Alpaca fibre-based product as a filling material for garments and method for producing same

Abstract

The present invention is aimed at an alpaca fiber-based product as a filling material for garments, wherein alpaca fiber is in a proportion between 40% and 75% and synthetic fibers in a proportion between 25% and 60%, wherein the synthetic fibers are virgin polyester, low melt polyester, recycled polyester, recovered fiber or mixtures thereof. The invention also includes the process for obtaining the alpaca fiber-based product as a filling material and garments containing them.

Description

TECHNICAL FIELD

[0001] The present invention relates to the technical field of the textile industry, mainly in the field of thermal materials for garment fillings that allow thermal insulation.STATE OF THE ART

[0002] The fast fashion industry has been classified by the UN as an environmental emergency. Within this industry, the outdoor clothing category is one that shows rapid growth and, only in the United States, the market is 119 billion dollars, which represents approximately 35% of the global market and within this category the most consumed product is coats (overcoats, jackets, parkas, etc.).

[0003] In coats with padding, there are two options: those filled with synthetic fibers (polyester) or those filled with animal supplies (feather). In both cases, the inputs are necessary to achieve thermal insulation. On the one hand, there are coats with synthetic filling that, although their performance is good, have their counterpart of being inputs that come from hydrocarbons and also generate micro plastic and a high consumption of water in their production processes. In the case of those that use fillers from animal inputs (feathers), it has triggered a series of complaints of animal abuse and exploitation.

[0004] In relation to filling materials, lately there has been a search for materials that can provide good thermal insulation and that involve recycled and sustainable materials, where the carbon footprint in the production operations of these materials is reduced and alternative materials of animal origin such as alpaca hair (fiber) are used to achieve outdoor garments with desirable thermal insulation characteristics.

[0005] In the field of patents, for example, the document CN09534380 which shows an anti-wrinkle fabric of mixed double-faced herringbone wool of alpaca. The fabric comprises a mixed outer fabric of alpaca wool and a hard backing plate platform, the bottom surface of the mixed outer fabric of alpaca wool is provided with a layer of wool fabric in a way glued through an adhesive; the wrinkle-resistant filler block comprises a lower textile fixing block, elastic tension fibers and an upper textile fixing block; the layer of mixed woven fibers is woven between the elastic tension fibers in a cross manner; the lower textile fixing block is installed on the bottom layer of wool fabric in glued mode through an adhesive, and the padding etching block is firmly attached to the bottom layer of wool fabric placed on the hard backing plate platform.

[0006] In addition, document CN211251617 is known, which discloses a heating fabric, where the key points are heat maintenance fabric, base fabric, the base fabric comprises a surface layer, a middle layer and a bottom layer; wear-resistant convex particles are arranged in the surface layer; the middle layer comprises a thermal insulation layer and an antibacterial layer; the thermal insulation layer comprises warp yarns and weft yarns; warp yarns are core spinning yarns; where the core spinning yarn is formed by wrapping cotton fibers outside the spandex filaments that serve as the core yarn, the weft yarn is fine alpaca wool, the warp yarn and weft yarn are woven in the form of cross twill, the antibacterial layer comprises polyvinyl chloride fiber.

[0007] On the other hand, document WO2020 / 214860 reveals articles that include one or more coated substrates, in which the coatings include silk protein fragments (SPF), including but not limited to silk fibroin or silk fibroin fragments, and a chemical or physical modifier. The chemical modifier chemically binds to one or more of a silk fibroin side group and a silk fibroin terminal group. The silk fibroin side group and the silk fibroin terminal group are independently selected from an amine group, an amide group, a carboxyl group, a hydroxyl group, a thiol group, and a sulfhydryl group. The fiber or yarn includes one or more of alpaca fiber, alpaca fleece, alpaca wool, llama fiber, llama fleece, llama wool, cotton, cashmere, sheep fiber, sheep fleece, sheep wool, yak, rabbit, lamb wool, mohair wool, camel hair, angora wool, silkworm silk, abaca fiber, coconut fiber, flax fiber, jute fiber, kapok fiber, kenaf fiber, raffia fiber, bamboo fiber, hemp.

[0008] In addition, the document DE20202210196 shows the use of alkyl (met)acrylate polymers containing 2-octyl acrylate to make textiles hydrophobic, wherein the polymers are alkyl methacrylate and can be combined with textiles made of natural fibers and synthetic fibers, among the natural fibers is cotton, wool, silk, linen, cashmere, angora, alpaca and jute. The fibers are treated with a solution or suspension containing 50 to 500 g / l, of the alkyl (met)acrylate polymers.

