45% 35% 30% 50% Total 100% 100% 100% 100% 100% 100%

[0196] Examples of composite layers

[0197] Six generic examples of composition for a composite layer according to the invention are given in the table below. The percentage of each component is given by weight relative to the total mass of the composite layer before drying.

[0198] [Tables8] % by weight CCG1 CCG2 CCG3 CCG4 CCG5 CCG6 Non-bio-based binder 15% 30% 10% 40% 10% Bio-based binder 15% 10% 32% 33% 5% 37% Non-bio-based filler 15% 18% 10% 13% 18% 24% Bio-based filler 15% 12% 20% 21% 12% 6% Coalescing agent 1% 0.1% 5% 3% 0.1% 2% Water 39% 29.9% 23% 30% 29.9% 21% Total 100% 100% 100% 100% 100% 100%

[0199] Three specific examples of compositions for a composite layer according to the invention are given in the table below. The percentage of each component is given by weight relative to the total mass of the composite layer before it dries.

[0200] [Tables9] % by weight CCI CC2 CC3 Bio-based binder: Vytex® 50% 8% Bio-based binder: Impranil® DL 1545 8% 40% 8% Bio-based binder: Impranil® DLP 40% Non-bio-based filler: synthetic polyurethane fibers 5% Bio-based filler: calcium carbonate powder 5% 6% 8% Bio-based filler: Agaricus bisporus mycelium powder 5% 7% Coalescing agent: ethylene glycol monoethyl ether acetate 7% 2% 2% Water 30% 34% 35% Total 100% 100% 100%

[0201] In this table, example CCI relates to a first layer which is a rubber-type layer intended to be an outer layer of textile 2, example CC2 relates to a second layer which is an intermediate layer and example CC3 relates to a third layer which is intended to be an inner layer of textile 2 and which is compatible with an intermediate sole on which it is intended to be glued, usually referred to by the English term midsole, made of thermoplastic polyurethane (TPU) or thermoplastic polyamide elastomer (TPA).

[0202] These three layers form a textile which can for example be used for the manufacture of a shoe sole, more particularly for the outsole of a shoe, that is to say the part of the shoe which is in contact with the ground, usually referred to by the English term outsole.

[0203] The parameters for the formation of these three layers are given in the table below.

[0204] [TableauxlO] CCI parameter CC2 CC3 Spray duration 2x1 minute 2x2+1 minutes 2x2 minutes Spray pressure 70 bar 80 bar 50 bar Thickness 0.5 mm 0.5 mm 0.5 mm Drying temperature 90 °C 90 °C 90 °C Drying time 2 to 5 minutes 2 to 5 minutes 2 to 5 minutes

[0205] Example of implementation of the process

[0206] An example of implementing the method of the invention according to the invention is given below for the manufacture of the outsole of a shoe.

[0207] A complete cleaning of the equipment used is carried out beforehand, in particular the spraying systems 3. The working environment must be clean to guarantee the quality of spraying (no fibers, clean surfaces, controlled and filtered air quality to eliminate foreign particles).

[0208] Temperature and humidity are controlled at 20°C and 80% respectively.

[0209] The equipment used is housed in an enclosure. It consists of the following equipment. Its number is also indicated in parentheses. • 14-inch enclosure measuring 4.10 x 5.40 x 2.40 m including lighting, security door and window, camera, security sensors and door closing contact (xl). • Enclosure air filtration devices (x4). Air conditioning and humidity control device for the enclosure (xl). Spraying units 4 (x3) Spray nozzles 11 (x3) equipping the spray unit 4, comprising two nozzles 1 la,l 1b adapted for spraying a composite mixture and one nozzle 1 le adapted for spraying loose fibers. Tanks 6 (x3), including two tanks 6a,6b for liquid composite mixture and one tank 6c for loose fibers. Multi-way valve 13, in the form of a mixing solenoid valve, suitable for connecting each spray nozzle 1 la,l lb,l le to one of the tanks 6a,6b,6c. Fluid displacement device 5 (x3) each associated with one of the reservoirs 6 to supply the multi-way valve 13 with fluid, two fluid displacement devices 5a, 5b being pumps connected to the reservoirs 6a,6b for composite mixture, while the last fluid displacement device 5c is a compressor connected to the reservoir 6c for fibers. Flow and / or pressure regulators 7 (x3) in the form of solenoid valves 7a,7b,7c each associated with one of the fluid supply lines of the multi-way valve 13 from the tanks 6a,6b,6c. 8 polymer supply hoses (x3) each connecting the multi-way valve 13 to a spray nozzle. Polymer supply pipes 8 (x3) each connecting a tank 6, to the multi-way valve 13, as well as to the flow and / or pressure regulator 7 and the associated fluid displacement device 5. Positioning device 9 (xl) for the spraying unit 4 in the form of a cobot 9a. Support 1 (xl) in the form of three pairs of right and left foot prints, each in the shape of a predominantly flat shoe sole with a textured surface. Positioning device 9 (xl) for support 1 in the form of an articulated arm 9b. Drying system (xl). Plasma processing unit (xl). Controller 10 (xl), in the form of a control cabinet for the spray units 4, the multi-way valve 13, the solenoid valves 7a, 7b, 7c, the pumps 5a, 5b, the compressor 5c, the cobot 9a and the articulated arm 9b with touch screen, synchronizing in particular the articulated arm 9b and the cobot 9a. Electrical cabinet (xl) and electrical cables to supply electricity to the various devices.

