Method for manufacturing a planar vegetable fiber structure

Abstract

The present invention relates to a method for making a non-synthetic fibrous surface structure, and to the non-synthetic fibrous surface structure itself.

Description

[Technical field]

[0001] The present invention relates to a method for making a non-synthetic fiber surface structure and to a non-synthetic fiber surface structure. [Background technology]

[0002] Leather has always been an important material for the manufacture of clothing and objects. However, genuine leather is generally rejected by an increasing number of vegans. Furthermore, the use of leather has been criticized for various ecological and ethical reasons. In particular, leather production produces significant CO2 emissions during the rearing of animals. 2 Ecologically questionable chemicals are often used in tanneries for further processing. It is a by-product of the meat industry, but the suffering of animals is a crucial argument against leather.

[0003] Therefore, for these reasons, many products that are traditionally made from or with leather are now provided in artificial leather (eg, bags, furniture, or car interior panels).

[0004] However, in most cases, artificial leather is based on synthetic petroleum-based components (e.g. PU coatings, carrier materials made of synthetic fibers) that limit biodegradability and lead to other ecological problems such as microplastic wear.

[0005] The production of artificial leather or leather-like substitutes is generally known, for example DE 16 35 546 C3 describes a process for producing leather-like sheet materials from aqueous slurries.

[0006] DE 10 2006 001 095 A1 goes in a similar direction and describes a method for producing a leather-containing surface structure having a top layer and a backing layer.

[0007] However, after these two methods, pure leather is still used, at least in fiber form. Summary of the Invention

[0008] The underlying objective is to provide improved leather substitutes and suitable manufacturing processes therefor.

[0009] The problem is solved by a method for producing a non-synthetic fibrous surface structure, which comprises the steps of: a) providing a pulp comprising at least one liquid, in particular water, at least one non-synthetic fibrous material, at least one binder, at least one process additive; and b) at least partially separating the liquid, in particular the water, from the pulp, thereby producing a non-synthetic fibrous surface structure, wherein the at least one binder comprises at least one natural latex.

[0010] The process according to the invention may further comprise, in step a), one or more of the following substeps: a1) providing a non-synthetic fibre material, which comprises or consists of shortened and / or non-shortened fibres; and / or a2) adding at least one liquid, in particular water, to the non-synthetic fibre material; and / or a3) mechanical preparation of the non-synthetic fibre material; and / or a4) washing the non-synthetic fibre material; and / or a5) adding at least one binder; and / or a6) adding at least one process additive; and / or a7) adding at least one auxiliary; and / or a8) producing pulp.

[0011] The method according to the invention may further comprise, in step b), one or more of the following substeps: b1) applying the pulp provided in step a) to a liquid-permeable carrier element, in particular a water-permeable carrier element, in order to at least partially separate at least one liquid, in particular water; and / or b2) producing a pulp layer comprising the pulp from step a), in which at least one liquid, in particular water, is at least partially removed from the pulp layer; and / or b3) drying the pulp layer; and / or b4) carrying out a shaping step on the pulp layer, in particular the dried pulp layer, to obtain a non-synthetic fiber surface structure; and / or b5) adding at least one auxiliary agent.

[0012] The process according to the invention may further comprise splitting the non-synthetic fibre material into fibres or fibrillating the fibres during the mechanical preparation in step a3).

[0013] The process according to the invention may comprise at least one process additive selected from the group consisting of polysaccharides, in particular starches, modified starches, cationically modified starches, cellulose or derivatives thereof, in particular carboxymethylated cellulose, cellulose acetate, hydroxypropyl methylcellulose, aluminium sulphate or mixtures thereof.

[0014] The method according to the present invention may further comprise at least one binder further comprising a synthetic latex.

[0015] The process according to the invention may further comprise at least one auxiliary selected from plasticizers, fillers, dyes, pigments, UV protection agents, hydrophobizing agents, antimicrobial agents, flame retardants, wet strength agents, sizing agents or mixtures thereof.

[0016] In the process according to the invention, the non-synthetic fibre material may be selected from vegetable fibre materials, preferably natural fibres, cellulose, preferably recycled cellulose, fibres made from natural fibres, preferably recycled fibres made from natural fibres, or mixtures thereof.

[0017] The method according to the invention may further comprise the following step c): carrying out a post-treatment on the non-synthetic fibre surface structure produced in step b).

[0018] The present invention also provides the use of cationic starch as a process additive in the method according to the present invention.

[0019] The invention also provides a non-synthetic fibre surface structure obtainable by the method according to the invention.

[0020] The present invention also provides a non-synthetic fibrous surface structure comprising a non-synthetic fibrous material, at least one processing additive, and at least one binder, wherein the at least one binder comprises natural latex.

[0021] The non-synthetic fiber surface structure according to the present invention may further comprise at least one adjuvant selected from plasticizers, dyes, UV protection agents, hydrophobizing agents, antimicrobial agents, flame retardants, wet strength agents, sizing agents, pigments, or mixtures thereof.

