COMPOSITION CONSISTING OF PLANT MATERIAL WITH CELLULOSE, IN PARTICULAR FROM APPLE WASTE PRODUCTS, FOR PRODUCING A LAMINATE AND A METHOD FOR PRODUCING A LAMINATE FROM PLANT MATERIAL WITH CELLULOSE, IN PARTICULAR FROM APPLE WASTE PRODUCTS, AND LAMINATE PRODUCED BY SAID METHOD

Description

[0001] Composition consisting of plant material with cellulose, in particular from waste products of apples, for producing a laminate and a method for producing a laminate from plant material with cellulose, in particular from waste products of apples and laminate produced by said method.

[0002] The present invention relates to a composition consisting of plant material with cellulose, in particular from waste products of apples, for producing a laminate according to the characterizing part of patent claim 1 and a method for producing a laminate from plant material, in particular from waste products of apples according to the characterizing part of patent claim 4 and laminate produced by the said method according to the characterizing part of the patent claims.

[0003] Publication WO 2008 / 012662 describes a composition produced from residues from the fruit industry, particularly from apple processing. The composition described in WO 2008 / 012662 consists of apple powder mixed with an adhesive, particularly a natural adhesive. The composition produced by the described process can be formed into a laminate similar to leather. The problem with the described composition is its difficulty in processing and its low resistance to stress and wear.

[0004] A biodegradable artificial leather product is known from PD 2012 A000 227. This product comprises the following layers in order: a carrier layer made of natural fibers, a middle layer formed by a coagulated foam, and a surface made of polymer, preferably a biodegradable polymer. In particular, the carrier layer is made of fibers, in particular natural fibers, and / or a nonwoven fabric.

[0005] The product manufactured using this process has a surface that is aesthetically and tactilely very similar to leather. Furthermore, primary resources are used.

[0006] JP H04 30442A discloses a composition for producing artificial leather. The resin used in JP H04 30442A is a synthetic resin, and only through the use of the synthetic resin can the desired properties be achieved. A plant protein is also used. To produce plant proteins, the plant material must undergo a series of processes. Furthermore, the use of plant proteins is tied to certain characteristics of the material to be used.

[0007] US 3,607,481 describes a process for producing artificial leather in which the carrier material is impregnated and then, in a second process step, combined with a resin layer.

[0008] US 5 518 764 describes a process for coagulating a textile fabric.

[0009] The object of the present invention is to provide a composition for the realization of a laminate formed from vegetable material fruit powder with cellulose, in particular a process for producing a laminate which comprises residues of the agri-food industry and can be used on an industrial scale and a laminate which is produced by said process and is a laminate which is resistant and can be produced industrially.

[0010] This object can be achieved by a composition according to the invention with a method comprising a first procedure by applying the composition and / or a second procedure by means of a coagulation process.

[0011] The first method according to the invention comprises the following steps: a first step of preparing a textile support structure, a second step in which a composition comprising at least one polymer and a fruit powder from plant residues with cellulose having a grain size of less than 1 mm is applied.

[0012] For the process according to the invention, an additive can be used which consists of at least one polymer, preferably a natural polymer, and of fruit powder from plant residues with cellulose with a moisture content of 1-20% and a grain size which is from 1µ to 450µ.

[0013] The process according to the invention is used to produce a laminate.

[0014] This laminate is similar to leather both in its visual characteristics and in its durability.

[0015] From the point of view of the use of resources, the method according to the invention proposes a more ecological and eco-compatible solution than known from the prior art.

[0016] In a second method, this is achieved through a coagulation process. This industrial process involves impregnating a carrier material, for example, a nonwoven fabric, with a dissolved polymer. This dissolved polymer is polyurethane-based, preferably from a renewable / biological source, for example, a thermoplastic polyurethane.

[0017] This solution produces a foam with a preferential rate of cell formation. This coagulated foam is formed from a composition comprising a thermoplastic polyurethane with an ester / ether / carbonate base and their plasticized blends, cellulose powder, coagulation additives, cellular acetobutyrate, pigments, and water.

[0018] The resulting material is similar to animal leather in appearance, durability, and other characteristics, such as tactile properties. The foaming is achieved through a chemical reaction that is exothermic in a coagulation bath with water.

[0019] Carrying out the process according to the invention requires a high quality standard and the use of specially selected materials. Further features and details of a preferred, non-limiting embodiment of the process of the invention are set forth clearly and explicitly in the following description and with reference to the accompanying figures. They show: Figure 1 a distributor for applying the material, Figure 2 a system according to the invention for processing the material, which Figure 3 a second plant for using a method according to the invention, Figure 4a,4b,4c a laminate according to the invention produced by a first method, and Figure 4d,4e,4fa laminate according to the invention produced by a second process comprising a bath.