[0009] The document CN107761208 discloses a simple thread curling yarn with a high alpaca fiber content and a production method of it. The single thread type curling yarn with high alpaca fiber content comprises a core yarn, a press yarn and a decorative yarn, where the core yarn is 8:2 cotton brocade yarn, the press yarn is 150D polyester silk, and the decorative yarn is mixed yarn that is formed by mixing alpaca fiber and mercerized wool tops according to the weight ratio of 8:2. The weight ratio of Soulik alpaca fiber in the decorative yarn is improved to 80 percent, so that the rough surface of the curly wool fabric prepared by the yarn is smoother, the touch feel of the wool fabric is good, and the visual effect is greatly improved.

[0010] Finally, document PE20211426 refers to a procedure for obtaining fine fabrics, where such fabrics have at least 50% fine alpaca fiber yarn and the other 50% can be cotton, polyester etc., without breaking in circular knitting machines with gauges between 22-31. The process comprises the stages of providing a fine yarn with at least 50% alpaca fiber with yarn titer between 1 / 20 and 1 / 120 with a yarn twist between 600 and 900 turns; place the yarn in a circular knitting machine, control the knitting speed at a speed of less than 25 RPM and operate blowers constantly.

[0011] From an environmental point of view, the alpaca is considered among the 5 most eco-friendly animals on the planet, since the pads on their paws prevent the mistreatment of the soil. Also, their way of feeding is special since they do not pull up the grass but cut it, which encourages their growth. In relation to their waste, they are low in acidity which allows them to be easily converted into natural fertilizer for the soil. They are raised in freedom feeding on the pastures of the high Andes making them organic animals and obtaining the fiber does not harm the animal, since it is done by shearing, which must be done once a year, since these animals do not shed their hair naturally. The process of making these fibers does not require high water consumption.

[0012] Alpaca fiber has a special characteristic as it is fiber containing an air pocket inside, which allows correct thermoregulation. This is why alpacas are comfortable in low temperatures in high areas of the Andes, but also when the sun is shining, they are also comfortable when temperatures rise. Also, alpaca fiber has the characteristic of quick drying and is a soft and light short fiber.

[0013] However, there are some difficulties in the use of the fiber of this animal, since, being a very fine fiber, it tends to migrate between the seams of the fabric, including through nylon and polyester, even between fabrics treated with coatings to prevent such migration. This alpaca fiber has an average length between 3 and 7 centimeters, depending on the part of the body from which it is obtained, which makes it very easy to form lumps and knots when the fiber gets wet and then it is very difficult for the fiber to recover its original state. When these lumps or knots form inside the coats, due to the effect of gravity, they are grouped in the lower part of the coat or garment, even in coats that have horizontal seams along the garment.

[0014] Another difficulty that has been encountered is in the manufacturing process, which is more complicated when the fiber is used, since it requires a manual process where the fiber must be selected by weight between the seams and manually fill each of the compartments.

[0015] In this sense, it is clear that there is still an unmet need to provide a filling material based on alpaca fiber, hair or wool that is a more sustainable optional material but that, at the same time, enhances inputs such as alpaca fiber with remarkable technical properties, mainly in terms of thermal insulation and that can be used in garments that can then be easily washed without matting and clumping of alpaca fibers as occurs with conventional garments, since this fiber is very short and very fine and at the same time reduce the migration of alpaca fibers through the fabric of the garment.

[0016] The present invention makes a contribution to the state of the art since clothing, for example, coats filled with the alpaca fiber-based material according to the present invention, provide a lighter, more versatile, warm and easy to wash final product while also being friendly to the planet and people by employing a process with minimal or almost zero waste, since the waste resulting from the combination of natural and synthetic fibers from a process can enter a new process as recovered fiber.SUMMARY

[0017] The present invention is directed at an alpaca fiber-based product as a filling material for garments, a process for obtaining it and garments that comprises said product.DESCRIPTION OF THE FIGURES

[0018] Figure 1 shows a photograph of the product (alpaca fiber plus synthetic fiber) before it passed through the furnace according to the process of the present invention. Figure 2 shows a photograph of the final product (alpaca fiber and synthetic fiber) of the process, where alpaca fibers and synthetic fibers are observed. Figure 3 shows a photograph of the alpaca fiber to be used in the process for obtaining the alpaca fiber-based product in accordance with the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0019] The present invention refers in a first aspect to an alpaca fiber-based product as a filling material for garments, where the final product or composition is a mixture comprising alpaca fibers in a proportion by weight between 40% and 75% by weight of the total mixture, more preferably 50% by weight of the total mixture and more preferably 60% by weight of the total mixture and synthetic fibers in a weight proportion between 25% by weight and 60% by weight of the total mixture, where such fibers may be virgin polyester, lowmelt polyester (low melt) also virgin, recycled polyester, recovered fiber or mixtures thereof.