[0022] The invention further provides the use of the non-synthetic fiber surface structures according to the invention as leather substitutes, in particular for the production of fashion (shoe parts, bags, accessories, clothing), furniture (seat covers, furniture surfaces), car interiors, stationery (e.g. covers), facade panels or floor coverings.

[0023] The present invention also provides a leather substitute comprising a non-synthetic fiber surface structure according to the present invention.

[0024] Additionally, the leather substitute according to the present invention may include decoration, engraving, embossing, embroidery, coating, gluing, or mixtures thereof. [Brief description of the drawings]

[0025] [Figure 1] FIG. 1 is a photographic representation of a non-synthetic fiber material made from non-shortened fibers. [Diagram 2] FIG. 2 is a photographic representation of a partially dewatered pulp layer for sheet formation. [Diagram 3] FIG. 3 is a photographic representation of the completed non-synthetic fiber surface structure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] This object is solved by a method for producing a non-synthetic fibrous surface structure, which comprises the steps of: a) providing a pulp comprising at least one liquid, in particular water, at least one non-synthetic fibrous material, at least one binder, at least one process additive; and b) at least partially separating the liquid, in particular the water, from the pulp, thereby producing a non-synthetic fibrous surface structure, wherein the at least one binder comprises at least one natural latex.

[0027] The method according to the invention has the advantage that it makes it possible to produce non-synthetic fibre surface structures which can be used as leather substitutes.

[0028] The term "pulp" as used in the present application refers to a fibrous pulp mixture, in particular a fibrous pulp material, which comprises at least one liquid, in particular water, at least one non-synthetic fibrous material, at least one binder, in particular a vegetable binder, and at least one process additive, in particular a vegetable process additive. The pulp used in the method according to the invention is similar in its properties to the pulps known, for example, from papermaking. The fiber concentration in the pulp can be set to a value preferably between 0.1% and 5% by weight.

[0029] At least one liquid comprises water. In one embodiment, the pulp is an aqueous pulp, meaning that the liquid is water. The water can be selected from distilled water or tap water or a mixture thereof. The liquid may further comprise an organic solvent or an oil. In one embodiment, the liquid is a mixture of water and oil. The proportion of oil in the liquid may range from 5% to 40% by weight, based on the dry weight of the non-synthetic fiber material used.

[0030] At least one non-synthetic fiber material is preferably selected from vegetable fiber materials, preferably natural fibers, cellulose, preferably recycled cellulose, fibers made from natural fibers, preferably recycled fibers made from natural fibers, or mixtures thereof. In one embodiment, the non-synthetic fiber material is not present as a non-woven or woven material, but rather in the form of a loosely isolated collection of fibers, such as a bale or ball. The non-synthetic fiber material does not contain synthetic fibers, i.e. fibers obtained from petroleum-based polymers. Furthermore, the non-synthetic fiber material does not contain leather fibers of animal origin. This has the advantage that a non-synthetic fiber surface structure can be obtained that does not contain leather fibers of animal origin and does not contain fibers made from petroleum-based polymers.

[0031] The natural fibers may be agricultural by-products or may be obtained from annual plants. Examples of plants from which natural fibers can be obtained are hemp, banana, pineapple, silphium, flax, kenaf, jute, cotton, sisal, agave, abaca, ramie, ananas, coconut and kapok. Hemp fibers are particularly preferred according to the invention. Mixtures of the abovementioned natural fibers may also be used. For economic and ecological reasons, it is advantageous to use non-synthetic fiber materials, natural fibers, obtained as agricultural by-products. In this way, CO 2 The balance is better, all else being equal, compared with plants planted solely for fiber production. It is also favorable if the value of the plants is not based solely on fiber and economic expansion is possible.

[0032] For the purposes of this application, "cellulose" means a fibrous material consisting of cellulose and resulting from the chemical and mechanical processing of fiber-containing plants or wood. The plants can be selected from the plants disclosed above, from which natural fibers can also be obtained. The cellulose can also consist of recycled cellulose or at least include recycled cellulose.

[0033] Furthermore, the non-synthetic fiber material can be selected from fibers made from natural fibers, preferably recycled fibers made from natural fibers, such as old clothing made from natural fibers suitable for making clothing, such as jute, cotton, sisal or hemp.

[0034] The term "binder" as used in the present application is understood to mean a substance that elastically binds together the fibers of the non-synthetic fiber material to form a three-dimensional network. According to the present invention, the at least one binder comprises a vegetable-based binder of natural latex. Natural latex can be obtained from rubber trees (Hevea Brasilensis), guayule (Parthenium argentatum), Russian dandelion (Taraxacum koksaghyz), or mixtures thereof. The latter in particular can also be cultivated in Europe, so that this raw material can be sourced locally and therefore in a more climate-friendly way. Preferably, the at least one binder consists of natural latex. However, in one embodiment, the binder can also comprise synthetic latex, for example obtained from petroleum-based polymers. By using latex or rubber, or latex or rubber-based binders, a leather-like, softer texture is achieved in the final product, i.e. in the leather substitute or non-synthetic fiber surface structure according to the present invention.

