Method for manufacturing nonwoven fabric, and nonwoven fabric

Abstract

The present invention provides a method for producing a nonwoven fabric, the method comprising: i) applying a layer of a dispersion comprising a dispersion medium and bio-based first fibers (110) onto a support, the bio-based first fibers (110) being derived from microorganisms cultured in a liquid medium, and a plasticizer being added to the dispersion prior to said application; ii) depositing reinforcing second fibers (120) onto the layer of dispersion, the reinforcing second fibers (120) being separate fibers not part of the fabric, the second fibers having an average length at least 10 times the average length of the first fibers; and iii) removing the dispersion medium to form a nonwoven fabric (100) comprising a web of the bio-based first fibers (110). Nonwoven fabrics and seamless products comprising such nonwoven fabrics are also provided.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a non-woven fabric.

Background Art

[0002] Non-woven fabrics are well known and are widely used, from disposable diapers and surgical gowns to durable materials for windstoppers and raincoats.

[0003] Non-woven fabrics can be manufactured by various methods such as the wet-laid method. In the wet-laid method, a dispersion of fibers in a dispersion medium is applied to the surface of a support, and then the dispersion medium is removed, and the fibers form a web. This web conforms to the shape of the support, and thus, in the case of a three-dimensional support of a desired shape, the non-woven fabric has the desired shape without cutting and sewing. The non-woven fabric may also have a surface structure, for example, when an embossed support is used.

[0004] Non-woven fabrics can be made from various materials such as synthetic fibers including polyethylene, but fabrics based on natural materials including tactile (feel) characteristics are desirable.

[0005] Making non-woven fabrics from bio-based fibers, which are fibers derived from living organisms (i.e., natural), is known in the art, but they may lack the desired strength and / or durability. For example, in WO2020 / 006133A1, a second material in the form of a woven fabric layer is embedded in a matrix of bio-based fibers to provide strength to the bio-based fibers. However, according to WO2020 / 006133A1, growing bio-based fibers in the form of a fungal matrix on a woven fabric layer is a time-consuming process, difficult to control, and requires the bio-based fibers to be alive during the manufacture of the non-woven fabric.

[0006] CA2,718,435A1 teaches that fibers are applied in an isotropic orientation, where the fibers are oriented transversely to the product material. These transversely oriented fibers are intended to provide a specific feel but do not substantially contribute to the strength of the product material, and in particular, these fibers do not form a web. [Overview of the Initiative]

[0007] The object of the present invention is to provide a biofiber-based nonwoven fabric with enhanced strength and / or durability in a simple manner without compromising its feel against the skin.

[0008] For this purpose, according to a first aspect, the present invention provides a method, the method is i) A step of coating a support with a layer of dispersion containing a dispersion medium and a bio-based first fiber, ii) A step of depositing a second reinforcing fiber on a layer of dispersion, wherein the second reinforcing fiber is another fiber, iii) the step of removing the dispersion medium to form a nonwoven fabric containing a web of bio-based first fibers.

[0009] In this way, enhanced strength is provided to the nonwoven fabric based on the first bio-based fiber, - Maintaining the simplicity of the method, - The texture of the nonwoven fabric on the side facing the support material is substantially maintained.

[0010] The second fiber is typically applied collectively, for example, as a suspension, using a brush, or by spraying. In this application, "another fiber" means that they are individual fibers. Therefore, they are not part of a woven, nonwoven, or fabric in which the fibers are interconnected by adhesive or heat (melting of the fibers), or by the addition of adhesive or crosslinking agents.

[0011] At most, some of the dispersion medium may be removed before the second fibers are applied, in order to allow the second fibers to be embedded in the moist matrix of the first fibers. Removal typically involves drying, for example, by passing dry air over the surface of the dispersion layer, taking care not to blow it away. The air may be heated air. In this way, the redistribution or dripping of the dispersion applied in step i) under gravity is reduced. Thus, irregularities formed by, for example, the dripping of the dispersion can be reduced, which may facilitate the production of nonwoven fabrics on non-horizontal surfaces.