[0210] For reasons of clarity of the figures, only part of this equipment is illustrated schematically and in a simplified manner on [Fig.6].

[0211] As a reminder, a cobot, or collaborative robot, is a robot designed for direct human-robot interaction within a space where humans and robots are in close proximity.

[0212] To prepare a shoe outsole, three composite layers CCI, CC2, and CC3 are required, as well as at least one mold-shaped support 1 to receive the prepared solutions. The composition of these three composite layers CCI, CC2, and CC3 is given in Table 9 above.

[0213] In this example, six outsoles are manufactured simultaneously, namely three outsoles for right feet and three outsoles for left feet.

[0214] The mold-shaped supports 1 are made of TPU using 3D printing, which offers versatility and responsiveness for testing numerous design options. Once a mold is made, it is coated with silicone to facilitate demolding of the textile 2 after spraying.

[0215] In this example, we assumed that five liters of composite material (liquid composition + filler) for spraying would be required. To facilitate the start-up of the installation and to achieve the required pressure and homogeneous spraying conditions, 10 liters of composite material were produced. Indeed, to ensure a constant supply pressure to the spraying units, it is important to have enough solution to prevent the pumps from cavitating.

[0216] The composition by weight (Kg) for each layer is given in the table below

[0217] [Tableauxll] Weight in kg CCI CC2 CC3 Bio-based binder: Vytex® 5.00 0.80 Bio-based binder: Impranil® DL 1545 0.80 4.00 0.80 Bio-based binder: Impranil® DLP 4.00 Non-bio-based filler: synthetic polyurethane fibers 0.50 Bio-based filler: calcium carbonate powder 0.50 0.60 0.80 Bio-based filler: Agaricus bisporus mycelium powder 0.50 0.70 Coalescing agent: ethylene glycol monoethyl ether acetate 0.70 0.20 0.20 Water 3.00 3.40 3.50 Total 10.00 10.00 10.00

[0218] The preparation of the mixtures for the first CCI composite layer, which is the layer that will be in contact with the ground, is carried out by the following steps: • draining and cleaning of the three tanks 6a, 6b, 6c, of the pumps 5a, 5b, of the compressor 5c and of the spraying unit 4, in particular of the three spray nozzles 1 la, l lb, l le, even though only one will be used here, namely the first spray nozzle lia suitable for spraying a composite mixture; • weighing of the two binders, i.e. 5 kg of Vytex® and 0.8 kg of Impranil® DL 1545 respectively; • weighing of the water, divided into two equal volumes, i.e. 1.5 kg each; • weighing of the bio-based feed (calcium carbonate powder) divided into two equal volumes, i.e. 0.25 kg each; • weighing of the coalescing agent (ethylene glycol monoethyl ether acetate) divided into two equal volumes, i.e. 0.35 kg each; • mixture of 5 kg of Vytex® with 1.5 kg of water, 0.35 kg of coalescing agent, and 0.25 kg of bio-based filler, i.e.: 5 + 1.5 + 0.35 + 0.25 = 7.1 kg of a first mixture designated as Ml; • mixture of 0.8 kg of Impranil® DL 1545 with 1.5 kg of water, 0.35 kg of coalescing agent and 0.25 kg of bio-based filler, i.e.: 0.8 + 1.5 + 0.35 + 0.25 = 2.9 kg of a second mixture designated as M2; • filling the first tank 6a with 7.1 kg of the Ml mixture; and • filling the second tank 6b with the 2.9 kg of M2 mixture.