[0035] The term "process additive" as used in this application refers to a precipitating agent that allows the formation of a three-dimensional network of non-synthetic fiber material and binder. The at least one process additive is selected from the group consisting of polysaccharides, in particular starch, modified starch, cationically modified starch, cellulose or derivatives thereof, in particular carboxymethylated cellulose, cellulose acetate, hydroxypropyl methylcellulose, aluminum sulfate (also called alum), or mixtures thereof. The at least one process additive is preferably a plant process additive selected from polysaccharides, in particular starch or cellulose or mixtures thereof. The use of polysaccharides, in particular cationic starch, has the advantage that polysaccharides are at least partially water-soluble (both in cold and hot water) and exert their effect in the neutral range. Thus, the pulp is no longer acidic or contaminated with acids. Furthermore, the use of metal salts, which are harmful to health and the environment, is avoided. In particular, the use of cationic starch as a process additive is also according to the invention, preferably by a method according to the invention.

[0036] Step a) of the method according to the invention comprises the following sub-steps: a1) providing a non-synthetic fibre material, the non-synthetic fibre material comprising or consisting of shortened and / or non-shortened fibres; and / or a2) adding at least one liquid, in particular water, to the non-synthetic fibre material; and / or a3) mechanically processing non-synthetic fibre materials; and / or a4) washing the non-synthetic textile material; and / or a5) adding at least one binder; and / or a6) adding at least one process additive; and / or a7) adding at least one auxiliary agent; and / or a8) pulp manufacturing process; may include one or more of the following:

[0037] In step a1), a non-synthetic fiber material is provided, which comprises or consists of shortened and / or non-shortened fibers. The non-synthetic fiber material used in the method according to the invention must generally be prepared to achieve a uniform distribution and increased strength. Depending on the type and extraction of the non-synthetic fiber material, it must be disentangled, for example using a carding machine. In the case of fibers, the fibers must first be chopped into small pieces, for example using a shredder.

[0038] In step a2), at least one liquid as already mentioned above is added to the provided non-synthetic fiber material, possibly having passed through step a1). This can be done by placing the non-synthetic fiber material in a suitable container and then adding the liquid, or by using the reverse order. The fiber concentration can be adjusted as required. The fiber concentration can be at least 0.1% by weight, or at least 0.2% by weight, or at least 0.3% by weight, or at least 0.5% by weight, or at least 0.7% by weight, or at least 1% by weight, or at least 1.3% by weight, or at least 1.5% by weight, or at least 2% by weight, or at least 2.5% by weight, or at least 3% by weight, and / or up to 10% by weight, or up to 9% by weight, or up to 8% by weight, or up to 7% by weight, or up to 6% by weight, or up to 5% by weight, or up to 4% by weight. In particular, the fiber concentration can be at least 0.1% by weight and up to 10% by weight, or up to 0.1% by weight and up to 8% by weight, or up to 0.1% by weight and up to 5% by weight.

[0039] In step a3), the non-synthetic fibrous material is mechanically processed. The non-synthetic fibrous material may have undergone at least steps a2) and a4). The term "mechanical preparation" as used in this application means that the non-synthetic fibrous material is subjected to a mechanical processing, including separating the non-synthetic fibrous material into fibers and fibrillating the fibers.

[0040] In step a3), the non-synthetic fibrous material is mechanically processed. The non-synthetic fibrous material may have undergone at least steps a2) and a4). The term "mechanical preparation" as used in the present application means that the non-synthetic fibrous material is subjected to a mechanical processing, which includes separating the non-synthetic fibrous material into fibers and fibrillating the fibers. This has the advantage that the fiber bundles are broken down into their individual fibers, increasing the contact surface between the fibers and the binder. In this way, a more resistant and homogeneous material can be formed in the subsequent steps. Essentially all processes known in the prior art are suitable for this purpose. According to the invention, the non-synthetic fibrous material is mechanically processed in the formation of a grinding step. For this purpose, the non-synthetic fibrous material is introduced into a grinding unit and subjected to a grinding step. Suitable grinding units are cone refiners, disc refiners, Hollaender, Papillon refiners, PFI mills and Jokro mills. One or more grinding steps can be carried out. The grinding step can be adjusted depending on the desired degree of grinding of the non-synthetic fibrous material. Usually, a higher degree of grinding also provides a better product quality. Typically, the grinding process takes between 1 min and 2 h. In principle, however, the duration of the grinding process depends on the targeted degree of grinding as well as the energy input during the grinding process (kWh / t fibre). During the grinding process, the fibres are shortened, separated and fibrillated. As a result, a homogeneous fibre suspension is obtained. The suspension can then be washed, rinsed or reconcentrated using pressure screens.