[0012] It is known in the art that nonwoven fabrics with improved strength can be produced by chemical treatment or modification of bio-based fibers or nonwoven fabrics. Such treatments may remove desired properties of the nonwoven fabric in terms of tactile feel. Where chemical treatment or modification requires the undesirable use of chemicals, the present invention makes it possible to avoid these. By reducing or eliminating the use of chemicals, this method becomes more sustainable.

[0013] Nonwoven fabrics can be manufactured without additional steps after step iii) interconnecting the first fibers after the formation of the web. This reduces the work required to manufacture the nonwoven fabric by avoiding chemical bonding, thermal bonding, mechanical bonding, or any other step required to connect the first fibers to each other.

[0014] In this application, the term "bio-based first fiber" includes not only purified bio-based first fibers, such as mycelium and cellulose, but also chemically manufactured or processed bio-based first fibers, such as viscose or lyocell.

[0015] The first fibers are preferably dispersed in an aqueous dispersion medium. However, the dispersion fluid may be any fluid suitable for a wet-laid process and may be based on other volatile liquids, such as alcohols such as methanol, ethanol, or propanol, any other organic volatile fluid, or a combination of these liquids, such as water and ethanol. In this way, the dispersion medium can be easily removed or the first fibers can be dispersed more effectively in the dispersion medium. Preferably, the dispersion medium is non-toxic and / or naturally derived and / or non-harmful to the environment.

[0016] The concentration of the first fiber in the dispersion is at least 0.1% w / v, preferably at least 5% w / v, more preferably at least 10% w / v, and most preferably at least 15% w / v. Preferably, the concentration of the first fiber in the dispersion is less than 60% w / v.

[0017] In one embodiment, after step iii), the first fibers comprise 20-80% by weight of the nonwoven fabric, the second fibers comprise 1-40% by weight of the nonwoven fabric, and the plasticizer comprises 5-50% by weight of the nonwoven fabric, the total weight percentage of the first fibers, the second fibers, and the plasticizer is at least 65%, preferably at least 80%, of the weight of the nonwoven fabric, and the weight percentage of the second fibers is less than the weight percentage of the first fibers.

[0018] Preferably, the first fibers have a diameter of less than 50 micrometers, more preferably less than 25 micrometers, even more preferably less than 15 micrometers, and most preferably less than 8 micrometers. In this way, the surface of the web facing the support structure adopts a smooth texture after the removal of the dispersion medium.

[0019] The second reinforcing fiber may be a fiber that i) has a higher tensile strength than the first fiber, and / or ii) has an average length at least three times, preferably at least ten times, the average length of the first fiber.

[0020] Typically, the second fiber has a cylindrical cross-section, but it may be flat, curved, bent, or any other elongated shape. The method may also be carried out using a second fiber whose circumferential surface is microfibrillated. In this way, the strength and / or durability of the web can be improved.

[0021] The second fiber is preferably less than 100 micrometers in diameter, more preferably in the range of 15 to 50 micrometers. In this way, the second fiber provides strength to the nonwoven fabric, while also allowing for a more homogeneous distribution of the first fiber.

[0022] The second fiber is preferably at least 0.3 mm in length, more preferably at least 2 mm, even more preferably at least 5 mm, and most preferably at least 10 mm. In this way, the strength and durability of the nonwoven fabric produced according to this method are improved.

[0023] In a plane projected parallel to the surface of the web, the second fiber typically occupies 10-90%, preferably 20-75%, and more preferably 30-50% of the total surface area of ​​the first fiber lying on that plane.

[0024] The second fibers can be added, for example, by flocking, air-laying, spinning, or electrospinning. In this way, the distribution of the second fibers can be precisely controlled, and by using different deposition techniques on different parts of the nonwoven fabric, parts of the nonwoven fabric can have different properties.

[0025] The surface of the support may be a flat surface, a three-dimensional surface, or a structured surface. In this way, a two-dimensional sheet, a three-dimensional web, or a web having a structure can be manufactured. The surface of the support may be provided by the surface of a mold, or it may be the surface of a web previously formed on the mold, whether or not it is formed by the method according to the present invention. The mold may be, for example, a human torso.

