Hybrid nonwoven fabric of natural wool and synthetic fibers with thermal consolidation, product and use.

Description

1 / 11 Hybrid nonwoven fabric of natural wool and synthetic fibers with thermal consolidation, product and use. Technical sector

[001] The present invention falls within the technical sector of structured textile materials in the form of nonwovens, specifically encompassing the development of hybrid blankets composed of natural sheep's wool fibers combined with synthetic fibers and low-melting-point thermobonding fibers, intended for applications in the clothing, bedding, upholstery, and thermoacoustic insulation segments. The technical field also relates to the development of sustainable materials with a lower environmental impact, considering reduced energy consumption, the absence of chemical binding agents, and biodegradability potential. State of the art

[002] The state of the art relating to textile and nonwoven materials used in filling, thermal comfort, coating, upholstery and insulation applications shows a predominance of composites formed almost exclusively from conventional synthetic fibers, such as polyester, polypropylene and polyamide, consolidated by mechanical, chemical or thermochemical routes.

[003] Although these materials exhibit good mechanical strength and competitive cost, they lack functional attributes characteristic of natural wool, such as efficient moisture regulation, greater thermal comfort, superior tactile feel, less static electricity buildup, naturally flame-retardant behavior, and more effective thermoacoustic performance.

[004] These solutions still have important environmental limitations, such as low biodegradability, dependence on petrochemical inputs and frequent use of synthetic adhesives or resins, which increases the environmental impact both in production and in disposal.

[005] Conversely, materials produced exclusively with natural wool, despite offering superior physiological comfort and thermal performance, do not meet the requirements for durability, dimensional stability and Petition 870260002672, dated 12 / 01 / 2026, page 15 / 32 2 / 11 mechanical strength required by the nonwoven industry. Pure carded wool presents difficulties in stable consolidation without chemical additives or felting processes, making it incompatible with high-productivity industrial processes and hindering its application in uniform, robust, and economically viable blankets.

[006] The analysis of the prior art identified in the search report confirms that there are no solutions capable of simultaneously and functionally integrating natural wool, structural synthetic fibers, and low-melting-point thermobonding polymers into a single composite intended for comfort and insulation applications. Document WO2024 / 217389 describes crimped synthetic fibers for thermal fillings, but is limited to virgin synthetic polymers and does not consider combination with wool, nor selective thermofusion mechanisms to stabilize heterogeneous mixtures or allow the use of recyclables.

[007] Prior patent WO2025 / 196830 recognizes the potential of natural wool as an insulator, but is limited to the isolated use of wool and does not include its controlled integration with structural synthetic fibers or thermosetting polymers capable of promoting three-dimensional cohesion. It also does not contemplate the use of recyclable inputs or a scalable industrial process for complex fibrous blends.

[008] Document US2022380980A1 deals with biodegradable compositions with a focus on sustainability, but does not address the formation of a consolidated hybrid composite by partial melting of low-temperature polymers, nor does it combine natural fibers such as wool with structural synthetic fibers that support comfort, filling and insulation applications.

[009] The prior art US2025283252 describes multilayer biodegradable fibers, but its scope is limited to the engineering of the individual fiber, without proposing any consolidated mat structure or the integration of natural wool, synthetic fibers and thermosetting polymers.

[010] Document WO25163342 presents blankets containing PLA and natural wool, but it depends on specific chemical compatibility between PLA and wool, not Petition 870260002672, dated 12 / 01 / 2026, page 16 / 32 3 / 11 incorporates structural synthetic fibers, does not use low-melting-point thermofusible polymers, and does not allow for the stabilization of heterogeneous or recyclable mixtures.

[011] Document CN120537080 addresses three-dimensionally molded synthetic fibers for lightweight fillings, without incorporating natural wool or providing thermal consolidation capable of joining natural and synthetic fibers with different thermal and mechanical behaviors.

[012] The prior art WO24080885 A1 combines alpaca fibers with recycled polyester, representing a partial environmental effort, but does not address hybrid compositions with thermosetting polymers or technologies capable of consolidating complex mixtures with volumetric stability and superior thermoacoustic performance. Document IN202541073207 refers to rigid composites of vegetable fibers, without any relation to flexible, soft blankets or those suitable for comfort and thermal applications.

