A method for manufacturing a nonwoven fabric and a nonwoven fabric

Abstract

The invention provides a method for manufacturing a nonwoven fabric, comprising: i) applying a dispersion layer comprising a dispersion medium and biobased first fibers (110) on a support, wherein the biobased first fibers (110) are fibers derived from a microorganism cultivated in a liquid medium, and wherein, prior to said applying, a plasticizer has been added to the dispersion; ii) depositing reinforcing second fibers (120) on the dispersion layer, wherein the reinforcing second fibers (120) are individual fibers that do not belong to a textile, and wherein the average length of the second fibers is 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 biobased first fibers (110). Also provided is a nonwoven fabric and a seamless product comprising such a nonwoven fabric.

Description

Technical Field

[0001] This invention relates to a method for manufacturing nonwoven fabrics. Background Technology

[0002] Nonwoven fabrics are well-known and widely used as a durable material in disposable diapers and surgical gowns, as well as in windproof hoods and raincoats.

[0003] Nonwoven fabrics can be produced by various methods, such as wet-laying. In wet-laying, a dispersion of fibers in a dispersion medium is applied to the surface of a support, after which the dispersion medium is removed, and the fibers form a web. The fabric conforms to the shape of the support, thus, in the case of a three-dimensional support with a desired shape, the nonwoven fabric has said desired shape without cutting and sewing. Nonwoven fabrics can also have surface structures, for example, if an embossed support is used.

[0004] Nonwoven fabrics can be made from a variety of materials, such as synthetic fibers including polyethylene, but fabrics based on natural materials are preferred, including their tactile (skin-feeling) properties.

[0005] Nonwoven fabrics made from bio-based fibers (i.e., fibers derived from biological (i.e., natural) sources) are known in the art, but they may lack the desired strength and / or durability. In, for example, WO 2020 / 006133 A1, a second material is embedded in the bio-based fiber matrix in the form of a woven fabric layer to provide strength to the bio-based fibers. However, according to WO 2020 / 006133 A1, the growth of bio-based fibers in the form of a fungal matrix into the woven fabric layer is a time-consuming and difficult-to-control process, and requires the bio-based fibers to remain active during the nonwoven fabric production process.

[0006] CA 2718435 A1 teaches the application of fibers in an isotropic orientation, wherein the fibers are transverse to the orientation of the product material. These transversely oriented fibers are intended to provide a specific hand feel but do not substantially contribute to the strength of the product material, and in particular, these fibers do not form a fiber web. Summary of the Invention

[0007] The object of this invention is to provide, in a simple manner, bio-cellulose-based nonwoven fabrics with enhanced strength and / or durability without impairing skin feel.

[0008] Therefore, according to a first aspect, the present invention provides a method comprising the following steps:

[0009] i) Apply a dispersion layer containing a dispersion medium and a bio-based first fiber onto the support;

[0010] ii) Depositing a reinforced second fiber on the dispersion layer, wherein the reinforced second fiber is a separated fiber; and

[0011] iii) Remove the dispersion medium to form a nonwoven fabric comprising a bio-based first fiber web.

[0012] In this way, the nonwoven fabric based on the bio-based first fiber provides enhanced strength, while

[0013] - It basically maintains the simplicity of the method.

[0014] - Essentially maintains the skin feel of the non-woven fabric facing the support.

[0015] The second fiber is typically coated as a whole, for example, as a suspension, using a brush or by spraying. In this application, separate fibers mean that they are individual fibers. Therefore, they are not part of a fabric, whether it is a woven fabric, a nonwoven fabric, or a fabric in which fibers are interconnected by glue or heat (fiber melting) or by adding adhesives or crosslinking agents.

[0016] At most, a portion of the dispersion medium can be removed before the application of the second fiber to allow the second fiber to embed within the wet matrix of the first fiber. Removal typically involves drying, for example, by passing dry air through the surface of the dispersion layer, taking care not to blow it away. The air can be heated air. In this way, the redistribution or dripping of the dispersion applied in step i) under gravity is reduced. Therefore, irregularities formed, for example, by dispersion dripping can be reduced, and the production of nonwoven fabrics on non-horizontal surfaces can be facilitated.