[0041] In step a4), the non-synthetic fiber material is washed. It has been found to be advantageous for the quality and processability of the non-synthetic fiber material if it is free of foreign bodies (e.g. dust, debris / woody parts, other impurities) before or after step a1), or before or after step a2), or before or after step a3). Thus, in step a4), the non-synthetic fiber material can be free of foreign bodies, for example by mechanical methods. Furthermore, washing may also include one or more washing steps, and / or alkaline boiling and / or enzymatic treatment. For example, the non-synthetic fiber material can be boiled in an alkaline medium to decompose the fibers and remove the lignin. If lignin remains in the non-synthetic fiber material, a natural coloration will occur, depending on the origin of the non-synthetic fiber material. If this natural coloration is not desired, alkaline boiling can be applied. Alkaline boiling not only removes the lignin, but also reduces the strength of the non-synthetic fiber material. Refining generally has the advantage that undesirable components such as foreign bodies and interfering chemical compounds such as pectin or lignin can be at least partially, preferably completely, removed. This may support or simplify the fibrillation in step a3) or facilitate or accelerate the separation of the liquid in step b).

[0042] In step a5), at least one binder can be added. For example, the binder can be provided in a suitable container and the non-synthetic fiber material, optionally having undergone steps a1) and / or a2) and / or a3) and / or a4) and / or a6), can be added to the binder. The order can also be reversed, i.e. the non-synthetic fiber material, optionally having undergone steps a1) and / or a2) and / or a3) and / or a4) and / or a6), can be placed in a suitable container and the binder can be added. In this step, the binder and the non-synthetic fiber material can be mixed. The weight ratio of the binder to the non-synthetic fiber material can vary depending on the desired properties of the non-synthetic fiber surface structure. For example, if more latex is used than the fiber material, a more rubbery non-synthetic surface structure is obtained as a result. Typical weight ratios of non-synthetic fiber material:latex or binder range from 1:0.2 to 1:3, or from 1:0.3 to 1:3, or from 1:0.5 to 1:2.5, or from 1:0.7 to 1:2.

[0043] In step a6), at least one process additive can be added. The process additive can be provided, for example, in a suitable container, and the non-synthetic fiber material, optionally having undergone steps a1) and / or a2) and / or a3) and / or a4) and / or a5), can be added to the process additive. The order can also be reversed, i.e. the non-synthetic fiber material, optionally having undergone steps a1) and / or a2) and / or a3) and / or a4) and / or a5), can be placed in a suitable container and the process additive can be added. In this step, the process additive and the non-synthetic fiber material can be mixed. A typical weight ratio of non-synthetic fiber material:process additive is in the range of 1:0.02 to 1:0.2, or 1:0.03 to 1:0.2, or 1:0.05 to 1:0.15.

[0044] In step a7), at least one auxiliary agent can be added. The auxiliary agent can be provided, for example, in a suitable container, and the non-synthetic fiber material, optionally having undergone steps a1) and / or a2) and / or a3) and / or a4) and / or a5) and / or a6), can be added to the auxiliary agent. The order can also be reversed, i.e. the non-synthetic fiber material, optionally having undergone steps a1) and / or a2) and / or a3) and / or a4) and / or a5) and / or a6), can be placed in a suitable container and at least one auxiliary agent can be added. In this step, the auxiliary agent and the non-synthetic fiber material can be mixed.

[0045] Suitable additives may be selected from plasticizers, fillers, dyes, pigments, UV protectants, hydrophobizing agents, antimicrobial agents, flame retardants, wet strength agents, sizing agents or mixtures thereof.

[0046] Plasticizers are used when the non-synthetic fiber surface structure according to the invention must be more flexible. According to the invention, various kinds of plasticizers can be used. Preferably, inorganic chemical plasticizers are avoided. In particular, vegetable-based plasticizers can be used, which can be selected from modified natural oils, vegetable-based anhydrides of alkenyl succinic acid, vegetable-based alkylated ketene dimers, vegetable-based polyhydric alcohols or mixtures thereof. The vegetable-based modified oils can be sulfated. This has the advantage that these oils are easy to emulsify. In general, such natural oils can be vegetable-based oils selected from sunflower oil, turmeric oil (sulfated castor oil) or rapeseed oil. Furthermore, the natural oils can also be of animal origin, such as fish oil. The plasticizers, especially modified vegetable-based oils, remain in the material as small droplets, thus creating free space so that the individual fibers can move more freely. This makes the material softer and more flexible. Typical weight ratios of non-synthetic textile material:softener range from 1:0.01 to 1:0.4, or from 1:0.05 to 1:0.35, or from 1:0.1 to 1:0.3.

[0047] Fillers can be used when the non-synthetic sheet material according to the invention is to form a smooth surface and / or have a higher flexibility. Fillers can be selected from silicates, such as kaolin; carbonates, such as chalk or gypsum; metal oxides, such as titanium oxide or aluminum oxide; barium sulfate; nanocellulose, such as CNC (cellulose nanocrystals), CNF (cellulose nanofibrils), FNC (fibrillated nanocellulose); or mixtures thereof. Typical weight ratios of non-synthetic fiber material:filler range from 1:0.1 to 1:1, or from 1:0.15 to 1:0.9, or from 1:0.2 to 1:0.8.