[0026] The non-woven fabric may be removed from the support, but this is not done when it is desirable to provide the non-woven fabric on the support, i.e., when the non-woven fabric is part of the product. When the non-woven fabric is removed from the support, the support typically has a surface (selected so as not to adhere excessively to the fabric) that aids in the removal of the fabric. In the case of a product, the reverse is preferred.

[0027] According to a preferred embodiment, the layer of the dispersion in step i) is applied by spraying.

[0028] Spraying the dispersion enables more controlled application of the layer of the dispersion and the first fibers, thereby obtaining a higher quality non-woven fabric. For example, the risk of bubble formation is reduced, thereby obtaining a more homogeneous and uniform layer of the dispersion and thus a higher quality non-woven fabric.

[0029] According to a preferred embodiment, step i) supplying a dispersion of the first bio-based fibers, wherein the first fibers are dispersed in a dispersion medium, and removing at least a part of the dispersion medium to form a web on the support, is performed prior to the step, which is carried out at least once, and step i) includes applying a layer of the dispersion to the web.

[0030] In this way, a thicker non-woven fabric can be produced with a sufficiently controlled thickness, and the second fibers protrude on the side of the fabric facing the support, thus reducing the risk of delamination of the non-woven fabric layers. The dispersion medium is typically removed by evaporation, which can be facilitated using the supply of heat and / or dry air.

[0031] Furthermore, this embodiment facilitates the production of nonwoven fabrics with a non-horizontal orientation because, in contrast to applying a relatively thick layer all at once, a stack of relatively thin layers is applied and dried to obtain the desired thickness of the nonwoven fabric. Typically, the step is performed at least twice, preferably at least five times, and more preferably at least ten times.

[0032] According to a preferred embodiment, the method further comprises a step between step ii) and step iii) of coating a further layer of further dispersion onto a layer of dispersion, wherein the further dispersion comprises a further dispersion medium and a third bio-based fiber.

[0033] In this way, the method provides an additional web on the side of the fabric opposite to the support, which provides a texture determined by the last applied bio-based third fiber.

[0034] The strength of the fabric can be improved by better embedding the second layer of fibers.

[0035] The further dispersion medium of the further dispersion may be the same dispersion medium as the first dispersion medium, or it may have a different composition. Furthermore, the third bio-based fiber may be the same fiber as the first or second fiber, or it may be a fiber having different properties such as antibacterial or skin-care properties.

[0036] In a particularly preferred embodiment, the first bio-based fiber is a fiber derived from microorganisms cultured in a liquid culture medium.

[0037] This allows for the avoidance of plant-based fiber production, which typically requires vast tracts of land, pesticides, and expensive harvests, followed by extensive processing of the fibers. In contrast, the growth of microorganisms such as mycelium in a bioreactor can be carried out efficiently, and the mycelium may be simply harvested (e.g., by filtration) or left as is without any harvesting step, with a liquid medium serving as the dispersion medium. Optionally, the mycelium may be diluted or resuspended in a dispersion medium (water) and then ready to form a nonwoven fabric.

[0038] The microorganisms may be, for example, fungi, protozoa, bacteria, or algae.

[0039] Furthermore, or instead of being derived from microorganisms, the first fiber may also include bio-based materials derived from fungal mycelium, yeast, algae, bacteria, cultured animal or plant cells, and fibers derived from animal and / or plant cells cultured in liquid medium. Cultured animal or plant cells can be cultured, for example, in a bioreactor.

[0040] According to a preferred embodiment, the first bio-based fiber is a form of biological material selected from fungal mycelium, yeast, algae, bacteria, cultured animal or plant cells, fibers derived from animal cells and / or plant cells cultured in liquid medium, fruit pulp, pulp from leaves, pulp from stems, fibers from leather, collagen, and / or a pulverized and / or microfibrillated form of any of the above materials.

[0041] In this way, the resources needed to form the web may be inexpensive and readily available, and may require little to no manufacturing equipment for production.

[0042] According to a preferred embodiment, the first bio-based fiber is not chemically treated.