[0017] It is known in the art to manufacture nonwoven fabrics with enhanced strength through chemical treatment or modification of bio-based fibers or nonwoven fabrics. Such treatment may reduce the expected performance of the nonwoven fabric in terms of skin feel. If the chemical treatment or modification requires undesirable chemicals, the present invention allows for their avoidance. Reducing or even eliminating the use of chemicals makes the method more sustainable.

[0018] The nonwoven fabric can be produced after step iii) without the additional step of interconnecting the first fibers after forming the web. This reduces the workload of producing the nonwoven fabric by avoiding chemical bonding, thermal bonding, mechanical bonding, or any other steps required to connect the first fibers to each other.

[0019] In this application, the term bio-based first fiber includes refined bio-based first fibers, such as mycelium, cellulose, etc., but also includes chemically produced or processed bio-based first fibers, such as viscose or lyocell.

[0020] The first fiber is preferably dispersed in an aqueous dispersion medium. However, the dispersion fluid can be any fluid suitable for a wet process and can be based on other volatile liquids, such as alcohols like methanol, ethanol, or propanol, any other organic volatile fluid, or combinations of these liquids, such as water and ethanol. In this way, the elimination of the dispersion medium can be facilitated, or the first fiber can be dispersed more effectively in the dispersion medium. Preferably, the dispersion medium is non-toxic and / or natural and / or environmentally friendly.

[0021] 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.

[0022] In one embodiment, after step iii), the first fiber accounts for 20-80% of the weight of the nonwoven fabric; the second fiber accounts for 1-40% of the weight of the nonwoven fabric; and the plasticizer accounts for 5-50% of the weight of the nonwoven fabric, wherein the combined weight percentage of the first fiber, the second fiber and the plasticizer is at least 65%, preferably at least 80%, of the weight of the nonwoven fabric; and wherein the weight percentage of the second fiber is less than the weight percentage of the first fiber.

[0023] Preferably, the diameter of the first fiber is 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, after the dispersion medium is eliminated, the surface of the mesh facing the support structure has a smooth texture.

[0024] The reinforcing second fiber may be i) a fiber having a higher tensile strength than the first fiber, and / or ii) a fiber with an average length at least 3 times, preferably at least 10 times, the average length of the first fiber.

[0025] Typically, the second fiber has a cylindrical cross-section, but it can also be flat, curved, bent, or any other elongated form. The method can also be carried out with a second fiber in which the circumferential surface of the second fiber is microfibrilated. In this way, the strength and / or durability of the fiber web can be improved.

[0026] The diameter of the second fiber is preferably less than 100 micrometers, more preferably in the range of 15 to 50 micrometers. In this way, the second fiber provides strength to the nonwoven fabric, but also allows for a more uniform distribution of the first fiber.

[0027] The second fiber is preferably at least 0.3 mm long, more preferably at least 2 mm, even more preferably at least 5 mm, and most preferably at least 10 mm long. In this way, the strength and durability of the nonwoven fabric produced according to the method are improved.

[0028] In a plane parallel to the projection of the mesh surface, the second fiber typically covers 10%-90% of the total surface area of ​​the first fiber located in that plane, preferably 20%-75%, and more preferably 30%-50%.

[0029] The second fiber can be added, for example, through flocking, air-laying, fiber spinning, or electrospinning. In this way, the distribution of the second fiber can be precisely controlled, and different properties can be provided to the nonwoven fabric by using different deposition techniques in different parts of the nonwoven fabric.

[0030] The surface of the support can be a flat surface, but it can also be a three-dimensional or structured surface. In this way, two-dimensional sheets, three-dimensional meshes, or structured meshes can be produced. The surface of the support can be provided by the surface of the mold, but it can also be the surface of a mesh previously formed on the mold, whether or not it is formed by the method according to the invention. The mold can be, for example, a human torso.