[0048] If the non-synthetic fiber surface structure has a specific color, a dye can be used. Thus, the non-synthetic fiber surface structure can be dyed, whereby the dyeing step can be carried out at different times during the process. For example, the dye can be carried out before step a), during step a), or after step a). Either the non-synthetic fiber material or the pulp can be dyed. The dye can be selected from inorganic pigments, such as carbon, metal oxides or metal sulfates; natural dyes, such as saffron, indigo, onion peel, quebracho wood extract, madder root extract, ward extract, brazilian, blue wood extract, synthetic dyes, such as direct dyes, cationic dyes, vat dyes, reactive dyes, developing dyes, food dyes, or mixtures thereof. The material to be colored can be placed in a corresponding liquid / suspension. In addition, the finished non-synthetic fiber surface structure can be dyed by applying the dye to the surface. Alternatively, the dye / pigment can be added to the pulp. By processing the dyed fiber, the material is completely dyed. This prevents the color from wearing off, as is the case, for example, with a painted finish.

[0049] In step a8) a pulp is produced, in which the non-synthetic fiber material, at least one binder, at least one process additive and at least one liquid are brought into contact with each other and mixed to form a pulp.

[0050] The sub-steps a1) to a8) of step a) of the method according to the invention can be carried out in any order or in parallel. For example, a part of the non-synthetic fibre material can be subjected to step a2), while another part of the non-synthetic fibre material can be subjected to step a5). Preferably, step a6) is carried out or performed as the last sub-step of step a).

[0051] Furthermore, the method according to the invention comprises a step b), which comprises the following sub-steps: b1) applying the pulp provided in step a) to a liquid-permeable carrier element, in particular a water-permeable carrier element, for at least partial separation of at least one liquid, in particular water; and / or b2) producing a pulp layer comprising the pulp from step a), comprising at least partially removing at least one liquid, in particular water, from the pulp layer; and / or b3) drying the pulp layer; and / or b4) carrying out a moulding process on the pulp layer, in particular on the dried pulp layer, to obtain a non-synthetic fibre surface structure; and / or b5) adding at least one auxiliary agent; may include one or more of the following:

[0052] In step b1), the pulp provided in step a) is applied to a liquid-permeable carrier element, in particular a water-permeable carrier element, for at least partial separation of at least one liquid, in particular water. Application can be carried out by any suitable method known from the prior art, such as brushing or pouring. A "liquid-permeable carrier element" is a device, such as a sieve or a perforated plate, to which the pulp is applied to separate the liquid.

[0053] In step b2), a pulp layer comprising the pulp from step a) is produced, and at least one liquid, in particular water, is at least partially removed from the pulp layer. The at least one liquid is removed by the action of gravity or by the action of an external force, such as a pressure plate, or by applying a vacuum. Once the liquid has been removed, the partially dried or partially dewatered pulp layer is removed from the liquid-permeable carrier element. This distinguishes the liquid-permeable carrier element from carrier materials known from the prior art, which remain in the finished product.

[0054] In step b3), for example, the pulp layer produced in step b2) is further dried until at least 90%, or at least 95%, or at least 98%, or at least 99% of the at least one liquid is removed from the pulp layer. Drying can be carried out at room temperature by evaporation or in suitable equipment such as drying ovens under pressure and / or at high pressure. In step b3), so-called sheeting takes place. This sheeting can be continuous or discontinuous. Continuous sheeting requires large screening equipment with vacuum suction (similar to papermaking equipment). Discontinuous sheeting can be carried out using laboratory equipment (for example, Rapid-Kоthen sheeting machines) or by hand, similar to scooping the paper.

[0055] In step b4), a shaping step is carried out on the pulp layer, in particular the dried pulp layer, to obtain a non-synthetic fiber surface structure. Steps b3) and b4) can be carried out simultaneously, i.e. drying is carried out simultaneously with the shaping step. However, steps b3) and b4) can also be carried out alternately, i.e. step b4) is carried out after b3) and vice versa. The shaping step can also be carried out using devices known from the prior art, such as rollers. The shaping carried out in step b4) can include pressing and / or embossing the material. By pressing the material in the dry state, the surface becomes smooth and, in some cases, slightly shiny with a satin finish.

[0056] In step b5), at least one auxiliary agent can be added, as already described above in step a7). Step b5) can be carried out at any time before, after or simultaneously with steps b1) to b4).

[0057] The above-mentioned substeps b1) to b5) of step b) of the method according to the invention can be carried out in any order or in parallel.

[0058] The method according to the invention comprises step c): c) performing a post-treatment on the non-synthetic fiber surface structure produced in step b); It may further include.