[0043] In this way, the production of nonwoven fabrics can be carried out more quickly and safely, as no chemical treatment or modification steps are required. Suitable biological materials may be, for example, harvested fungal mycelium, algal materials, bacteria, cultured animal or plant cells, fibers derived from animal and / or plant cells cultured in liquid medium, pulped plant materials such as pulped fruits, leaves and / or stems, and collagen-derived fibers. Biological materials may also be micronized and / or microfibrillated, thereby increasing the fluffiness of the fibers and improving their interbinding ability.

[0044] According to a preferred embodiment, the second fiber is selected from natural fibers, regenerated fibers, synthetic fibers, functional fibers, or any combination thereof, and preferably the second fiber is hydrophilic.

[0045] In this way, a second fiber can be selected to provide the nonwoven fabric with desired properties. Natural fibers can be used when the nonwoven fabric needs to be biodegradable and may be derived from plant materials such as wood, grass, leaves, and cellulose, or from animal materials such as wool, mohair, cashmere, angora, silk, and spider silk. However, mineral materials such as chrysotile, amosite, crocidolite, tremolite, antphyllite, and actinolite can also be used as the second fiber. Preferably, the fiber is a natural fiber. Regenerated fibers may be suitable for the same purpose and may be made from materials such as viscose, lyocell, cellulose acetate, azuron, or any other modified cellulose. Furthermore, regenerated fibers that are too short for respinning and would otherwise have to be discarded for the manufacture of the fabric may be used. Synthetic fibers can reduce the cost of the nonwoven fabric, and suitable synthetic fibers can be made from materials such as polypropylene, polyester, elastane, and polyvinyl chloride. By using second fibers made from aramid, liquid crystal polymer (LCP), carbon, glass, or metal fibers, special properties such as resistance to abrasion, tearing, and / or higher temperatures can be provided to the nonwoven fabric. Fibers with special properties can impart resistance or conductivity to the manufactured nonwoven fabric, and thus provide users with protection or usefulness in measuring biological functions such as heart rate or muscle function. Multiple properties can be imparted by using a mixture of fibers from any of these materials. Hydrophilic fibers provide better adhesion to the first bio-based fibers.

[0046] According to a preferred embodiment, the second fibers are added isotropically to each other.

[0047] The isotropic orientation of the second fibers relative to each other can be achieved, for example, by carding the second fibers before step ii). The resulting isotropically oriented second fibers can then be applied in step ii) in a direction parallel to the support, either manually or, for example, using a robot. In this way, the isotropic orientation of the second fibers provides improved strength to the nonwoven fabric when added to the layer of dispersion.

[0048] CA2718435A1 also coats a second layer of fibers in an isotropic orientation, but these fibers are oriented transversely to the support and therefore do not substantially contribute to the strength of the nonwoven fabric.

[0049] According to a preferred embodiment, the second fibers are added anisotropically to each other.

[0050] This can be achieved, for example, by electrostatic flocking, which involves applying an electric charge to a support while adding a second fiber. This causes at least a portion of the second fiber to be oriented perpendicular to the support. After the charge is removed, at least a portion of the perpendicularly oriented second fiber will fall over and assume an orientation parallel to the support but random to each other. This anisotropic orientation can improve the flexibility of the nonwoven fabric.

[0051] In a preferred embodiment, a plasticizer is added to the dispersion before step i), where the plasticizer is preferably a sugar, sugar alcohol, polyol, polyester and / or α-hydroxy acid, or a combination thereof, more preferably sorbitol and citric acid. Typically, the resulting nonwoven fabric has a plasticizer content of 5 to 50% by weight, preferably 10 to 30% by weight.

[0052] The addition of plasticizers can strengthen the resulting nonwoven fabric. Plasticizers can prevent the nonwoven fabric from becoming brittle, fragile, and / or rigid. Examples of plasticizers include glycols, glyceryl triacetates, high molecular weight polyols, and quilaria, but may also be composite compositions or any combination thereof, such as honey, molasses, aloe vera, castor oil, glycerides, triglycerides, and other mineral or organic oils.