[0031] The nonwoven fabric can be removed from the support, but this is not necessary if you want to use the nonwoven fabric as a support, i.e., if the nonwoven fabric is part of the product. If the nonwoven fabric is to be removed from the support, the support typically has surfaces that facilitate fabric removal (choosing not to over-adhere to the fabric). The opposite is true if it is part of the product.

[0032] According to an advantageous embodiment, the dispersion layer in step i) is applied by spraying.

[0033] Spraying dispersions allows for more controlled application of the dispersion layer and the first fiber, resulting in higher quality nonwoven fabrics. For example, the risk of bubble formation is lower, leading to a more uniform and consistent dispersion layer, thus resulting in higher quality nonwoven fabrics.

[0034] According to an advantageous embodiment, step i) is preceded by the following steps:

[0035] - Provides a dispersion of a bio-based first fiber, wherein the first fiber is dispersed in a dispersion medium, and

[0036] - Remove at least a portion of the dispersion medium to form a web on the support; the step is performed at least once, and step i) includes applying the dispersion layer to the web.

[0037] In this way, thicker nonwoven fabrics can be produced with well-controlled thickness, and the second fiber protrudes to the side of the fabric facing the support, thereby reducing the risk of delamination of the nonwoven fabric. The dispersion medium is typically eliminated by evaporation, which can be promoted by heating and / or supplying dry air.

[0038] Furthermore, this embodiment facilitates the manufacture of nonwoven fabrics in a non-horizontal direction because relatively thin layers can be applied and dried in stacks to achieve the desired thickness of the nonwoven fabric, rather than applying a relatively thick layer all at once. Typically, this step is performed at least twice, preferably at least five times, and more preferably at least ten times.

[0039] According to an advantageous embodiment, the method further includes a step between steps ii) and iii) of applying another dispersion layer on top of the dispersion layer, the other dispersion comprising another dispersion medium and a bio-based third fiber.

[0040] In this way, the method provides another mesh that provides the skin feel determined by the last applied bio-based third fiber to the back side of the fabric.

[0041] The strength of the fabric can be improved by better embedding the second fiber.

[0042] The additional dispersion medium of the other dispersion can be the same as the dispersion medium or have a different composition. Furthermore, the bio-based third fiber can be the same fiber as the first or second fiber, or it can be a fiber with different properties, such as antibacterial or skin-care properties.

[0043] According to a particularly preferred embodiment, the bio-based first fiber is a fiber derived from microorganisms cultured in a liquid culture medium.

[0044] This makes it possible to bypass the production of plant-based fibers, which typically requires large tracts of land, pesticides, and expensive harvesting, followed by extensive fiber processing. Instead, the growth of microorganisms such as mycelium in a bioreactor can be carried out efficiently, and the mycelium can be harvested simply (e.g., by filtration), or even without a harvesting step, with the liquid culture medium serving as the dispersion medium. Optionally, the mycelium can be diluted or resuspended in the dispersion medium (water) and then prepared to form a nonwoven fabric.

[0045] Microorganisms can be, for example, fungi, protozoa, bacteria, or algae.

[0046] Alternatively, instead of being derived from microorganisms, the first fiber may include bio-based materials derived from fungal mycelium, yeast, algae, bacteria, cultured animal or plant cells, and animal and / or plant cells cultured in a liquid culture medium. The cultured animal or plant cells may, for example, be cultured in a bioreactor.

[0047] According to an advantageous embodiment, the bio-based first fiber is in the form of a biomaterial selected from: fungal mycelium, yeast, algae, bacteria, cultured animal or plant cells, fibers derived from animal and / or plant cells cultured in a liquid culture medium, fruit pulp, leaf pulp, stem pulp, leather fibers, collagen, and / or any of the aforementioned materials in a micronized and / or microfibrillated form.

[0048] In this way, the resources used to form the network are cheap and readily available.

[0049] According to an advantageous embodiment, the bio-based first fiber is not chemically treated.