[0020] The synthetic fibers according to the present invention may comprise virgin polyester which may be siliconized polyester 7D HC (conjugated hollow fiber) and may be in a minimum proportion of 12% and a maximum of 35% by weight of the total mixture of the final product. Also, it can include "lowmelt" polyester which is polyester with a low melting point and can be in a minimum proportion of 12% and a maximum of 20% by weight of the total mixture of the final product. Recycled polyester can be, for example, recycled PET (RPET) and can be in a minimum proportion of 6% and a maximum of 24% by weight of the total mixture of the final product and the recovered fiber is waste from nappa (siliconized polyester 7D HC) or the fibers that result from the mixing of the product resulting from the waste of previous production processes and can be in a proportion between 1% and 5% by weight of the total mixture of the final product.

[0021] The alpaca fiber product or composition according to the present invention, may have a grammage of from 80 grams per square meter (g / m 2< ) to 200 grams per square meter (g / m 2< ), more preferably between 80 g / m 2< and 140 g / m 2< , for example, 80 g / m 2< , 100 g / m 2< and 120 g / m 2< where the grammage determines the thickness of the alpaca fiber-based product and, therefore, the thickness of the garment, for example, a coat, jacket or other garment with thermal insulation filling material. As for the width of the alpaca fiber-based product as a filling material for garments, the width can be from 50 cm to 300 cm.

[0022] In another aspect, the present invention also covers garments comprising the alpaca fiber-based product of the present invention as a filling material, wherein the garments, such as coats, jackets, overcoats, parkas, vests, etc.) are made of 100% recycled nylon fabrics or comprising 50% recycled material and may have recycled nylon or virgin nylon linings.

[0023] In another aspect, the present invention is also aimed at the process for obtaining the product or composition based on alpaca fibers as a filling material for garments, which includes the steps of: a) Provide alpaca fiber; b) Select alpaca fibers; c) Clean alpaca fibers; d) Card alpaca fibers to achieve a homogeneous material; e) Provide synthetic fibers; f) Weigh the natural alpaca fiber and the synthetic fibers so that the final mixture at this stage comprises between 65% and 75% alpaca fiber and between 25% and 35% synthetic fiber; g) Enter the mixture obtained in step f) into a hopper and mix the fibers; h) Enter the result of step g) into a crushing machine that joins the different fibers until a homogeneous felt-type material is reached; i) Discharge the felt obtained in step (h) onto a conveyor belt passing through a furnace and subject the felt to a temperature between 90°C and 170°C in order to fuse and stabilize the mixture; and j) Make the garments from the felt obtained in step i).

[0024] In step a) the alpaca fiber is obtained through shearing so that no harm is caused to the animal.

[0025] In step b) the fiber is separated by different qualities. In one embodiment of the invention, alpaca fibers of a length between 3 cm and 7 cm or more are selected, mainly Huarizo fibers that are approximately 7 cm. Fine fibers such as baby alpaca, alpaca fleece, alpaca medium fleece, as well as thick alpaca can also be used.

[0026] In step c) cleaning consists of removing impurities, such as pieces of wood, grass or small stones that can become entangled in the animal's hair.

[0027] In step d) carding can be carried out with a manual or mechanical carder with which a more homogeneous material is achieved.

[0028] In step e) synthetic fibers that can be used in the present invention may be polyester, for example, siliconized polyester 7D HC (conjugated hollow) wherein the synthetic fiber allows the mixture obtained to be soft and fluffy. Other synthetic fiber options that can be used in combination or blending with siliconized polyester 7D HC (conjugated hollow) in the process of this invention are "lowmelt" synthetic fiber (low melt polyester), which is a solid fiber that aids in the integration of other materials. The proportion of this virgin low-melt synthetic fiber is between 12% and 20% of the total weight of the total blend.

[0029] As for the recycled synthetic fiber, for the process of the present invention solid recycled polyester (RPET) can be used in such a proportion that it does not affect the resilience of the material, since the recycled polyester fiber is less versatile, wherein resilience of the material is understood as the ability of said material to recover its original state after being tightened.