[0219] The contents of the first and second reservoirs 6a,6b are summarized in the table below:

[0220] [Tables 12] Weight in kg CCI Tank 6a Tank 6b Bio-based binder: Vytex® 5.00 5.00 Bio-based binder: Impranil® DL 1545 0.80 0.80 Bio-based filler: calcium carbonate powder 0.50 0.250 0.250 Coalescing agent: ethylene glycol monoethyl ether acetate 0.70 0.350 0.350 Water 3.00 1.50 1.50 Total 10 7.10 2.90

[0221] A trial adjustment of the spraying system is then performed. For this purpose, the two pumps 5a, 5b connected to the first and second tanks 6a, 6b are started, and the spraying unit is first supplied with compressed air at 4 bar to ensure that the first and second spray nozzles 1a, 1b are not obstructed. The three pairs of footprints are also installed, spaced 20 cm apart so that, with the adjustments to the spraying unit, there are no homogeneity impacts when the cobot moves the spraying unit from one footprint to another.

[0222] After this, the spray unit's work program is defined for the first pass. With the indentations positioned, the cobot's collaborative work function is used. The spray unit is positioned on the cobot's arm. The operator's experience allows them to define a trajectory suitable for spraying the composite mixture into the six indentations. To do this, the operator manually moves the spray unit in the space between each indentation. When this step is completed, the trajectory is recorded. One step involves verifying this trajectory by running the cobot without a load until a "OK" signal is obtained. This OK is confirmed by adding compressed air to the spray nozzles to ensure the correct distance of each nozzle from the deposition surface.Flour, previously deposited using a fine mesh sieve (120 mesh nylon filter), is applied to the molds to observe, as the compressed air spray unit passes over them, whether the flour is properly cleaned, mold by mold. If this is not the case, the trajectory is optimized directly in the program.

[0223] To continue, the spray unit's work program is defined for a second pass at 90° to the first pass, in order to achieve an isotropic effect. The indentations remain in the same position as before. The spray unit is positioned on the cobot arm, oriented at 90° to its previous orientation. The operator's experience allows them to define a trajectory suitable for spraying the composite mixture. To do this, the operator manually moves the spray unit in the space between one indentation and the other. When this step is completed, the trajectory is recorded. One step consists of verifying this trajectory by running the cobot without a load until an OK signal is obtained. This OK is confirmed by adding compressed air to the spray nozzles to ensure The correct distance between each nozzle and the application surface is determined. Flour, previously applied using a fine-mesh sieve (120-mesh nylon filter), is placed on the indentations to observe, as the compressed air spray unit passes over them, whether the flour is properly cleaned, indentation by indentation. If this is not the case, the trajectory is optimized directly within the program.

[0224] The following table summarizes the parameters of the experiments carried out and the results obtained:

[0225] [Tables 13] Spray Power (W) Nozzle Diameter (mm) Spray Flow Rate (ml / min) 410-600 0.5 100-150 600-800 0.8 200-300 800-1200 1.0 300-500 Spray Distance (cm) Spray Time (min) Number of Passes 20-30 10-15 3-4 15-20 5-10 2-3 10-15 3-5 1-2

[0226] Spraying power: pump power, which influences flow rate and pressure, affecting spray quality.

[0227] Spray nozzle diameter: a smaller diameter allows for finer spraying, while a larger diameter increases flow rate and coverage.

[0228] Spray flow rate: measured in ml / min, it indicates the quantity of composite mixture sprayed per minute.

[0229] Spraying distance: distance between the spray nozzle and the deposition surface, generally between 10 and 30 cm depending on the type of application.

[0230] Spraying time: time required to cover the deposition surface 101, depending on the flow rate and the number of passes.

[0231] Number of passes: number of layers required to obtain uniform coverage, often recommended between 1 and 3 depending on the type of composite mixture sprayed and the condition of the deposition surface.