[0050] In this way, the production of nonwoven fabrics can be faster and safer because no chemical treatment or modification is required. Suitable biomaterials can be, for example, harvested fungal mycelium, algal material, bacteria, cultured animal or plant cells, fibers derived from animal and / or plant cells cultured in liquid media, pulping plant materials such as pulping fruits, leaves and / or stems, and fibers derived from collagen. Biomaterials can also be micronized and / or microfibrilized, thereby increasing fiber hairiness and enhancing their interlocking ability.

[0051] According to an advantageous embodiment, the second fiber is selected from natural fibers, regenerated fibers, recycled fibers, synthetic fibers, functional fibers, or any combination thereof, and preferably the second fiber is hydrophilic.

[0052] In this way, a second fiber can be selected to provide the desired properties to the nonwoven fabric. If the nonwoven fabric needs to be biodegradable and can be extracted from plant materials (such as wood, grass, leaves, cellulose) or animal materials (such as wool, mohair, cashmere, angora, silk, spider silk), natural fibers can be used. However, mineral materials such as chrysotile, asbestos, crocidolite, tremolite, anthocyanin, and actinolite can also be used as the second fiber. Preferably, the fiber is a natural fiber. Regenerated fibers can be used for the same purpose and can be made from materials such as viscose, lyocell, cellulose acetate, Azlon, or any other modified cellulose. Furthermore, regenerated fibers that are too short can be used, and these fibers must be discarded to produce woven fabrics. Synthetic fibers can reduce the cost of nonwoven fabrics; suitable synthetic fibers can be made from materials such as polypropylene, polyester, elastic fibers, polyvinyl chloride, etc. By using a second fiber made from aramid, liquid crystal polymer (LCP), carbon fiber, glass fiber, and metal fiber, special properties can be provided to nonwoven fabrics, such as resistance to environmental conditions such as abrasion, tearing, and / or higher temperatures. Fibers with special properties endow the produced nonwoven fabrics with electrical or conductive properties, thus providing users with practical applications such as protection or measurement of biological functions like heart rate or muscle function. Any blend of these materials can be used to impart a variety of properties. Hydrophilic fibers offer better adhesion to primary bio-based fibers.

[0053] According to an advantageous embodiment, the second fibers are added isotropically relative to each other.

[0054] The isotropic orientation of the second fibers relative to each other can be achieved, for example, by combing the second fibers prior to step ii). The resulting isotropically oriented second fibers can be applied manually in step ii) or by using, for example, a robot in a direction parallel to the support. In this way, the isotropic orientation of the second fibers provides improved strength to the nonwoven fabric when the second fibers are added to the dispersion layer.

[0055] CA2718435A1 also applies a second fiber in an isotropic orientation; however, these fibers are oriented transversely to the support and therefore do not substantially affect the strength of the nonwoven fabric.

[0056] According to an advantageous embodiment, the second fibers are added anisotropically relative to each other.

[0057] This can be achieved, for example, by electrostatic flocking, in which an electric charge is applied to the support while the second fiber is being added. This causes at least a portion of the second fiber to be oriented perpendicular to the support. After the charge is removed, the at least partially perpendicularly oriented second fiber will fall off and adopt an orientation parallel to the support but random relative to each other. This anisotropic orientation can improve the softness of the nonwoven fabric.

[0058] According to an advantageous embodiment, a plasticizer is added to the dispersion prior to step i), wherein 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.

[0059] The addition of plasticizers makes the resulting nonwoven fabrics more durable. Plasticizers protect nonwoven fabrics from becoming brittle, fragile, and / or stiff. Examples of plasticizers are glycols, triacetin, polymeric polyols, and soapberry compounds, but also include complex compositions such as honey, molasses, aloe vera, castor oil, glycerides, triglycerides, and other mineral or organic oils or any combination thereof.

[0060] According to an advantageous embodiment, after all other steps, a coating is applied to at least one exposed surface of the nonwoven fabric, preferably all exposed surfaces.