[0030] As for the recovered fiber involved in the process of the present invention, it is nappa fiber (siliconized polyester 7D HC) or fibers left over from the mixture of the same alpaca fiber-based product according to the present invention of waste from previous production processes and may be in a proportion between 1% and 5% by total weight of the total mixture of the final product.

[0031] In step f), the mixture is made based on weight, by means of a scale where all the materials are placed, for example, between 65% and 75% alpaca fiber and between 25% and 30% polyester (virgin, low-melt polyester, recycled polyester and / or the fiber recovered from waste of previous processes) and mixed. As can be seen, the highest percentages in this process are due to the fact that when passing through step i) which includes subjecting the felt to a temperature between 90°C and 170°C, a part of the natural fiber is affected by the temperature losing moisture, so with these values the percentage established for the final product is guaranteed.

[0032] In step g), the heavy materials and their defined percentages are placed in a hopper, preferably in a kind of blender where all the materials are mixed until a homogeneous mixture is obtained.

[0033] In step h), after mixing in the hopper, the mixture is passed through a crushing machine which includes rollers, which join the different fibers until a homogeneous felt-type material with desired characteristics of width and thickness is achieved. In one embodiment of the invention, three different thicknesses of felt can be obtained, for example, which are measured in grammage per square meter, for example, 80 g / m 2< , 100 g / m 2< , 120g / m 2< , 150 g / m 2< and 200g / m 2< . Other thicknesses may be obtained that are less or greater than those described above. However, with these grammage it is possible to obtain more functional and lighter garments, for example, coats, jackets and the like. The width of the felt can be any desirable width depending on the width of the garment work tables, preferably, but not limited to, the width can be between 50 cm and 300 cm. More preferably 150 cm which can be a comfortable measurement for tailoring and also reduces waste.

[0034] In step i) the felt obtained in the previous stage can be unloaded manually or mechanically on a conveyor belt that advances at a speed between 2 and 10 meters per minute (m / min), which passes through a furnace at a temperature between 90°C and 170°C. With the speed indicated above, the fusion and stabilization of the mixture is achieved in an optimal way to obtain the alpaca fiber-based product as filling material for garments in accordance with the present invention. The final percentage of each of the components in the final alpaca fiber-based product is between 40% and 70% alpaca fiber, between 25% and 55% synthetic fibers and 5% recovered fiber.

[0035] In the RPET (recycled fiber) process modality, the proportion of recycled fiber (recovered polyester) is between 6% and 24% by weight of the total mixture of the final product and virgin polyester in a proportion of between 12% and 35% by weight of the total mixture of the final product and "lowmelt" polyester in a proportion between 12% and 20% by weight of the total mixture of the final product.

[0036] For the making of a garment, for example, a coat, the process can be as follows: 1. Provide a recycled nylon or nylon fabric, e.g., nylon from fishing nets, post-industrial waste, and factory discards; 2. Lay the fabric and trace the pieces that make up the garment; 3. Cut the pieces; 4. Stamp the cuts that have prints; 5. Perform steps 2 and 3 on the lining fabric and lay the alpaca fiber-based product (felt) in accordance with the present invention as a filling material over it and lay the outer fabric of nylon or other suitable material over it; and 6. Pass the seam over the "sandwich" fixing the three layers and then assemble the garments.

[0037] The alpaca fiber-based product as a filling material according to the present invention manages to solve all the problems mentioned above, facilitates the manufacture and accelerates the process, allows the garment to be washed in the washing machine, which makes it provide a desired functionality in the articles of clothing containing the product of the invention. As it is a filling with more consistency, no lumps form and it is not affected by gravity. It does not migrate between the fabric or between the seams and best of all, the technical attributes of the fiber are not lost. In addition, a sustainable product is achieved that contributes to the transformation of the textile industry, encourages consistent consumption and will allow many people to access technologies based on alpaca, a recognized Peruvian product.EXAMPLE OF THE BEST WAY TO CARRY OUT THE INVENTION Example 1