[0232] In this example, the composite mixture is quite viscous and the parameters chosen for the two passes are as follows: • Spraying power: 1200 Watts • Nozzle diameter: 1 mm • Spray rate: 500 ml / min • Spraying distance: 15 cm • Spraying time: 1 minute per pass • Number of passes: 2

[0233] At that point, we therefore have two prepared composite mixtures M1 and M2 contained respectively in the first tank 6a and in the second tank 6b, of positioned footprints, of two validated trajectories in empty and of validated spraying parameters.

[0234] The pumps 5a,5b and the solenoid valves 7a,7b associated with them are suitable for supplying the first nozzle lia with the two mixtures M1,M2, the first nozzle lia being adapted for spraying the CCI layer, that is to say that the diameter of the first nozzle 1 la as well as the pressure are chosen as specified above.

[0235] With the prepared composite mixtures M1 and M2 mixed in the multiport valve 13, spray tests are then carried out via the first nozzle lia on an adjacent surface to prime the pumps 5a, 5b and ensure that the flow rate is constant. The solenoid valves 7a, 7b and the pumps 5a, 5b are controlled to guarantee a homogeneous mixture. It is also verified that the composite mixtures M1 and M2 are available for spraying.

[0236] The spraying program is now launched with two spray passes using the M1+M2 mixtures through the first nozzle 1 la to cover the three pairs of impressions, in two opposite directions. For each spray of the CCI layer, the spraying time is 1 minute per pass, with a spraying pressure of 70 bar.

[0237] This spray program is followed by drying the CCI layer at 90 °C with circulating hot air for 2 minutes.

[0238] This step is completed by a stabilization treatment of the first CCI composite layer once it is dry, using an atmospheric plasma at 200 Watts for 1 minute. The gas used is fluorinated gas CF4 to make the external surface more hydrophobic.

[0239] The first composite CCI layer of the textile material 2 is then available, the face of which in contact with the support 1 has a textured surface. The raised and recessed areas of said textured surface are those usually used for the face of a sole intended to be in contact with the ground,

[0240] The second composite layer CC2 is then deposited. To do this, the material is prepared as indicated below.

[0241] The preparation of the mixtures for the second composite layer CC2, which is the intermediate layer, is carried out by the following steps: • draining and cleaning of the first and second tanks 6a,6b, of the two pumps 5a,5b and of the spraying unit 4, in particular of the two nozzles 11a, 11b adapted for spraying a composite mixture, even if only one will be used here, as well as the nozzle 11 adapted for spraying loose fibers which has already been cleaned; • weighing of the two binders, i.e. 0.8 kg of Vytex® and 4 kg of Impranil® DL 1545 respectively; • weighing of the water, divided into two equal volumes, i.e. 1.7 kg each; • Weighing of the bio-based feedstock (0.6 kg of calcium carbonate powder) and 0.5 kg of Agaricus bisporus mycelium powder) divided into two equal volumes, i.e. 0.55 kg each; • weighing of the non-bio-based charge (0.5 kg of synthetic polyurethane fibers); • weighing of the coalescing agent (ethylene glycol monoethyl ether acetate) divided into two equal volumes, i.e. 0.1 kg each; • mixture of 0.8 kg of Vytex® with 1.7 kg of water, 0.1 kg of coalescing agent and 0.55 kg of bio-based filler, i.e.: 0.8 + 1.7 + 0.1 + 0.55 = 3.15 kg of a first mixture designated as M3; • mixture of 4 kg of Impranil® DL 1545 with 1.7 kg of water, 0.1 kg of coalescing agent, and 0.55 kg of bio-based filler, i.e.: 4 + 1.7 + 0.1 + 0.55 = 6.35 kg of a second mixture designated as M4; • filling the first tank 6a with 3.15 kg of mixture M3; • filling the second tank 6b with 6.6 kg of M4 mixture; and • filling the third 6c tank with 0.5 kg of synthetic polyurethane fibers.