[0053] According to a preferred embodiment, after all other steps, the step of applying the coating is performed on at least one exposed surface of the nonwoven fabric, preferably all exposed surfaces.

[0054] The coating may be, for example, a flexible, protective, and / or reinforcing coating. Thus, the durability of the nonwoven can be improved by retaining the dispersion medium and / or retaining the plasticizer in the nonwoven after the linking of the web and / or further webs. The coating may be biodegradable and / or UV resistant and may optionally contain coloring pigments.

[0055] According to a preferred embodiment, the method includes the step of applying and adhering at least one component to a web.

[0056] In this way, additional functionality can be embedded in the nonwoven fabric. Technical components, such as LED lighting, sensors, RFID tags or NFC chips, or decorative elements, such as sequins, beads, cords, appliques, and lace, can be directly incorporated without gluing or sewing, or without attaching the components to the nonwoven fabric, reducing the cost and number of steps during the manufacturing of the reinforced nonwoven fabric.

[0057] According to a preferred embodiment, the method includes a dyeing step. This step is typically carried out by mixing the dye and / or pigment into the dispersion to be applied in step i), for example, before step ii).

[0058] Preferably, in this step, the dye and / or pigment is co-coated to at least one selected from the first and second fibers. In this way, the dye and / or pigment is incorporated into the fabric together with the fiber, avoiding a separate dyeing step. In particular, no additional liquid is required to mix the dye and / or pigment into the fabric. The dye and / or pigment is embedded in the fabric, making the dye in the fabric less likely to deteriorate when the fabric is used.

[0059] Furthermore, there is no need to wash the fabric to remove excess dye, which is typically a tedious step in the production of state-of-the-art fabrics.

[0060] In one embodiment, step ii) is performed and completed within 2 hours, preferably within 0.5 hours, from the start of step i). Thus, steps i) and ii) of the method of the present invention can be carried out rapidly, in particular, without the need to wait for fungal cells, etc., to provide the first fibers.

[0061] In one embodiment, step iii) is carried out and completed within 72 hours, preferably within 5 hours, from the start of step ii). In particular, in combination with the previous embodiment, this may allow the nonwoven fabric to be manufactured within 4 days.

[0062] According to a second aspect, the present invention relates to a nonwoven fabric, the nonwoven fabric can be obtained by the method described in any of the above claims. Preferably, the nonwoven fabric has a seamless circumferential surface.

[0063] According to a third aspect, the present invention provides a nonwoven fabric comprising a bio-based first fiber and a reinforcing second fiber, preferably obtained using the method of the present invention, wherein the first fiber and the second fiber are irreversibly embedded in a matrix comprising a plasticizer, the bio-based first fiber being a fiber derived from microorganisms cultured in a liquid medium, and the second fiber having an average length at least 10 times the average length of the first fiber.

[0064] In addition to the plasticizer, the matrix typically further contains some moisture from the dispersion medium, which may have been, for example, in step i) of the claimed method.

[0065] In one embodiment, the plasticizer comprises an amorphous matrix containing a hydroxy acid and a polyol.

[0066] In a preferred embodiment, the first fibers constitute 20 to 80% by weight of the nonwoven fabric, the second fibers constitute 1 to 40% by weight of the nonwoven fabric, the plasticizer constitutes 5 to 50% by weight of the nonwoven fabric, the total weight percentage of the first fibers, the second fibers, and the plasticizer is at least 65%, preferably at least 80%, of the weight of the nonwoven fabric, and the weight percentage of the second fibers is less than the weight percentage of the first fibers.

[0067] In one embodiment, oil droplets and / or fat droplets are embedded in a matrix, and the droplets have a maximum diameter in the range of 1 μm to 20 μm. For example, the oil droplets may include dry oil or non-drying oil. Optionally, a desiccant is also included in the matrix.

[0068] According to a fourth aspect, the present invention provides a wearable shape seamless garment, accessory or footwear, or any other three-dimensional seamless nonwoven product, comprising a nonwoven fabric of the second or third aspect and / or a nonwoven fabric manufactured according to the first aspect of the present invention. Thus, the present invention provides seamless garments, accessories, footwear, or other products.