[0061] The coating can be, for example, a flexible, protective, and / or reinforcing coating. In this way, the durability of the nonwoven fabric can be improved by retaining the dispersion medium and / or plasticizer within the nonwoven fabric after consolidation of the fiber web and / or additional fiber webs. The coating can be biodegradable and / or UV resistant, and optionally includes colored pigments.

[0062] According to an advantageous embodiment, the method includes the step of applying and adhering at least one component to a web.

[0063] In this way, additional functions can be embedded in nonwoven fabrics. Components such as technical elements, like LED lighting, sensors, RFID tags, or NFC chips, or decorative elements such as sequins, beads, ropes, appliqués, and lace, can be directly integrated without gluing, sewing, or otherwise attaching components to the nonwoven fabric, thereby reducing the cost and number of steps in the production process of reinforced nonwoven fabrics.

[0064] According to an advantageous embodiment, the method includes a dyeing step. This step is typically performed prior to step ii), for example by mixing dyes and / or pigments in a dispersion applied in step i).

[0065] Preferably, in this step, the dye and / or pigment are applied together with at least one selected from the first and second fibers. In this way, the dye and / or pigment are absorbed into the fabric along with the fibers, avoiding a separate dyeing step. In particular, additional liquid may not be required to mix the dye and / or pigment into the fabric. The dye and / or pigment are embedded in the fabric, making the dye less susceptible to damage during fabric use.

[0066] Furthermore, there is no longer a need to wash textiles to remove excess dye, which is typically a laborious step in the production of state-of-the-art textiles.

[0067] In one embodiment, step ii) is completed within 2 hours, preferably within 0.5 hours, after the start of step i). Therefore, steps i) and ii) of the method of the present invention can be performed quickly, especially without waiting for fungal cells or the like to provide the first fibers.

[0068] In one implementation, step iii) is performed and completed within 72 hours of the start of step ii), preferably within 5 hours. In particular, in conjunction with the preceding embodiments, this can allow the production of nonwoven fabric within 4 days.

[0069] According to a second aspect, the present invention relates to nonwoven fabrics, wherein the nonwoven fabric can be obtained by the method described above. Preferably, the nonwoven fabric has a seamless circumferential surface.

[0070] According to a third aspect, the present invention provides a nonwoven fabric, preferably obtained using the method of the present invention, comprising a bio-based first fiber and a reinforcing second fiber, wherein the first and second fibers are irreversibly embedded in a matrix containing a plasticizer; wherein the bio-based first fiber is a fiber derived from microorganisms cultured in a liquid culture medium, and wherein the average length of the second fiber is at least 10 times the average length of the first fiber.

[0071] In addition to plasticizers, the matrix typically contains some moisture, such as from the dispersion medium that may have been used in step i) of the method for which protection is sought.

[0072] In one embodiment, the plasticizer comprises an amorphous matrix, including hydrochloric acid and polyol.

[0073] In a preferred embodiment, the first fiber accounts for 20-80% of the weight of the nonwoven fabric; the second fiber accounts for 1-40% of the weight of the nonwoven fabric; and the plasticizer accounts for 5-50% of the weight of the nonwoven fabric; wherein the combined weight percentage of the first fiber, the second fiber, and the plasticizer is at least 65%, preferably at least 80%, of the weight of the nonwoven fabric; and wherein the weight percentage of the second fiber is less than the weight percentage of the first fiber.

[0074] In one embodiment, oil droplets and / or fat droplets are embedded in a matrix, the maximum diameter of which is in the range of 1 µm to 20 µm. For example, the oil droplets may comprise dried or non-dried oil. Optionally, a desiccant may also be included in the matrix.

[0075] According to a fourth aspect, the present invention provides a molded seamless garment, accessory, or footwear, or any other three-dimensional seamless nonwoven product, comprising the nonwoven fabric of the second or third aspect and / or a nonwoven fabric produced according to the first aspect of the present invention. Therefore, the present invention provides seamless clothing, accessories, footwear, or other products. Attached Figure Description

[0076] The invention will now be described with reference to the following example section and the accompanying drawings, wherein...