[0242] The contents of the three tanks 6a, 6b, 6c are summarized in the table below:

[0243] [Tables 14] Weight in kg CC2 Tank 6a Tank 6b Tank 6c Bio-based binder: Vytex® 0.80 0.80 Bio-based binder: Impranil® DL 1545 4.00 4.00 Non-bio-based filler: synthetic polyurethane fibers 0.50 0.50 Bio-based filler: calcium carbonate powder 0.60 0.30 0.30 Bio-based filler: Agaricus bisporus mycelium powder 0.50 0.25 0.25 Coalescing agent: ethylene glycol monoethyl ether acetate 0.20 0.10 0.10 Water 3.40 1.70 1.70 Total 10.00 3.15 6.35 0.5 0

[0244] A trial run of the spraying system is then performed with the second nozzle 11b, adapted for spraying the second composite mixture M3+M4, and with the third nozzle 11, whose larger diameter is adapted for spraying loose fibers. For this purpose, the pumps 5a, 5b and the compressor 5c, connected to the three reservoirs 6a, 6b, 6c, are started, and the spraying unit 4 is initially supplied with compressed air at 4 bar to ensure that the second nozzle 11b and the third nozzle 11c are not obstructed. The three pairs of indentations retain the position they had for spraying the first CCI layer.

[0245] For the first pass, the same working program of the spraying unit is used as for the first CCI coat.

[0246] Similarly, for the second 90° pass, the same spray unit work program is used as for the first CCI coat.

[0247] The parameters chosen for the two passes are as follows: • Spraying power: 1000 Watts • Nozzle diameter: 2 mm • Spray rate: 400 ml / min • Spraying distance: 15 cm • Spraying time: 2 minutes per pass • Number of passes: 2

[0248] At that time, we therefore have two prepared composite mixtures M3 and M4, a non-bio-based filler in the form of synthetic polyurethane fibers, positioned impressions, two validated trajectories in a vacuum and validated spraying parameters.

[0249] With the prepared composite mixtures M3 and M4 mixed in the multiport valve, spray tests are then carried out via the second nozzle 11b on an adjacent surface to prime the pumps 5a, 5b and ensure that the flow rate is constant. The solenoid valves 7a, 7b and the pumps 5a, 5b are controlled to guarantee a homogeneous mixture. Spray tests are also carried out with the synthetic polyurethane fibers via the third nozzle 11 on an adjacent surface to prime the compressor 5c and ensure that the flow rate is constant. The following is also verified: that M3 and M4 composite blends and synthetic polyurethane fibers are available for spraying.

[0250] The CC2 layer spraying program is now launched. It begins with two spray passes using the M3+M4 mixture through the second nozzle 11b to cover the three pairs of impressions, in two opposite directions, to create the first layer of the CC2 layer. Next, a spray pass using the synthetic polyurethane fibers through the third nozzle 11b is applied to cover the first layer of the CC2 layer, creating the second layer. Finally, two more spray passes using the M3+M4 mixture through the second nozzle 11b are applied to cover the second layer of the CC2 layer, creating the final layer.

[0251] For each spraying, the spraying time is 1 minute per pass for the first layer, then 1 minute for the second layer and finally 1 minute per pass for the last layer, i.e. a total of 2xl + l + 2xl = 5 minutes, with a spraying pressure of 80 bars.

[0252] This spray program is followed by drying the CC2 layer at 90°C with circulating hot air for 2 minutes.

[0253] This step is completed by a stabilization treatment using an atmospheric plasma at 200 Watts for 1 minute. The gas used is oxygen O2 to improve the hydrophilicity of the filler fibers and ensure better adhesion to the polymer matrix.

[0254] The first and second composite layers CCI and CC2 of the textile material 2 are then available, and the third and final composite layer CC3 is deposited. To do this, the material is prepared as indicated below.

[0255] The preparation of the mixtures for the third and final CC3 composite layer is carried out by the following steps: • draining and cleaning of all tanks 6a, 6b, 6c, pumps 5a, 5b, compressor 5c and spray unit 4, including the three spray nozzles 1 la, l lb, l le, even though only one will be used here, namely the first spray nozzle lia suitable for spraying a composite mixture; • weighing of the two binders, i.e. 4 kg of Impranil® DLP and 0.8 kg of Impranil® DL 1545 respectively; • weighing of the water, divided into two equal volumes, i.e. 1.75 kg each; • Weighing of the bio-based feedstock (0.8 kg of calcium carbonate powder) and 0.7 kg of Agaricus bisporus mycelium powder) divided into two equal volumes, i.e. 0.75 kg each; • weighing of the coalescing agent (ethylene glycol monoethyl ether acetate) divided into two equal volumes, i.e. 0.1 kg each; • mixture of 4 kg of Impranil® DLP with 1.75 kg of water, 0.1 kg of coalescing agent and 0.75 kg of bio-based filler, i.e.: 4+1.75 + 0.1 + 0.75 = 6.6 kg of a first mixture designated as M5; • mixture of 0.8 kg of Impranil® DL 1545 with 1.75 kg of water, 0.1 kg of coalescing agent and 0.75 kg of bio-based filler, i.e.: 0.8 + 1.75 + 0.1 + 0.75 = 3.4 kg of a second mixture designated as M6; • filling the first tank 6a with 6.6 kg of mixture M5; and • filling the second tank 6b with the 3.4 kg of M6 mixture.