[0059] The post-treatment may consist of one or more treatments selected from: fulling, anti-slip and / or milling; providing UV protection and / or flame retardancy and / or antimicrobial protection (e.g. by applying nanosilver), hydrophobization (e.g. by applying a polymer emulsion); applying wet strength agents and / or sizing agents; embroidery; (laser) engraving; embossing (e.g. by a plate or roller); coating (e.g. with proteins or wax); surface dyeing; pigment application (e.g. effect pigments). The purpose of the post-treatment is to refine the non-synthetic fibrous surface structure or to provide specific properties. According to the invention, such post-treatments include coating or impregnating the non-synthetic fibrous surface structure, for example hydrophobizing the surface with wax. The surface can also be laser engraved or embroidered using suitable equipment. The material can be embossed to give it a special look and feel, for example abrasive embossing to create the appearance of animal leather. Logos, letters, etc. can also be embossed. As already mentioned, further mechanical processing can also be carried out, for example by fulling, de-slipping and / or milling, which loosens the fibres and makes the material less stable and therefore softer or more flexible.

[0060] One embodiment of the method according to the invention for producing a non-synthetic fiber surface structure comprises the following steps: a1) providing a non-synthetic fiber material, the non-synthetic fiber material comprising or consisting of shortened and / or non-shortened fibers; a2) adding at least one liquid, in particular water, to the non-synthetic fibre material; a3) mechanically processing non-synthetic fiber materials; a5) adding a vegetable binder; a6) adding a plant-based process additive to obtain a pulp; b1) applying the pulp to a water-permeable carrier element to separate water from the pulp; b3) drying the pulp layer; b4) forming the material; b) obtaining a non-synthetic fiber surface structure; Includes.

[0061] The method according to the invention has the advantage that it can be entirely based on plants and / or plant-based raw materials, so that it can be carried out vegan on the one hand and non-petroleum based on the other hand, resulting in non-synthetic fiber surface structures that are vegan and non-petroleum based according to the invention.

[0062] The terms "plant-based" or "natural" are used synonymously in this application to mean free of synthetic petroleum-based materials / substances, or, for example, that a plant-based binder is derived from plant components without the addition of artificial materials.

[0063] The method according to the invention can preferably be completely ecological, since the non-synthetic fiber surface structures produced do not generate any microplastic wear, as is the case with synthetic fibers or artificial leather.By using natural fibers and plant-based raw materials, the products of the method according to the invention can be biodegradable.

[0064] Furthermore, the object of the present invention is solved by a non-synthetic fiber surface structure. In particular, the non-synthetic fiber surface structure can be obtained by the method according to the present invention described above. Preferably, the non-synthetic fiber surface structure has a single-layer structure and consists entirely of plant-based materials. The non-synthetic fiber surface structure according to the present invention does not contain leather of animal origin. Preferably, the non-synthetic fiber surface structure according to the present invention does not contain petroleum-based components. Preferably, the non-synthetic fiber surface structure according to the present invention does not contain chemicals harmful to human health.

[0065] For the purposes of this application, the term "non-synthetic fiber surface structure" refers to a material that resembles genuine or artificial leather, can be processed like leather, and can therefore be used as a substitute for leather. The non-synthetic fiber surface structure is a nonwoven fabric. The non-synthetic fiber surface structure within the meaning of this application comprises at least one non-synthetic fiber material, at least one processing additive, and at least one binder, the at least one binder comprising natural latex.

[0066] Furthermore, the non-synthetic fiber surface structure according to the invention can comprise at least one auxiliary agent selected from plasticizers, dyes, UV protection agents, hydrophobizing agents, antimicrobial agents, flame retardants, wet strength agents, sizing agents, pigments, or mixtures thereof, examples and specific embodiments of which have already been described above in connection with the method according to the invention.

[0067] The plant-based fiber surface structure has essentially the same advantages as those described above for the method according to the invention.The non-synthetic fiber surface structure according to the invention can be entirely produced from plant and / or plant-based raw materials, and is therefore vegan on the one hand and non-petroleum-based on the other hand.Due to the method according to the invention and the raw materials or auxiliary agents used, it cannot contain any metal residues.The non-synthetic fiber surface structure according to the invention does not produce any microplastic wear and is also biodegradable.

[0068] In contrast to animal skin, the thickness of the non-synthetic fiber surface structure according to the invention is not essentially predetermined, but can be freely selected and controlled. The non-synthetic fiber surface structure according to the invention can have a thickness customary for leather, for example, between 0.2 mm and 5 mm.

[0069] The non-synthetic fiber surface structure according to the invention, unlike multi-layer artificial leather, can be processed with open edges.

[0070] The non-synthetic fiber surface structures according to the present invention are single layer products that can be further processed using conventional methods, for example, they can be sewn, glued, nailed, and embroidered.

[0071] The present invention further provides the use of the non-synthetic fiber surface structures according to the invention, in particular for the manufacture of textiles, seat covers, bags, applications. Possible areas of application are fashion (shoe parts, bags, accessories, clothing), furniture (seat covers, furniture surfaces), car interiors, stationery (e.g. covers). The non-synthetic fiber surface structures according to the present invention can also be used in the construction industry or in interior design, for example for facade panels or floor coverings.