[0069] Next, the present invention will be described with reference to the following illustrative sections and drawings. [Brief explanation of the drawing]

[0070] [Figure 1] This is a schematic representation of the cross-section of a nonwoven fabric. [Figure 2] Figures 2A-2C show a schematic representation of another embodiment of the nonwoven fabric according to the present invention, as well as its first and second details, respectively. [Figure 3] Figures 3A-3C. These figures show schematic representations of yet another embodiment of the nonwoven fabric according to the present invention, as well as first and second details thereof, respectively. [Figure 4] This figure shows one embodiment of a nonwoven fabric having a three-dimensional non-planar shape and in the form of a bag, manufactured according to the method of the present invention. [Modes for carrying out the invention]

[0071] Figure 1 shows a schematic representation of a cross-section of a nonwoven fabric 100 containing first fibers 110 and second fibers 120 manufactured according to the present invention. The first fibers 110 are derived from cultured mycelium and dispersed in a dispersion medium. A first layer of the dispersion containing the first fibers 110 is coated onto a support, and the second fibers 120 are added to the layer of dispersion. The second layer of dispersion is added on top of the first layer of dispersion, and the dispersion medium is removed by evaporation at room temperature. In the resulting nonwoven fabric, the first fibers 110 exist as a continuous web without a distinguishable boundary between the first fibers 110 coated on the first layer of dispersion and the first fibers 110 coated on the second layer of dispersion. The second fibers 120 are embedded in the continuous web of the first fibers 110.

[0072] To produce nonwoven fabric, fungal biomass in the form of mycelium from the basidiomycetes Schizophyllum commune was grown in 1 liter of Duran-Erlenmeyer medium with standard malt extract. The growth procedure followed a standard culture procedure at 30°C with shaking at 200 rpm. The mycelium was collected by Buchner filtration. Citric acid and sorbitol were pre-mixed with water, and then added to the collected mycelium and the remainder of the growth medium to form a dispersion containing the first fibers.

[0073] In step a), a first layer of the dispersion was applied to the mold by spraying the dispersion onto the surface of the solid and 3D-shaped support using a sprayer used for spraying paint. In step b), the dispersion was removed by evaporation at room temperature. The dispersion was evaporated until a web of dry mycelium (MYC) formed upon contact with the support.

[0074] Steps a) and b) were repeated once more. Subsequently, in step c), a further layer of dispersion was applied onto the web. In step d), individual second fibers, such as polyamide (PA) 100 dtex or carded rayon (CV) 28 dtex, were applied to the web by flocculating with FK1-PRO, and carded flux (LI) was applied manually. For example, the rayon fiber had a circular circumferential surface between its two ends and was 12 mm in length. In a plane projected parallel to the surface of the second web, the area of ​​the first fiber covered by the second fiber was 30-50%.

[0075] Next, steps a), b), c), and d) were repeated twice, and finally, steps a) and b) were performed once.

[0076] The resulting nonwoven fabric was removed from the mold. In the cross-section of the nonwoven fabric, individual webs or first fibers were indistinguishable, rather presented as a single web of first fibers with second fibers embedded within a single web of first fibers. The second fibers do not exist as a separate continuous layer in the nonwoven fabric. Instead, the second fibers, applied in the same step, are substantially aligned on any outer surface of the nonwoven fabric, and may be in contact with each other, or aligned with each other as well as intersecting each other at various angles.

[0077] Elongation and peak force were measured from each nonwoven fabric to evaluate the effect of the second fiber on the nonwoven fabric. Elongation and peak force were measured according to EN13934-01, except that the dimensions of the tested samples were 4 × 4 cm. Experiments were conducted as single experiments or in pairs. A nonwoven fabric of pure mycelium was used as a control.

[0078] Table 1 shows the effects of various second fibers on elongation and peak force. [Table 1]

[0079] The addition of a second fiber resulted in a peak strength 1.6 to 6.8 times higher than that of nonwoven fabric made from pure mycelium, indicating that the addition of the second fiber imparts strength to the nonwoven fabric.