[0077] Figure 1 A schematic diagram of the cross-section of a nonwoven fabric is shown;

[0078] Figure 2A-2C Schematic diagrams of another embodiment of the nonwoven fabric according to the present invention, and its first and second details are shown respectively;

[0079] Figures 3A-3C Schematic diagrams of yet another embodiment of the nonwoven fabric according to the present invention, and their first and second details, are shown respectively; and

[0080] Figure 4 An embodiment of a nonwoven fabric in the form of a bag is shown, which has a three-dimensional non-planar shape and is manufactured according to the method of the invention. Detailed Implementation

[0081] Figure 1 A schematic cross-section of a nonwoven fabric 100 comprising a first fiber 110 and a second fiber 120 produced according to the present invention is shown. The first fiber 110 is derived from cultured mycelium and dispersed in a dispersion medium. A first layer of dispersion comprising the first fiber 110 is applied to a support, and the second fiber 120 is added to the dispersion layer. A second dispersion layer is added on top of the first dispersion layer, and the dispersion medium is removed by evaporation at room temperature. In the resulting nonwoven fabric, the first fiber 110 exists as a continuous fiber web, with no distinguishable boundary between the first fiber 110 applied to the first dispersion layer and the first fiber 110 applied to the second dispersion layer. The second fiber 120 is embedded in the continuous web of the first fiber 110.

[0082] To produce nonwoven fabric, fungal biomass in the form of *Schizophyllum commune* mycelium from the basidiomycete group was grown in 1 liter of Duran Erlenmeyer medium in standard malt extract. The growth procedure followed standard culture procedures at 30°C and 200 rpm. The mycelium was harvested via Buchner filtration. Citric acid and sorbitol were premixed with water and subsequently added to the harvested mycelium and the remaining growth medium to form a dispersion containing the first fibers.

[0083] In step a), the dispersion is sprayed onto the solid and 3D shaped support surface using a sprayer for spraying coatings, thus coating the mold with a first layer of the dispersion. In step b), the dispersion medium is removed by evaporation at room temperature. The dispersion medium is evaporated until a contact-dry mycelial (MYC) network forms on the support.

[0084] Steps a) and b) are repeated again. Then, in step c), another layer of dispersion is applied on top of the web. In step d), individual second fibers (e.g., 100 dtex polyamide (PA) or 28 dtex carded rayon (CV)) are applied to the fabric by flocking with FK1-PRO, while simultaneously applying carded linen (LI) by hand. For example, the rayon fibers are 12 mm long and have a circular circumferential surface between the ends. In a plane parallel to the surface projection of the second fiber web, the area of ​​the first fibers covered by the second fibers is 30-50%.

[0085] Then repeat steps a), b), c), and d) twice, and finally execute steps a) and b) once.

[0086] The resulting nonwoven fabric is removed from the mold. In the cross-section of the nonwoven fabric, no individual fiber web or first fiber is distinguishable; instead, it presents as a single fiber web of the first fiber, with the second fiber embedded within this single fiber web. The second fiber does not exist as a distinct continuous layer in the nonwoven fabric. Instead, the second fibers applied in the same step are substantially aligned with either outer surface of the nonwoven fabric and can contact each other, and can be aligned and intersected at different angles.

[0087] Tensile strength and peak force were measured on each nonwoven fabric to assess the effect of the second fiber on the nonwoven fabric. Tensile strength and peak force were measured according to EN13934-01, but the size of the tested samples was 4 x 4 cm. The experiment could be performed as a single experiment or repeated. As a control, a nonwoven fabric made entirely of mycelium was used.

[0088] Table 1 shows the effects of various second fibers on tensile and peak forces.

[0089]

[0090] The peak force produced by adding the second fiber is 1.6-6.8 times higher than that of nonwoven fabric made of pure mycelium, indicating that adding the second fiber gives the nonwoven fabric strength.

[0091] In addition, a panel of five people evaluated the skin feel of nonwoven fabrics, independently assessing that nonwoven fabrics containing a second fiber had the same skin feel as nonwoven fabrics derived from pure mycelium.