[0038] Below is an alpaca fiber-based product as a filling material for garments obtained by the process in accordance with the present invention, wherein the composition of the final product is as follows: Table 1. Formulation 1. Version: alpaca fiber / virgin polyester fiber / recovered fiber.Component Percentage by weight in relation to the total weight of the final product Long-haired alpaca fiber (70 mm to 80 mm)40%Siliconized polyester 7D HC (Conjugated hollow)35%Lowmelt Polyester20%Recovered fiber (nappa or from the waste of previous production processes of alpaca fiber-based product according to the invention5% Table 2. Formulation 2. Version: alpaca fiber / virgin polyester fiber / recovered fiber. Component Percentage by weight in relation to the total weight of the final product Long-haired alpaca fiber (70 mm to 80 mm)70%Siliconized polyester 7D HC (Conjugated hollow)13%Lowmelt Polyester12%Recovered fiber (nappa or from the waste of previous production processes of alpaca fiber-based product according to the invention5% Example 2

[0039] Below is an alpaca fiber-based product as a filling material for garments obtained by the process in accordance with the present invention, wherein the composition of the final product is as follows: Table 3. Formulation 3. Version: alpaca fiber / virgin polyester fiber / recycled polyester.Component Percentage by weight in relation to the total weight of the mixture or composition Long-haired alpaca fiber (70 mm to 80 mm)40%Recycled Polyester24%Lowmelt Polyester12%Siliconized polyester 7D HC (Conjugate hollow)24% Table 4. Formulation 4. Version: alpaca fiber / virgin polyester fiber / recycled polyester. Component Percentage by weight in relation to the total weight of the mixture or composition Long-haired alpaca fiber (70 mm to 80 mm)70%Recycled Polyester6%Lowmelt Polyester12%Siliconized polyester 7D HC (Conjugated hollow)12%

[0040] A person skilled in the art will understand that there are modifications both in the process and in the proportions of the alpaca fiber-based product that do not deviate from the spirit of the present invention.

Claims

1. An alpaca fiber-based product as a filling material for garments, wherein it comprises alpaca fibers in a proportion by weight between 40% and 75% by weight and synthetic fibers in a proportion by weight between 25% and 60%.

2. The alpaca fiber-based product as a filling material for garments according to claim 1, wherein alpaca fibers are between 3 cm and 7 cm in length.

3. The alpaca fiber-based product as a filling material for garments in accordance with claim 1, wherein the synthetic fibers comprise virgin polyester, virgin low-melt polyester, recycled polyester, recovered fiber or mixtures thereof.

4. The alpaca fiber-based product as a filling material for garments in accordance with claim 3, wherein the virgin polyester is siliconized polyester 7D HC (conjugated hollow fiber) and low-melt polyester; and recycled polyester is recycled PET (RPET).

5. The alpaca fiber-based product as a filling material for garments in accordance with claim 3, wherein the recovered fiber is waste from nappa leather (siliconized polyester 7D HC) or fibers resulting from the mixing of the product resulting from waste of previous production processes and is in a proportion between 1% and 5% of the total weight of the final product mixture.

6. A process for obtaining the alpaca fiber-based product as a filling material for garments, characterized by the following steps: a) Provide alpaca fiber; b) Select alpaca fibers; c) Clean alpaca fibers; d) Card the alpaca fibers to achieve a homogeneous material; e) Provide synthetic fibers; f) Weigh the natural alpaca fiber and synthetic fibers and mix; g) Enter the mixture obtained in step f) into a hopper and mix the fibers; h) Enter the result of step g) into a crushing machine that joins the different fibers until a homogeneous felt-type material is reached; i) Discharge the felt obtained in step (h) onto a conveyor belt passing through a furnace and subject the felt to a temperature between 90°C and 170°C in order to fuse and stabilize the mixture; and j) Make the garments from the felt obtained in step i).

7. The process for obtaining the alpaca fiber-based product as a filling material for garments according to claim 6, wherein alpaca fibers are between 3 cm and 7 cm in length.

8. The process for obtaining the alpaca fiber-based product as a filling material for garments in accordance with claim 6, wherein in step (f) the final mixture at that stage comprises between 65% and 75% alpaca fiber and 25% to 35% synthetic fibers; wherein the synthetic fibers comprise virgin polyester, virgin low-melt polyester, recycled polyester, recovered fiber or mixtures thereof, and wherein the recycled polyester is solid recycled polyester (RPET) and the recovered fiber is nappa fiber (siliconized polyester 7D HC) or fibers left over from the mixture of the product itself based on alpaca fiber of waste from previous production processes.

9. The process for obtaining the alpaca fiber-based product as a filling material for garments in accordance with claim 6, wherein in step (i) the conveyor belt has a speed between 2 and 10 meters per minute (m / min).

10. A garment wherein it comprises an alpaca fiber-based product as a filling material in accordance with claims 1 to 5.

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