[0080] Furthermore, five panelists evaluated the texture of the nonwoven fabric and independently assessed that the texture of the nonwoven fabric containing the second fiber was the same as the texture of the nonwoven fabric made from pure mycelium.

[0081] Figure 2A shows a schematic representation of a cross-section of another nonwoven fabric 200 containing a first bio-based fiber 210 and a second reinforcing fiber 220, manufactured according to the present invention. In the cross-section, the fabric 200 has an upper outer surface 201 and a lower outer surface 202, which are positioned between the first and second fibers. In the illustrated example, the first and second fibers are embedded in a single fusion layer, but it will be understood that instead, the nonwoven fabric may contain stacks of multiple fusion layers of the first and second fibers. The first fibers form a web reinforced by the second fibers.

[0082] Figure 2B provides a detail of sub-II-B of Figure 2A, showing the first fiber 210 and the second fiber 220 in more detail. As can be seen, the first fiber is orders of magnitude smaller than the second fiber 220. In the illustrated example, the first fiber 210, shown in more detail in Figure 2C, has an average diameter of about 2 μm, and the second fiber 220 has an average diameter of about 100 μm. As can be seen, the larger second fiber 220 is substantially aligned with the upper and lower outer surfaces 201, 202, such that their centerlines are substantially parallel to these surfaces 201, 202. The much smaller first fiber 210 is oriented substantially randomly and is substantially not aligned with the first and second outer surfaces.

[0083] The first and second fibers are embedded in a matrix 230 containing a plasticizer, which, in addition to helping to substantially hold the first and second fibers in place, also provides the nonwoven fabric with enough flexibility to allow it to be bent or folded without damaging the nonwoven fabric. The plasticizer preferably comprises 5 to 50% by weight, preferably 15 to 30% by weight, of the finished nonwoven fabric, and preferably comprises a mixture of a polyol such as sorbitol and an α-hydroxy acid such as citric acid.

[0084] Figure 3A shows a schematic representation of a cross-section of yet another nonwoven fabric 300 according to the present invention, in addition to bio-based first fibers 310 and second reinforcing fibers 320 embedded in a matrix 330 containing a plasticizer and, optionally, any remaining dispersion medium. Furthermore, oil droplets 340, which are embedded in the matrix 330 and can have various sizes, are shown, with the maximum diameter of each oil droplet typically ranging from 1 μm to 20 μm. The oil droplets 340 can be used for delayed control or controlled release of beneficial fat-soluble components, and in this example, they contain aloe vera oil, which provides a pleasant aroma. The oil droplets 340 typically have an average diameter that is larger than the average length of the first fibers, for example, at least 5 times larger than the average length of the first fibers 310.

[0085] Figure 4 shows an oblique view of the nonwoven fabric 400 according to the present invention, formed in a non-planar shape, here in the form of a handbag. The nonwoven fabric 400 is manufactured by coating a layer of dispersion onto a non-planar support (not shown) having the positive shape of the nonwoven fabric 400. The layer is typically applied by spraying the dispersion onto the non-planar 3D surface of the support and / or by using a brush to apply the dispersion to the support. After coating a layer of dispersion containing a dispersion medium, a first bio-based fiber, and a plasticizer, a layer of second fibers for reinforcement was deposited on top of the dispersion layer, and then the two layers were dried to form the nonwoven fabric 400. The nonwoven fabric 400 has a circumferential surface 401 with ridges 402 and dimples 403. In this example, after coating a layer of dispersion onto a flexible support, applying the second fiber, removing the dispersion medium to form the nonwoven fabric 400, the flexible support was folded and removed from the inside of the fabric 400. As will be apparent to those skilled in the art, in addition, or instead, to allow for easy removal of the nonwoven fabric from the support, one or more supports can be used to create positive or negative shapes, for example, in a manner similar to that of a mold used in a casting process. By using one or more supports, the final product can be manufactured without seams or bonded joints, etc.