[0256] The contents of the first and second tanks 6a,6b are summarized in the table below:

[0257] [Tables 15] Weight in kg CC3 Tank 6a Tank 6b Bio-based binder: Impranil® DL 1545 0.80 0.80 Bio-based binder: Impranil® DLP 4.00 4.00 Bio-based filler: calcium carbonate powder 0.80 0.40 0.40 Bio-based filler: Agaricus bisporus mycelium powder 0.70 0.35 0.35 Coalescing agent: ethylene glycol monoethyl ether acetate 0.20 0.10 0.10 Water 3.50 1.75 1.75 Total 10.00 6.60 3.40

[0258] A trial adjustment of the spraying system is then carried out. For this purpose, the two pumps 5a, 5b connected to the first and second reservoirs 6a, 6b are started, and the spraying unit is first supplied with compressed air at 4 bar to ensure that the first and second spray nozzles 1a, 11b are not obstructed. The three pairs of indentations retain the position they had for the spraying of the two previous layers CCI and CC2.

[0259] For the first pass, the same working program of the spraying unit is used as for the two previous coats CCI and CC2.

[0260] Similarly, for the second 90° pass, the same working program of the spraying unit is used as for the two previous coats CCI and CC2.

[0261] The parameters chosen for the two passes are as follows: • Spraying power: 1200 Watts • Nozzle diameter: 2 mm • Spray rate: 500 ml / min • Spraying distance: 15 cm • Spraying time: 2 minutes per pass • Number of passes: 2

[0262] At that time, we therefore have two prepared composite mixtures M5 and M6, positioned impressions, two validated trajectories in vacuum and validated spraying parameters.

[0263] The pumps 5a,5b and the solenoid valves 7a,7b associated with them are suitable for supplying the first nozzle 1 la with the two mixtures M5,M6, the first nozzle 1 la being adapted for spraying the CC3 layer, that is to say that the diameter of the first nozzle lia as well as the pressure are adjusted as specified above.

[0264] With the prepared composite mixtures M5 and M6 mixed in the multiport valve 13, spray tests are then carried out via the first nozzle lia on an adjacent surface to prime the pumps 5a, 5b and ensure that the flow rate is constant. The solenoid valves 7a, 7b and the pumps 5a, 5b are controlled to guarantee a homogeneous mixture. It is also verified that the composite mixtures M5 and M6 are available for spraying.

[0265] The spray program is now launched with two spray passes with the M5+M6 mixtures through the first nozzle to cover the three pairs of impressions, in two opposite directions.

[0266] For each spraying of the CC3 layer, the spraying time is 1 minute per pass, with a spraying pressure of 50 bar.

[0267] This spray program is followed by drying at 90 °C with circulating hot air for 2 minutes.

[0268] After drying and stabilization treatment, the textiles 2 resulting from the superposition of the sprayed layers are demolded from their respective molds and stored in the open air. Quality controls (dimensional, weight) are carried out.

[0269] Although described through a number of examples, variants and embodiments, the process according to the invention includes various variants, modifications and improvements which will be obvious to a person skilled in the art, it being understood that these variants, modifications and improvements form part of the scope of the invention.