[0092] Figure 2AA schematic cross-sectional view of another nonwoven fabric 200 is shown, which includes a first bio-based fiber 210 and a second reinforcing fiber 220 produced according to the present invention. In cross-section, the fabric 200 has an upper outer surface 201 and a lower outer surface 202 disposed between the first and second fibers. Although in the example shown, the first and second fibers are embedded in a single molten layer, it should be understood that the nonwoven fabric may comprise a stack of multiple molten layers of first and third fibers. The first fiber forms a web reinforced by the second fiber.

[0093] Figure 2B Showing Figure 2A The details of section II-B, which shows the first fiber 210 and the second fiber 220 in more detail, are shown below. It can be seen that the first fiber is several orders of magnitude smaller than the second fiber 220. In the example shown, Figure 2C The first fiber 210, shown in more detail, has an average diameter of approximately 2 µm, while the second fiber 220 has an average diameter of 100 µm. It can be seen that the larger second fiber 220 is substantially aligned with the upper and lower outer surfaces 201, 202, such that its centerline is substantially parallel to these surfaces 201, 202. The much smaller first fiber 210 is substantially randomly oriented and substantially not aligned with the first and second outer surfaces.

[0094] The first and second fibers are embedded in a matrix 230 containing a plasticizer. This matrix 230, in addition to helping to hold the first and third fibers substantially in place, provides a degree of flexibility to the nonwoven fabric, allowing it to be bent or folded without damaging it. The plasticizer preferably comprises 5–50% by weight, more preferably 15–30% by weight of the finished nonwoven fabric, and preferably a mixture of polyols (such as sorbitol) and α-hydroxy acids (such as citric acid).

[0095] Figure 3A A schematic cross-sectional view of another nonwoven fabric 300 according to the invention is shown. In addition to the bio-based first fiber 310 and second reinforcing fiber 320 embedded in the matrix 330, the matrix 330 includes a plasticizer and, optionally, any remaining dispersion medium. Oil droplets 340 embedded in the matrix 330 are further shown, which can have various sizes, with the maximum diameter of each droplet typically ranging from 1 µm to 20 µm. The oil droplets 340 can be used for delayed, controlled, or controlled release of beneficial fat-soluble components, and in this embodiment include aloe vera oil, which provides a pleasant odor. The oil droplets 340 typically have an average diameter larger than the average length of the first fiber, for example, at least 5 times larger than the average length of the first fiber 310.

[0096] Figure 4A perspective line drawing of a nonwoven fabric 400 according to the present invention is shown, which is formed in a non-planar shape, here in the form of a handbag. The nonwoven fabric 400 is manufactured by applying a layer of dispersion to a non-planar support (not shown) having the positive shape of the nonwoven fabric. This layer is typically applied by spraying the dispersion onto a non-planar 3D surface of the support and / or by applying the dispersion to the support using a brush. After applying a dispersion layer comprising a dispersion medium, a first bio-based fiber, and a plasticizer, a layer of reinforcing second fiber is deposited onto the dispersion layer, and then both layers are dried to form the nonwoven fabric 400. The nonwoven fabric 400 includes a circumferential surface 401 provided with ridges 402 and recesses 403. In this embodiment, the dispersion layer is applied to a flexible support, and after applying the second fiber and removing the dispersion medium to form the nonwoven fabric 400, the flexible support is folded and removed from the inside of the fabric 400. Those skilled in the art will appreciate that, additionally or alternatively, one or more supports may be used to form positive or negative shapes, for example, in a manner similar to casting molds used in casting processes, to allow easy removal of the nonwoven fabric from the supports. By using one or more supports, the final product can be produced without seams or glued joints, etc.