[013] The set of prior art reveals that all assume homogeneous raw materials, combine only two compatible types of fibers, or develop the individual fiber without proposing a consolidated hybrid composite. None anticipates the formation of a hybrid nonwoven structured by the obligatory combination of natural wool and synthetic fibers, stabilized by a low-melting-point thermobonding polymer, capable of integrating recyclable materials and forming a cohesive three-dimensional microstructure by selective thermofusion.

[014] Thus, a consistent technological gap remains evident: the lack of a multifunctional material capable of combining high thermal comfort, sensory properties of wool, mechanical resistance, dimensional stability, thermoacoustic performance, industrial durability and real sustainability, including the possibility of integrating textile waste. This gap is precisely what the present invention overcomes. New features and purpose of the invention

[015] The present invention introduces a novel hybrid nonwoven, necessarily formed by the controlled combination of natural wool fibers of Petition 870260002672, dated 12 / 01 / 2026, page 17 / 32 4 / 11 sheep, structural synthetic fibers and low melting point thermosetting fibers, and may optionally include recyclable synthetic fibers. This composition allows the consolidation of heterogeneous fibrous blends that, until now, could not be stabilized by conventional industrial carding and thermoforming processes due to differences in fineness, elasticity, length and thermal behavior between the fibers.

[016] Unlike existing technologies, which depend on homogeneous raw materials or restricted combinations of chemically compatible fibers, the present solution enables the synergistic integration between wool, synthetic fibers and optional textile waste, overcoming mechanical, thermal and chemical limitations that previously prevented the formation of sustainable nonwovens with high functional performance. The invention breaks the paradigm of homogeneity required by the previous technique and allows the production of stable blankets even when there is significant variation in the inputs.

[017] The novelty lies in the ability to transform materials of different origins into a single cohesive three-dimensional microstructure composite, thanks to the controlled surface fusion of the thermobonding fibers, which act as a stabilizing matrix for the blanket. This matrix, by selectively melting, establishes bonding points distributed throughout the structure, ensuring volumetric uniformity, dimensional stability and high mechanical strength, without sacrificing essential characteristics conferred by wool, such as softness, thermal comfort, hygroscopic regulation and naturally flame-retardant behavior.

[018] The technical effect achieved does not result from the mere sum of the individual properties of the fibers, but from a synergistic and unexpected interaction between wool, synthetic fibers and a thermosetting polymer, whose controlled thermofusion stabilizes complex mixtures that would be unfeasible by traditional routes. The result is a multifunctional nonwoven capable of simultaneously offering resilience, thermal comfort, superior thermoacoustic performance, durability and industrial processability, characteristics not foreseen or suggested by prior art. Petition 870260002672, dated 12 / 01 / 2026, page 18 / 32 5 out of 11 known.

[019] The central objective of the invention is to provide a sustainable nonwoven with high added value, capable of substantially reducing the consumption of virgin synthetic polymers, expanding the use of textile waste and minimizing environmental impacts associated with disposal.

[020] The solution also establishes a cleaner technological route, eliminating the need for chemical resins and promoting energy savings, while replacing traditional synthetic materials used in bedding, apparel, upholstery, furniture, and thermal and acoustic insulation applications. Advantages and technical effects of the invention

[021] The present invention provides a set of advantages and technical effects that emerge directly from the synergistic interaction between natural wool fibers, functional synthetic fibers and low-melting-point thermosetting fibers, with the incorporation of recycled synthetic fibers being optional. These fibers, when subjected to the thermal consolidation process, undergo controlled surface fusion that stabilizes the mat and forms a cohesive three-dimensional microstructure, resulting in superior structural integrity, dimensional stability and functional performance compared to that observed in traditional composites.

[022] The combination of the intrinsic properties of wool — including softness, elasticity, thermal comfort, hygroscopic regulation, and naturally flame-retardant behavior — with the mechanical strength and resilience conferred by synthetic fibers and the anchoring points of thermo-bonded fibers generates a nonwoven that combines softness to the touch with high durability and elastic recovery capacity. This synergy overcomes limitations typical of exclusively natural materials, which exhibit lower volumetric stability, and of purely synthetic materials, which do not reproduce the physiological comfort or thermal performance characteristic of wool.