[0020] In the Figure 1 Reference numeral 1 denotes a device for applying material to a support layer. According to the invention, a polyurethane solution is applied to a layer of textile material 2, which in a preferred embodiment may be a fabric made of natural fibers, for example, a nonwoven fabric. This polyurethane solution is applied to the fabric carrier 2. This polyurethane solution comprises a powder made of dry or dried fruits with cellulose.

[0021] This fruit powder with cellulose has a moisture content between 1-20%, preferably between 2% and 15%, and a grain size between 1µ-450µ. The use of apple powder is particularly advantageous. Apple powder obtained from industrial processing residues, such as those from the apple juice industry or similar, is particularly preferred.

[0022] In a second step, pigments or other additives are added to create the water-based colors.

[0023] In a third step, additional coagulating additives are applied. To better adhere the applied material to the fabric substrate, an additional layer of composite polymer is applied, consisting of polyurethane polymers in aqueous form, dissolved water-based pigments and inks, or coagulating solvents and coagulating additives.

[0024] A laminate 300 produced by such a process is shown in the Figures 4A, 4b and 4c This laminate 300 comprises Figure 4A a first layer 301 made of polyurethane, preferably biological polyurethane, leveling agents, hardening agents, pigments, binders, etc., and plant material with cellulose. The second layer 303 is made of polyurethane and the plant fruit powder material with cellulose. All of this is applied to the carrier layer 307, which consists of nonwoven fabric, fabric, natural fiber fabric, jersey fabric, polyester fabric, and the like.

[0025] In the Figure 4B Layer 302 is inserted between layers 301 and 303. This layer is constructed similarly to layer 303, but slightly smaller amounts of plant material with cellulose can be used.

[0026] In the Figure 4CLayer 304 is located between layers 301 and 303. This layer can be constructed from foamed or compact materials, which is a composition according to the invention with a higher proportion of plant fruit powder material with cellulose than layer 303.

[0027] In a second method, a fabric carrier, for example a nonwoven fabric made of 100% viscose, is immersed in a solvent which comprises a composition according to the invention, preferably a polymer from a renewable source based on a thermoplastic polyurethane, dried fruit powder with cellulose, preferably powder from residues of the apple industry, other plant materials, various colors and additives for coagulating.

[0028] Polymers from a renewable / biological source are those produced from plants, fruits, seeds, algae or other renewable raw materials.

[0029] The carrier layer according to the invention and the composition according to the invention coagulate after they are immersed in a vat of solvent and form the surface structure. This process has the following advantages: because the composition according to the invention is used, the carrier layer, for example the carrier material, forms a single layer with the composition, thereby bonding the materials, whereas in the first process according to the invention the composition is applied to the carrier layer. The advantage of the first process is that the surface can be better processed and / or structured, for example by a decal / layer, and no solvents are used, whereas with the second process the durability is increased and there is no risk of the two layers separating from one another, i.e. the composition becoming detached from the carrier layer.Both processes produce a product that looks very similar to natural leather.

[0030] All other characteristics such as physical or mechanical properties also allow its use in the above-mentioned area, ie it can be used as a substitute material for leather or leather-like products.

[0031] The method may involve applying a decal / layer to a paper support, on the surface of which a negative relief image is applied. This relief image is applied to the composition according to the invention, thus creating a natural structure.

[0032] By applying polymers based on thermoplastic material, such as biological water-based thermoplastic polyurethane, the surface is refined / embossed.

[0033] Through a system of wiper / stroking elements as in Figure 1shown and a plant 100 with drying oven as in Figure 2 As shown, a film with different layers is obtained, which is always bonded to the carrier 2 using a polyurethane-based adhesive. At the end of the process, the product is separated from the decal / layer. The material is sent through oven 101, where it dries.

[0034] After the decal / layer 102 is removed, the surface structure remains embossed into the material, giving the surface a more natural and thus leather-like appearance. The material thus produced is then rolled up 103.

[0035] A laminate is produced using the process according to the invention. This laminate is an artificial leather comprising the following layers: a first layer as a carrier layer in a fabric made of natural fibers, a second layer which is formed from a composition according to the invention, this composition comprising at least one polymer and a powder of plant residues with cellulose with a grain size not exceeding 1 mm and wherein the plant residues contain less than 20% moisture by weight.

[0036] In the composition, the ratio between plant residues and polymer is such that up to 65% by weight is plant residues and at least 35% by weight is polymer.

[0037] In the Figure 32 shows a coagulation process on a system 200 in which a method according to the invention is used. In particular, in a first step, a carrier layer, for example nonwoven fabric 201, is unwound. Then, a layer according to the invention is applied 202. After that, the material is pre-coagulated in an area 203 and then a composition according to the invention 202 can be applied again. The material with the composition according to the invention then runs through the bath 205, which activates the coagulation. In a subsequent step 206, pressure is exerted on the material several times, for example by rollers, press rollers 204, and the material then runs through several baths 207 to be washed. This helps to wash out the agents that were necessary for the coagulation and / or to wash out unconsolidated parts. After this process, the laminate thus produced is rolled up.