[0072] Also provided according to the present invention is a leather substitute comprising a non-synthetic fiber surface structure according to the present invention. The leather substitute according to the present invention may comprise decoration, engraving, embossing, embroidery, coating, gluing, or mixtures thereof. The leather substitute according to the present invention may be combined with other materials that can normally be combined with leather. The leather substitute according to the present invention may be processed and used in the same way as conventional leather or artificial leather of animal origin. In particular, the leather substitute according to the present invention, as well as the non-synthetic fiber surface structure according to the present invention, may have the same, similar, or even improved properties compared to conventional leather or artificial leather of animal origin. Such properties include, for example, a strength of 15 N / mm 2 More than 50N / mm 2These include tensile strength in the range of, for example, 10% to 50% elongation at break, tear resistance in the range of, for example, 4 N / mm to 40 N / mm, residual moisture in the range of, for example, 0.5% to 10%, or abrasion resistance in the range of, for example, 20,000+ cycles according to Martindale.

[0073] The leather substitutes according to the invention differ from the non-synthetic fiber surface structures according to the invention in that the leather substitutes according to the invention are already optimized for subsequent applications, for example by cutting or further (surface) treatments, to achieve specific properties. Examples of such (surface) treatments have already been mentioned above.

[0074] Further objects, features, advantages and possible applications are illustrated in the drawings and the following non-limiting examples of embodiments of the invention. All the features described and / or illustrated form an object of the invention, individually or in any combination, independently of their summary in the claims or their mutual relations.

[0075] FIG. 1 is a photographic representation of a non-synthetic fiber material made from non-shortened fibers. FIG. 2 is a photographic representation of a partially dewatered pulp layer for sheet formation. FIG. 3 is a photographic representation of the completed non-synthetic fiber surface structure.

[0076] In one embodiment, the non-synthetic fiber surface structure according to the invention is made from hemp fiber. The fiber is obtained from a farm in Germany. The fiber is available in the form of bales and as wool, as shown in the photograph in Figure 1. In addition to the fiber, the wool contains residual wood chips and other impurities. To improve the product quality, these wood chips and impurities can be separated from the remaining fiber in a first process step. The use of hemp fiber has the advantage that the plant is not cultivated for the purpose of fiber production. Thus, the fiber is a by-product.

[0077] In order to be able to produce a robust and homogeneous surface structure from the fibres according to the invention, the fibres must first be mechanically processed. The preparation can be carried out on various machines. This method can be carried out either with cone refiners or with Hollanders, known from the paper industry. Before processing, water can be added to the fibres. During the so-called refining process, the fibres are shortened, separated and fibrillated in a refining unit. As a result, a homogeneous fibre suspension is obtained. The suspension can then be washed, rinsed or thickened again using pressure screens.

[0078] In the next step, the pulp is produced. A preferably diluted (plant-based) binder and (plant-based) process additives are added alternately to the fiber suspension. Successful fixation is clearly visible to the eye. The fibers clump noticeably and settle to the bottom of the vessel after a rest period.

[0079] The so-called sheet is then formed. Sheeting can be done in both continuous and discontinuous processes. Continuous sheeting requires large screening equipment with vacuum suction (similar to papermaking equipment). Discontinuous sheeting can be done using laboratory equipment (e.g. Rapid-Kоthen sheet formers) or by hand, similar to scooping the paper.

[0080] During sheet formation, the water is separated from the other solids in the pulp. The pulp is placed on a sieve (a water-permeable carrier element) for this purpose. Such a pulp layer is shown photographically in Figure 2. In the manual process, sieving boxes are used for this purpose. The water is allowed to drain through the sieve while the solids are retained. In sieving machines, the process can be accelerated by applying a vacuum.

[0081] The partially dewatered pulp layer in the form of a fiber mat is then transferred from the screen to a felt by (only temporarily) inverting the screen box. For further dewatering, the fiber mat is pressed between two nonwovens in a press. The remaining liquid must be pushed out as slowly as possible so as not to damage the three-dimensional structure. After pressing, the formed sheet is already tear-resistant enough to be easily handled. Now the sheet must be further dried in room air until equilibrium is reached. Drying is carried out in an oven at moderate temperature or in air.

[0082] In a continuous process, pressing and drying is accomplished via a pair of rollers and drying cylinders, or via a calender.

[0083] The surface of the dried material can be further refined by embossing or pressing between metal plates or rollers.

[0084] In this way, a non-synthetic fiber surface structure according to the invention is obtained, a specific embodiment of which is photographically shown in FIG. EXAMPLES

[0085] The present invention will be further described below with reference to examples, but the present invention is not limited to these.

[0086] Example 1 200 g of fibre (hemp, long wool fibre) are added to 18 L of water in a hollander. The subsequent grinding step is carried out for 30 minutes under standard weight. 10 g of carbon black (as colour pigment) and 60 g of latex (binder) are added with stirring. 30 g of cationic starch (process additive) are dissolved in 3 L of water and then this is also added. The pulp is stirred and allowed to settle under stirring. This pulp is then placed in a sieve box for dewatering. After dewatering, the resulting partially dewatered pulp layer is placed between two layers of felt, pressed and then air dried.