[023] The resulting microstructure is lightweight, uniform, and maintains its volume even Petition 870260002672, dated 12 / 01 / 2026, page 19 / 32 6 / 11 when manufactured with recycled fiber fractions, eliminating recurring problems of the previous technique, such as permanent deformation, shrinkage, loss of thickness, and the need for aggressive chemical additives. The thermofusion mechanism generates bonding points distributed throughout the entire mat, allowing the material to withstand subsequent industrial operations—such as sewing, lamination, or molding—with less risk of delamination, surface fracture, or dimensional instability.

[024] Thermoacoustic performance is another relevant technical effect, resulting from the interaction between the controlled porosity of the blanket, the hygroscopic capacity of the wool, and the structural stabilization provided by the thermo-binding fibers. The formation of micro air chambers allows for acoustic damping and reduces thermal transmission, making the material suitable for comfort clothing, bedding products, quilt fillings, upholstery, and insulation solutions. This performance surpasses pure natural blankets—which lack structural cohesion—and conventional synthetic blankets, which do not offer the combination of moisture regulation, physiological comfort, and thermal insulation characteristic of wool.

[025] The invention also introduces a novel technical capability to incorporate post-consumer or post-industrial recycled synthetic fibers, even when they exhibit great variability in fineness, length or composition, since the thermobonding mechanism standardizes the microstructure of the composite. Thus, a typical limitation of the textile industry — the heterogeneity of waste — is transformed into an opportunity to produce sustainable materials with high added value and a quality standard compatible with industrial requirements.

[026] In addition to its functional performance, the invention generates significant environmental advantages. The mandatory presence of wool reduces dependence on virgin synthetic fibers, while the possibility of incorporating recycled fibers decreases the volume of waste destined for landfills and reduces the demand for non-renewable raw materials. The thermal consolidation process, which Petition 870260002672, dated 12 / 01 / 2026, page 20 / 32 7 / 11 eliminates the need for chemical resins, solvents or adhesives, reduces emissions, lowers energy consumption and prevents the generation of effluents.

[027] The combination of these effects — structural stability, multifunctionality, high thermal and acoustic efficiency, durability, consistent industrial processability, and real sustainability — characterizes a technological advance not anticipated by the state of the art. The invention breaks with the dependence on homogeneous matrices and establishes a new paradigm for nonwoven engineering, integrating natural and synthetic fibers in an optimized and environmentally responsible manner, representing a significant leap for the textile sector and for the sustainability of the production chain. List of attached drawings

[028] The invention will be better understood from the attached drawings, which represent, in an exemplary and non-limiting manner, different views and functional schemes associated with the product and the industrial manufacturing process of the non-woven blanket. Figure 1 illustrates, in the form of a process diagram, the main industrial steps used to obtain the blanket, including opening, mixing, carding, web formation, overlapping, heat fusion and cooling, representing the continuous flow of transformation of textile waste into consolidated material. Figure 2 presents a schematic view of the resulting blanket, highlighting its fibrous structure consolidated by fusion points of the thermoplastic polymer, allowing visualization of the three-dimensional distribution of the recycled fibers and how they are anchored by partial fusion. Figure 3 presents an enlarged detail of the internal microstructure of the composite, in which the interaction between fibers of different compositions and the molten polymer distributed in the form of bonding points can be observed, demonstrating the three-dimensional consolidation effect responsible for the mechanical stability and superior thermoacoustic behavior of the material. Petition 870260002672, dated 12 / 01 / 2026, page 21 / 32 8 / 11 Figure 4 shows the hybrid nonwoven fabric. Figure 5 shows the transverse microscopy of the Bicomponent Fiber. Figure 6 shows a cross-sectional microscopy image of sheep's wool.

[029] These figures serve the purpose of illustrating relevant aspects of the invention, without limiting its scope, and correspond to the essential views necessary for a full understanding of the structural and functional configuration of the product and process described in this report. Detailed description of the invention

[030] The present invention relates to a high-performance hybrid nonwoven obtained from the controlled combination of natural sheep's wool fibers with functionalized synthetic fibers and low-melting-point thermobonding fibers, with the incorporation of recycled synthetic fibers being optional.

[031] The consolidation of the blanket occurs exclusively through partial fusion of the thermo-bonding fibers during the thermal process, which stabilizes the heterogeneous fibrous mixture and forms a cohesive three-dimensional microstructure. The result is a multifunctional material that integrates properties of comfort, thermal performance, mechanical resilience and sustainability, suitable for industrial applications in the textile, apparel, bedding, upholstery and thermoacoustic insulation segments.