Claims

1. A method for manufacturing a nonwoven fabric (100), i) A step of coating a layer of a dispersion containing a dispersion medium and a bio-based first fiber (110) onto a support, wherein the bio-based first fiber (110) is a fiber derived from a microorganism cultured in a liquid medium, and a plasticizer is added to the dispersion before coating; ii) A step of depositing a second reinforcing fiber (120) on the layer of the dispersion, wherein the second reinforcing fiber (120) is a separate fiber that is not part of the fabric, and the second fiber has an average length at least 10 times longer than the average length of the first fiber, iii) The step of removing the dispersion medium to form the nonwoven fabric (100) containing a web of bio-based first fibers (110) A method that includes this.

2. In step i), the layer of the dispersion is applied by spraying. The method according to claim 1.

3. Further comprising removing the nonwoven fabric from the support, The method according to claim 1 or 2.

4. The plasticizer is a sugar alcohol, polyol, polyol ester, and / or α-hydroxy acid, or a combination thereof. The plasticizer includes one or more of the following: glycols, glyceryl triacetate, high molecular weight polyol, quillaja, honey, molasses, aloe vera, castor oil, glycerides, triglycerides, and other mineral oils or organic oils. The method according to claim 1.

5. The aforementioned plasticizer includes a combination of sorbitol and citric acid. The method according to claim 4.

6. Step i) - Supplying a dispersion of a bio-based first fiber (110), wherein the first fiber (110) is dispersed in a dispersion medium. - In order to form a web on the support, remove at least a portion of the dispersion medium. This is performed prior to the steps that include, The step of supplying and removing is performed at least once prior to step i), and step i) includes coating the layer of dispersion onto the web, The method according to claim 1.

7. The method according to claim 1, further comprising the step of coating a further layer of a further dispersion onto the layer of the dispersion between step ii) and step iii), wherein the further dispersion comprises a further dispersion medium and a third bio-based fiber.

8. The method according to claim 1, wherein the bio-based first fiber (110) is in the form of a biological material selected from fungal mycelium, yeast, algae, bacteria, cultured animal or plant cells, or fibers derived from animals and / or plant cells cultured in a liquid medium.

9. The method according to claim 1, wherein the second fiber (120) is selected from natural fibers, regenerated fibers, synthetic fibers, or any combination thereof.

10. The method according to claim 1, wherein the concentration of the first fiber in the dispersion is at least 0.1% W / v.

11. The method according to claim 1, wherein the dispersion further comprises oil droplets.

12. The method includes the step of applying and adhering at least one component to the web, The at least one component is selected from the group consisting of LED lighting, sensors, RFID tags or NFC chips, or decorative items. The at least one component is embedded in the nonwoven fabric without adhering or sewing the component to the nonwoven fabric. The method according to claim 1.

13. The method according to claim 1, further comprising a dyeing step, wherein a dye or pigment is co-coated with at least one selected from the first and second fibers.

14. The method according to claim 1, wherein the support has a three-dimensional non-flat plane.

15. A nonwoven fabric comprising a bio-based first fiber and a reinforcing second fiber, wherein the first and second fibers are irreversibly embedded in an amorphous matrix containing a plasticizer. The bio-based first fiber (110) is a fiber derived from microorganisms cultured in a liquid culture medium. The second fiber has an average length that is at least 10 times longer than the average length of the first fiber. Nonwoven fabric.

16. The nonwoven fabric according to claim 15, wherein the plasticizer is formed from an α-hydroxy acid and a polyol.

17. The first fiber comprises 20 to 80% by weight of the nonwoven fabric. The second fiber comprises 1 to 40% by weight of the nonwoven fabric. The plasticizer comprises 5 to 50% by weight of the nonwoven fabric. The total weight percentage of the first fiber, the second fiber, and the plasticizer is at least 65% of the weight of the nonwoven fabric. The weight percentage of the second fiber is less than the weight percentage of the first fiber. The nonwoven fabric according to claim 15.

18. The nonwoven fabric according to claim 15, wherein oil droplets and / or fat droplets are embedded in a matrix, and these droplets have a maximum diameter in the range of 1 μm to 20 μm.

19. A seamless garment, accessory, or footwear in a wearable shape, or any other three-dimensional seamless nonwoven fabric product, comprising the nonwoven fabric according to claim 15.

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