[0087] A grey / black surface structure is obtained which is tactilely reminiscent of leather. The surface structure is hard after drying.

[0088] Example 2 30 g of hemp fibres are cut into lengths of 0.5 cm and mixed with water to a total weight of 300 g. The mixture is placed in a PFI mill and milled for 3 minutes at normal weight. The fibre suspension is then mixed with 1.5 L of water and whipped in a whisk. A pulp is then produced by adding 1 g of sulphated sunflower oil (plasticiser), 10 g of latex (binder), 2 g of kaolin (filler) and 1 L of water. 0.01 M to 0.02 M of aluminium sulphate (process additive) is added with stirring until a pH value of 5 is reached to precipitate or fix the pulp. The pulp thus obtained is placed in a sieve box for dewatering. After dewatering, the partially dewatered pulp layer produced is placed between two layers of felt, pressed and then air dried.

[0089] The result is a non-synthetic fiber surface structure as shown in FIG. 3, which is reminiscent of leather in its feel and appearance.

Claims

1. 1. A method for producing a non-synthetic fiber surface structure, comprising: a) providing a pulp comprising at least one liquid, in particular water, at least one non-synthetic fibrous material, at least one binder, and at least one process additive; b) producing a non-synthetic fiber surface structure by at least partially separating the liquid, in particular the water, from the pulp; Including, the at least one binder comprises at least one natural latex; method.

2. Step a) comprises the following sub-steps: a1) providing said non-synthetic fibrous material, said non-synthetic fibrous material comprising or consisting of shortened and / or non-shortened fibres; and / or a2) adding said at least one liquid, in particular said water, to said non-synthetic fibre material; and / or a3) mechanically processing the non-synthetic fiber material; and / or a4) washing the non-synthetic fiber material; and / or a5) adding said at least one binder; and / or a6) adding said at least one process additive; and / or a7) adding at least one adjuvant; and / or a8) a process for producing the pulp; The method of claim 1 , comprising one or more of:

3. Step b) comprises the following substeps: b1) applying the pulp provided in step a) to a liquid-permeable carrier element, in particular a water-permeable carrier element, in order to at least partially separate the at least one liquid, in particular the water; and / or b2) producing a pulp layer comprising the pulp from step a), wherein the at least one liquid, in particular the water, is at least partially removed from the pulp layer; and / or b3) drying the pulp layer; and / or b4) carrying out a molding process on the pulp layer, in particular on the dried pulp layer, to obtain the non-synthetic fiber surface structure; and / or b5) adding said at least one adjuvant; The method of claim 1 or 2, comprising one or more of:

4. 3. The method of claim 2, wherein the mechanical preparation in step a3) comprises splitting the non-synthetic fibrous material into fibers or fibrillating the fibers.

5. The method according to claim 1 or 2, wherein the at least one process additive is selected from the group consisting of polysaccharides, especially starch, modified starch, cationically modified starch, cellulose or derivatives thereof, especially carboxymethylated cellulose, cellulose acetate, hydroxypropylmethylcellulose, aluminum sulfate, or mixtures thereof.

6. The method according to claim 1 or 2, wherein the at least one binder further comprises a synthetic latex.

7. The method according to claim 1 or 2, wherein the at least one auxiliary agent is selected from the group consisting of plasticizers, fillers, dyes, pigments, UV protectants, hydrophobizing agents, antibacterial agents, flame retardants, wet strength agents, sizing agents or mixtures thereof.

8. The method according to claim 1 or 2, wherein the non-synthetic fiber material is selected from the group consisting of plant fiber materials, preferably natural fibers, cellulose, preferably recycled cellulose, fiber products made from natural fibers, preferably recycled fiber products made from natural fibers, or mixtures thereof.

9. The following steps: c) a step of performing post-treatment on the non-synthetic fiber surface structure produced in step b). The method according to claim 1 or 2, further comprising.

10. Preferably, the use of cationic starch as a process additive in the method according to claim 1 or 2.

11. A non-synthetic fiber surface structure obtained by the method according to claim 1 or 2.

12. A non-synthetic fiber surface structure comprising a non-synthetic fiber material, at least one process additive, and at least one binder, wherein the at least one binder comprises a natural latex.

13. The non-synthetic fiber surface structure according to claim 12, further comprising at least one auxiliary agent selected from the group consisting of plasticizers, dyes, UV protectants, hydrophobizing agents, antibacterial agents, flame retardants, wet strength agents, sizing agents, pigments or mixtures thereof.

14. Use of the non-synthetic fiber surface structure according to claim 12 or 13 for the production of leather substitutes, especially in fashion (shoe parts, bags, accessories, clothing), furniture (seat covers, furniture surfaces), the interior of vehicles, stationery (e.g., covers), facade panels, or floor coverings.

15. A leather substitute comprising the non-synthetic fiber surface structure according to claim 12 or 13.

16. 16. The leather substitute of claim 15, further comprising decoration, engraving, embossing, embroidery, coating, gluing, or a combination thereof.

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