Claims

1. A method for manufacturing a nonwoven fabric (100), wherein the method comprises the following steps: i) Apply a dispersion layer comprising a dispersion medium and a bio-based first fiber (110) to a support, wherein the bio-based first fiber (110) is a fiber derived from microorganisms cultured in a liquid culture medium, and wherein a plasticizer has been added to the dispersion prior to the application. ii) Depositing a reinforcing second fiber (120) on the dispersion layer, wherein the reinforcing second fiber (120) is a separate fiber not belonging to the fabric, and wherein the average length of the second fiber is at least 10 times longer than the average length of the first fiber; and iii) Remove the dispersion medium to form a nonwoven fabric (100) comprising a web of bio-based first fibers (110).

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

3. The method of claim 1, further comprising removing the nonwoven fabric from the support.

4. The method according to claim 1, wherein the plasticizer is a sugar alcohol, a polyol, a polyester, and / or an α-hydroxy acid, or a combination thereof.

5. The method of claim 4, wherein the plasticizer comprises a combination of sorbitol and citric acid.

6. The method according to claim 1, wherein the plasticizer comprises one or more of ethylene glycols, triacetin, polymeric polyols, soapberry, honey, molasses, aloe vera, castor oil, glycerides, and other mineral or organic oils.

7. The method of claim 1, wherein step i) is preceded by the following steps: - Provides a dispersion of a bio-based first fiber (110), wherein the first fiber (110) is dispersed in a dispersion medium, and - Remove at least a portion of the dispersion medium to form a web on the support; the step is performed at least once, and step i) includes applying the dispersion layer to the web.

8. The method of claim 1, wherein the method further comprises the step between steps ii) and iii): applying another dispersion layer on top of the dispersion layer, the other dispersion layer comprising another dispersion medium and a bio-based third fiber.

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

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

11. The method of claim 1, wherein the concentration of the first fiber in the dispersion is at least 0.1% w / v.

12. The method of claim 1, wherein the method includes the step of applying and adhering at least one component to the net.

13. The method of claim 12, wherein the at least one component is selected from LED lighting, a sensor, an RFID tag, an NFC chip, or a decorative element; The at least one component is embedded in the nonwoven fabric without having to glue or sew the component to the nonwoven fabric.

14. The method of claim 1, wherein the method further comprises a staining step.

15. The method of claim 14, wherein the dye or pigment is applied together with at least one fiber selected from the first and second fibers.

16. The method of claim 1, wherein the support has a three-dimensional non-flat surface.

17. 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) described therein is a fiber derived from microorganisms already cultured in a liquid culture medium, and wherein The average length of the second fiber is at least 10 times longer than the average length of the first fiber; When viewed in cross-section of the nonwoven fabric, the bio-based first fiber appears as a continuous web, with the second fiber embedded in the continuous web between the upper outer surface (201) and the lower outer surface (202) of the nonwoven fabric. The second fiber reinforces the continuous network of the bio-based first fiber.

18. The nonwoven fabric (100) of claim 17, wherein the first and second fibers are embedded in a molten layer, wherein the nonwoven fabric comprises a stack of a plurality of molten layers of the first and second fibers, wherein the first fiber forms a web reinforced by the second fiber.

19. The nonwoven fabric according to claim 17 or 18, wherein oil droplets and / or fat droplets are embedded in the amorphous matrix, and the maximum diameter of the oil droplets is in the range of 1 µm to 20 µm.

20. A nonwoven fabric (100), wherein the nonwoven fabric (100) is obtained by the method according to claim 1.

21. The nonwoven fabric according to claim 17 or 20, wherein the plasticizer is formed from α-hydroxy acid and polyol.

22. The nonwoven fabric according to claim 17 or 20, wherein... The first fiber accounts for 20-80% of the weight of the nonwoven fabric; The second fiber comprises 1-40% by weight of the nonwoven fabric; and The plasticizer accounts for 5-50% of the weight of the nonwoven fabric. The combined weight percentage of the first fiber, the second fiber, and the plasticizer is at least 65% of the weight of the nonwoven fabric; and The weight percentage of the second fiber is less than the weight percentage of the first fiber.

23. A molded seamless garment, accessory, or footwear to be worn, or any other three-dimensional seamless nonwoven product, including the nonwoven fabric as described in claim 17 or 20.

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