[0038] A laminate 310 produced by such a method is shown in the Figures 4D, 4E, 4F and 4G This laminate 310 comprises Figure 4D a first layer 301 of polyurethane, preferably biological polyurethane, leveling agents, hardening agents, pigments, binders, etc., and of plant material with cellulose.

[0039] All this is applied to the carrier layer 309 which consists of nonwoven fabric, fabric, natural fabric, fabric, fabric made of natural fibers, jersey fabric, fabric made of polyester and the like and which is bonded to the layer according to the invention by the coagulation process.

[0040] The Figure 4E said laminate 310 comprises a first layer 301 of polyurethane, preferably biological polyurethane, agents to facilitate leveling, agents for hardening, pigments, binders, etc. and of the vegetable fruit powder material with cellulose.

[0041] The second layer 303 is made of polyurethane and the plant material with cellulose. All of this is applied to the carrier layer 309, which consists of nonwoven fabric, fabric, natural fiber fabric, jersey fabric, polyester fabric, and the like, and which bonds to the inventive layer through the coagulation process.

[0042] In the Figure 4F Layer 302 is inserted between layers 301 and 303. This layer is constructed similarly to layer 303: slightly smaller amounts of plant fruit powder material with cellulose can be used.

[0043] In the Figure 4G Layer 304 is located between layers 301 and 303. This layer can be made of foamed or compact material which has a composition according to the invention with a higher proportion of plant material with cellulose than layer 303.

[0044] The variants of the method and device described above serve only to better understand the structure, mode of operation, and properties of the solution presented; they do not limit the disclosure to the exemplary embodiments. The figures are schematic, with key properties and effects sometimes shown significantly enlarged to clarify the functions, operating principles, technical configurations, and features. Each mode of operation, principle, technical configuration, and feature disclosed in the figures or in the text can be freely and arbitrarily combined with all claims, each feature in the text and in the other figures, and other modes of operation, principles, technical configurations, and features contained in or resulting from this disclosure, so that all conceivable combinations can be attributed to the solution described.This also includes combinations between all individual embodiments in the text, i.e. in every section of the description, in the claims, and also combinations between different variants in the text, in the claims, and in the figures. The device and method details explained above are presented in context; however, it should be noted that they are also independent of one another and can be freely combined with one another. The relationships of the individual parts and sections thereof to one another, and their dimensions and proportions shown in the figures, are not to be understood as restrictive. Rather, individual dimensions and proportions may differ from those shown. The claims also do not limit the disclosure and thus the possible combinations of all the features shown with one another. All features shown are explicitly disclosed here, both individually and in combination with all other features.

Claims

1. Composition for forming artificial leather comprising at least one polymer and plant powder from plant residues containing cellulose with a particle size of 1 µ to 450 µ and a moisture content of between 1-20% by weight, wherein the polymer is polyurethane and the plant residues are fruit powder containing cellulose with a particle size of 1 µ to 450 µ and a moisture content of between 1 and 20%.

2. Composition according to claim 1, characterised in that the plant residues with cellulose are apples with a particle size of 1 µ to 450 µ.

3. Composition according to claim 2, characterised in that the polyurethane is made from biological material.

4. Composition according to one of the preceding claims 1-2, characterised in that the ratio of plant residues to polymer is such that up to 65% by weight consists of plant materials and at least 35% by weight consists of polymer.

5. Method for producing a laminate made of biodegradable artificial leather, characterised in that it comprises a composition according to one of claims 1-2 and the following steps: First step: preparation of a first layer of a fabric carrier, second step: application of a composition according to one of claims 1-2, third step: levelling the composition applied to the carrier and drying the composition.

6. Method according to claim 4, characterised in that a decal / layer is applied to the side of the layer formed by the composition opposite the fabric carrier side.

7. Method according to claim 4 or 5, characterised in that the carrier material is a non-woven fabric.

8. Method according to claim 5 or 6, characterised in that the decal / layer has a negative structure / relief.

9. Process for producing a laminate made of biodegradable artificial leather, characterised in that it comprises a composition according to one of claims 1-2 and the following steps: first step: preparation of a first layer of a fabric carrier, second step: application of a composition according to one of claims 1-2, third step: coagulating and drying the composition.

10. Method according to claim 8, characterised in that the carrier material is a non-woven fabric.

11. Composite laminate of biodegradable artificial leather comprising the following layers: a first layer as a carrier layer made of fabric from fibres, preferably natural fibres, a second layer in a composition of at least one polymer which is polyurethane and powder from plant residues with cellulose with a grain size of 1 µ to 450 µ, wherein the plant residues have a moisture content of less than 1-20% by weight and wherein the plant residues are fruit powders with a particle size of 1µ to 450µ and a moisture content of between 1-20%.