[032] The functional synthetic fiber used is developed to reproduce characteristic properties of natural wool, such as soft touch, elasticity, physiological comfort, heat retention capacity, and balanced hygroscopic behavior. These fibers may have undulations, crimps, or microstructures that favor air trapping and the formation of internal microchambers, increasing the thermal efficiency of the blanket and contributing to the characteristic sensory effect of wool. Sheep's wool is a mandatory component in the formulation and comprises between 40% and 80% by mass, while the synthetic fraction, which varies from 20% to 60% by mass, is composed of both functional fibers and thermosetting fibers, the latter being responsible Petition 870260002672, dated 12 / 01 / 2026, page 22 / 32 9 / 11 due to the structural cohesion of the composite.

[033] The fraction of thermobonded fibers represents at least 20% of the total synthetic fibers and is preferably made up of two-component fibers in a core-clad configuration, in which the cladding has a melting point lower than the core. This configuration allows that, during the thermal consolidation process, only the surface of the thermobonded fiber melts, preserving the integrity of the adjacent fibers and preventing collapse of the porous structure.

[034] The strong core contributes to dimensional stability and mechanical performance, while the partial fusion of the shell creates firm and distributed bonding points along the web. The functional synthetic fraction may include virgin or recycled fibers, such as post-consumer polyester, provided they are compatible with the opening, carding and consolidation process.

[035] The manufacturing process begins with the opening of the fibers, a fundamental step to ensure homogeneous dispersion of wool and synthetic fibers, even when recycled fibers are used. Next, the mixture goes to the automated dosing system, which ensures the exact proportion of each component according to the predefined formulation. The dosed mixture is fed to the carding machine, which untangles, parallelizes, and distributes the fibers, forming a uniform web with a predominantly longitudinal orientation. The web is then conveyed to the transverse folder, where successive layers are superimposed to form a multilayer blanket, whose final basis weight can be adjusted according to the requirements of the desired application.

[036] After the blanket is formed, it undergoes thermal consolidation. During its passage through the oven, adjusted between approximately 80 °C and 150 °C, controlled surface fusion of the thermosetting fibers occurs. This fusion creates three-dimensional bonding points distributed throughout the blanket, generating a stable microstructure that resists delamination, permanent deformation, and compression degradation. The process preserves the volume, soft touch, and resilience of the functional fibers and wool, forming a lightweight, stable, and thermally efficient composite. As the process eliminates Petition 870260002672, dated 12 / 01 / 2026, page 23 / 32 By eliminating 10 / 11 resins, solvents, glues, and other chemical agents, it reduces environmental impact, energy consumption, and effluent generation, creating a cleaner industrial route aligned with sustainability guidelines.

[037] The resulting structure combines the softness and thermal comfort provided by wool with the mechanical strength and stability conferred by the melting points of the thermosetting fibers. The porous microstructure generated by the interaction between wool and functionalized synthetic fibers creates micro air chambers that enhance thermal insulation and reduce heat transmission, favoring the use of the material in applications such as thermal clothing, quilted fillings, bedding products, upholstery, and thermoacoustic insulation solutions. When recycled synthetic fibers are incorporated, the product maintains high technical performance while simultaneously enhancing its sustainable character, contributing to waste reduction and promoting the circular economy.

[038] The synthetic fibers employed can be formulated to reproduce not only the thermal and tactile aspects of wool, but also its functional properties, such as hypoallergenic behavior, low dust retention, reduced tendency to static electricity, and microbiological resistance. Technical literature demonstrates that materials with porous microstructure tend to reduce the fixation of allergenic particles and minimize the accumulation of electrostatic charges. Synthetic fibers such as polyester and polypropylene, being chemically stable and inert, exhibit lower susceptibility to the proliferation of microorganisms, contributing to better hygiene, physiological comfort, and safety of use in products that come into direct contact with the user.