Claims

1. Demands A process for producing a textile (2), characterized in that it comprises the following successive steps: - supply (E01) of a support (1), of at least one liquid composition and of at least one charge to be sprayed onto said support, this supply step (E01) comprising the following sub-steps: • supply (E02) of at least one liquid composition comprising a water-soluble binder and a water-based solvent in which the binder is dissolved, the binder comprising one or more water-soluble polymers, which represent 30 to 70% by weight of the liquid composition, and the solvent comprising water representing 30 to 70% by weight of the liquid composition; • supply (E03) of a filler consisting of loose fibers and / or powder, at least 5% by weight of the filler being of bio-based origin; • supply (E04) of a support (1) having a deposition surface (101); - formation (E05) on the deposition surface (101) of a composite layer consisting of a liquid composition and a filler resulting from the supply step (E01), this formation step (E05) comprising the following sub-steps: • spraying (E06) onto the deposition surface (101) of a liquid composition resulting from the supply step (E01); and • spraying (E07) onto the deposition surface (101) of a charge consisting of loose fibers and / or a powder resulting from the supply step (E01); • the spraying substep (E07) of a charge being simultaneous with or subsequent to the spraying substep (E06) of the liquid composition; - drying (E08) of the composite layer resulting from the formation step (E05) and polymerization of the polymer water-soluble by evaporation of water at atmospheric pressure; - repetition (E09) at least once of the steps of formation (E05) and drying (E08) of a composite layer, and formation of a textile (2) on the deposition surface (101) of the support (1); and - removal (E13) of said textile (2) from the deposition surface (101) of the support (1).

2. A method according to claim 1, characterized in that, during the drying step (E08), the support (1) is subjected to vibrations.

3. A method according to claim 1 or 2, characterized in that prior to the textile (2) removal step (E13), it comprises a finishing layer formation step (E10) on the composite layer resulting from the repetition step (E09), this finishing layer formation step (E10) comprising the following successive substeps: - spraying (Eli) onto the deposition surface (101) of a liquid composition resulting from the supply step (E02) of at least one liquid composition; and - drying (E12) of the liquid composition sprayed during the preceding spraying substep (Eli) and polymerization of the water-soluble polymer thereof by evaporation of the water at atmospheric pressure.

4. A method according to any one of the preceding claims, characterized in that at least one drying step (E08, E12) is carried out at room temperature.

5. A process according to any one of the preceding claims, characterized in that at least one drying step (E08, E12) is carried out at a temperature between 50 and 90°C.

6. A process according to any one of the preceding claims, characterized in that after a drying step (E08, E12), it comprises a stabilization step (El4) of the textile material (2), this stabilization step (El4) comprising at least one of the following substeps: - a heat treatment; - a plasma treatment; and / or - a UV irradiation crosslinking.

7. A method according to any one of the preceding claims, characterized in that at least a part of the deposition surface (101) of the support (1) is textured in relief or intaglio.

8. A method according to any one of the preceding claims, characterized in that, during a formation step (E05) of a composite layer, the filler represents 30 to 60% by weight of said composite layer.

9. A method according to any one of the preceding claims, characterized in that, during a formation step (E05) of a composite layer, the weight ratio of the chargeant in said composite layer is in the range between 2:1 and 1:

2.

10. A method according to any one of the preceding claims, characterized in that, during a formation step (E05) of a composite layer, a bio-based filler represents 5 to 50%, preferably 10 to 40% and more preferably 15 to 30% by weight of said composite layer.

11. A method according to any one of the preceding claims, characterized in that during the feed supply step (E03), 5 to 70%, preferably 10 to 60% and more preferably 20 to 50% by weight of the feed is of bio-based origin.

12. A process according to any one of the preceding claims, characterized in that during the feed supply step (E03), 5 to 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the bio-based feed consists of viscose fibers, cotton fibers, wool fibers, silk fibers, cashmere fibers, flax fibers, fur fibers, mammal hair, mycelium fibers, cellulose fibers, wood fibers, hemp fibers, mycelium powder, rice powder, wheat powder, wood powder, starch powder, alginate powder, carbon black powder, wheat flour, corn flour, millet flour, hemp flour, rapeseed flour, soybean hull powder, walnut hull powder, olive kernel powder, and soybean hull powder. cellulose nanofiber, polyamide powder or fibers, polypropylene powder or fibers,of polyethersulfone powder or fibers or polyurethane powder or fibers, taken alone or in mixtures.

13. A method according to any one of the preceding claims, characterized in that during the supply step (E03) of a charge, 5 70%, preferably 30 to 65% and more preferably 40 to 60% by weight of the bio-based filler are made up of at least one bio-based material comprising at least 5% by weight of calcium, preferably at least 10% by weight of calcium.

14. A process according to claim 13, characterized in that at least one bio-based material comprising at least 5% by weight of calcium is gypsum powder, limestone powder, bone powder, calcium carbonate powder or chalk powder.

15. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the water-soluble binder comprises at least 10%, preferably at least 30% and more preferably at least 60% by weight of bio-based and / or biodegradable polymer.

16. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the water-soluble binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of elastomer.

17. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the water-soluble binder comprises at least 5%, preferably at least 30% and more preferably at least 70% by weight of natural latex of vegetable origin, latex of vegetable origin treated to reduce its protein content, bio-based polylactic acid, bio-based thermoplastic polyurethane, bio-based polyurethane dispersion, rosin dispersion of vegetable origin, terpene dispersion of vegetable origin, bio-based acrylic polymer or polymer matrix hydrogel, taken alone or in mixture.

18. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the water-soluble binder comprises at least 10%, preferably at least 20% and more preferably at least 30% by weight of electrically conductive polymer.

19. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the liquid composition comprises from 1 to 30% by weight of magnesium sulfate and / or sodium sulfate.

20. A method according to any one of the preceding claims, characterized in that, during the supply step (E02) of at least one liquid composition or during the supply step (E03) of a filler consisting of loose fibers and / or a powder, the liquid composition or the filler comprises a water-soluble bridging agent capable of forming ionic and / or covalent bonds with a water-soluble polymer of the binder.

21. A process according to claim 20, characterized in that the bridging agent comprises predominantly mushroom spores, mushroom mycelium, silicate derivatives or magnesium chloride derivatives, taken alone or in mixture.

22. A method according to claim 20 or 21, characterized in that during a formation step (E05) of a composite layer, the weight ratio of bridging agent in said composite layer is in the range between 1:100 and 1:1, preferably between 1:10 and 1:4, and more preferably between 2:10 and 3:

10.

23. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, the feed comprises a coalescing agent whose quantity represents from 0.1 to 10%, preferably 1 to 5% by weight of the liquid composition.

24. A process according to claim 23, characterized in that the coalescing agent is 2,2,4-trimethyl-1,3-pentane diol monoisobutyrate, glycol acetate, butyl glycol, fatty acid ester, propylene glycol or ethyl acetate, taken alone or in mixture.

25. A method according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, said liquid composition comprises at least one pigment.

26. A process according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, said liquid composition comprises a water-soluble viscosity agent.

27. ​​A process according to claim 26, characterized in that the viscosity-modifying agent is polylactic acid, sugar, a polysaccharide derivative, alginate, potato dextrose, agar, glucose, malt, peptone or yeast extract, taken alone or in mixtures.

28. A method according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, said liquid composition has a dynamic viscosity between 0.1 and 10,000 mPa.s at 20 °C.

29. A method according to any one of the preceding claims, characterized in that during the supply step (E02) of at least one liquid composition, said liquid composition comprises a water-soluble adhesive agent.

30. A method according to any one of the preceding claims, characterized in that, during a substep of spraying (E06) a liquid composition, said liquid composition completely covers a charge comprising fibers, at least 80% of these fibers having a length between 3 and 7 mm, preferably between 3 and 5 mm, and more preferably between 3 and 4 mm.

31. A method according to any one of the preceding claims, characterized in that, during a substep of spraying (E06) a liquid composition, said liquid composition does not completely cover a charge comprising fibers, at least 80% of these fibers having a length between 0.1 and 2 mm, preferably between 0.5 and 1.5 mm, and more preferably between 0.5 and 1 mm.

32. Textile (2), characterized in that it comprises an alternation of layers of water-soluble polymer-based material and a filler comprising a powder and / or fibers, said textile being a product resulting from the process according to any one of the preceding claims.

33. Textile (2) according to claim 32, characterized in that it has an average thickness of between 0.1 and 3 mm.

34. Textile article, characterized in that it is made from a textile (2) according to claim 32 or 33.

35. Spraying system (3) for carrying out the process according to any one of claims 1 to 31, characterized in that it comprises the following equipment: at least one spraying unit (4) equipped with one or more spray nozzles (11); at least fluid displacement device (5); at least one reservoir (6) containing: • a liquid composition comprising a water-soluble binder and a water-based solvent, • a powder charge, • a load in the form of loose fibers, taken alone or in mixtures; supply pipes (8) connecting at least one reservoir (6) to at least one fluid displacement device (5) and to at least one spray nozzle (11); at least one support (1) having a deposition surface (101) on which a textile (2) can be manufactured by spraying at least one fluid contained in a reservoir (6) and supplied by a fluid displacement device (5) to a spraying unit (4).

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