[039] The present invention differs substantially from conventional solutions by allowing the production of a hybrid nonwoven that combines natural wool — traditionally valued for its thermal and sensory properties — with functionalized synthetic fibers and thermosets, generating a material with superior performance and lower environmental impact. The thermal process without chemical additives and the possibility of incorporating synthetic fibers Petition 870260002672, dated 12 / 01 / 2026, page 24 / 32 Recycled 11 / 11 nonwovens reduce the carbon footprint, energy consumption, and volume of waste generated, making the technology highly compatible with sustainable innovation programs and green technology guidelines. Thus, the nonwoven produced according to the present invention constitutes a significant advance in textile engineering, offering high performance, industrial versatility, and environmental benefits aligned with contemporary demands. Petition 870260002672, dated 12 / 01 / 2026, p. 25 / 32

Claims

1 / 3 CLAIMS 1. HYBRID NONWOVEN, characterized by comprising a mixture of natural sheep's wool fibers, structural synthetic fibers and low melting point thermobonding fibers, in which the wool is present between 40% and 80% by mass and the synthetic fibers between 20% and 60% by mass and the thermobonding fibers partially fuse during thermal consolidation, forming three-dimensionally distributed anchoring points that stabilize the heterogeneous fibrous mixture.

2. HYBRID NONWOVEN, according to claim 1, characterized by comprising bicomponent thermobonded fibers with a core-shell structure, in which the shell has a melting point below 130 °C and the core maintains thermal stability above 180 °C.

3. HYBRID NONWOVEN, according to claim 1, characterized by comprising structural synthetic fibers selected from polyester, polypropylene, acrylic, polyamide or combinations thereof.

4. HYBRID NONWOVEN FABRIC, according to claim 1, characterized by having micro air chambers distributed along the fibrous structure, resulting from the interaction between wool and synthetic fibers, conferring thermal insulation and acoustic absorption properties.

5. HYBRID NONWOVEN FABRIC, according to claim 1, characterized by optionally incorporating post-consumer or post-industrial recycled synthetic fibers in adjustable proportions without compromising structural stability.

6. HYBRID NONWOVEN, according to claim 1, characterized by dispensing with the use of resins, adhesives or chemical solvents, being consolidated by partial heat fusion of the thermobonding fibers.

7. HYBRID NONWOVEN FABRIC, according to claim 1, characterized by having adjustable basis weight by varying the number of carded and folded layers. Petition 870260002672, dated 12 / 01 / 2026, page 26 / 32 2 / 3 8. MANUFACTURING PROCESS FOR HYBRID NONWOVEN, as defined in claim 1, characterized by comprising the following steps: (a) opening and disintegration of natural sheep's wool fibers, structural synthetic fibers and, optionally, recycled synthetic fibers; (b) dosing of fibers by an automated system to achieve compositions between 40% and 80% by mass of wool and between 20% and 60% of synthetic fibers; (c) carding of the mixture to form a homogeneous fibrous web; (d) successive folding of the web to form a multilayered mat with adjustable basis weight; (e) thermal consolidation of the mat, promoting partial fusion of the low-melting-point thermobonding fibers; (f) controlled cooling of the mat, solidifying three-dimensional bonding points that stabilize the microstructure of the nonwoven.

9. MANUFACTURING PROCESS FOR HYBRID NONWOVEN FABRIC, according to claim 8, characterized in that the thermal consolidation is carried out between 80 °C and 150 °C, promoting selective fusion of the cladding of the thermobonding fibers.

10. MANUFACTURING PROCESS FOR HYBRID NONWOVEN FABRIC, according to claim 8, characterized in that carding predominantly orients the fibers longitudinally, while folding redistributes layers transversely to ensure structural isotropy.

11. MANUFACTURING PROCESS FOR HYBRID NONWOVEN FABRIC, according to claim 8, characterized by allowing the incorporation of recycled synthetic fibers without the need for prior homogenization of diameter, fineness or length.

12. USE OF HYBRID NONWOVEN FABRIC, as defined in claim 1, characterized by its use in bedding products, apparel, upholstery, furniture fillings, comfort products and thermal and acoustic insulation applications.

13. USE OF HYBRID NONWOVEN FABRIC, according to claim 12, Petition 870260002672, dated 12 / 01 / 2026, p. 27 / 32 3 / 3, characterized by replacing traditional synthetic fillings based on virgin polymers, aiming at reducing the carbon footprint and increasing sustainability in the production chain. Petition 870260002672, dated 12 / 01 / 2026, p. 28 / 32

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