A biodegradable fireproof plant-based textile with high mechanical resistance and method for the manufacturing thereof

Abstract

A textile structure for manufacturing protective fireproof clothing and / or linen with high mechanical resistance, highly resistant to UV rays, washing and rubbing, for military use for users who may come into contact with flames and / or suffer the effects of other sources of heat by contact, radiation and convection, said textile structure being characterized in that it is made from a plurality of plant fibers that are eco-sustainable and environmentally-friendly, compostable and biodegradable, wherein, to a main matrix consisting of seaweed fibers, or alginate fibers, other fibers are mixed, said matrix of alginate fibers being present in the final textile structure in a range between 25% and 60%, the remaining part being compensated by plant-based fibers, such as hemp fibers, viscose fibers, beech fibers, bamboo, cotton, viscose or the like.

Description

[0001] A BIODEGRADABLE FIREPROOF PLANT-BASED TEXTILE WITH HIGH MECHANICAL RESISTANCE AND METHOD FOR THE MANUFACTURING THEREOF

[0002] The present invention belongs to the textile field, suggesting a textile structure provided with fire-proof properties and high mechanical resistance, completely made of plant fibers, and a manufacturing method thereof. in particular, considering the presence of plant fibers only, the textile is environmentally friendly and eco-sustainable.

[0003] More specifically, the present invention belongs mainly, but not exclusively, to the field of producing garments and / or linen for military use, protective clothing, and / or for rescue services, such as Fire Brigade and civil Protection as well as police forces, such as Carabinieri, Police, etc. in the military sector, to date, it has not been possible to create the right union between a fireproof individual protective device (IPD), which is also 100% eco-sustainable; this because the garments are mainly made of polyester and aramid yarns and a percentage of FR viscose is only used in some case, including sweaters, for example.

[0004] However, this does not make the garment 100% eco- sustainable and environmentally friendly.

[0005] The use of raw materials, such as synthetic fibers, nylon, polyester or aramid fibers has contributed to the accumulation of annual tons of items of clothing made from oil derivatives and intended for disposal, both in Italy and around the world; this results in considerable environmental damage, significant expenses for the sorting of waste and high costs for the complex disposal procedures .

[0006] Although the product composed of these materials can be recycled and transformed several times, in the end, disposal of the material is always necessary, being no longer recyclable and reusable, and this does not eliminate the problem of pollution and harm to the envi ronment .

[0007] Plant-based textiles of fireproof type are also commercially known, however made exclusively by two methods that determine a number of final properties thereof.

[0008] The first method provides the use of chemical treatments, which involve serious problems of pollution, in addition to the fact that, after a number of washes, the textiles lose their fire-proof properties.

[0009] The second method provides acting directly on the molecular structure of the cellulose fiber; this type of treatment is more commonly used on high-weight cotton textiles, such as textiles for curtains or sofa and armchair covers, for example, but it is not suitable for low weight textiles and for protective clothing because, besides not ensuring maximum fire resistance, it highlights a considerable loss of mechanical resistance in traction and tear (up to 50%) after the treatment, properties that are essential for protective clothing as required by European regulations and standards.

[0010] Patent CN 105463645 A describes an alginate yarn for intimate textile and relative production method; according to this patent, the alginate yarn has a composite skin-core structure with three layers, in which a wrapped yarn of the outer layer consists of alginate fibers, an intermediate layer consists of spandex fibers and the central layer consists of hemp fibers. The production process provides that the yarn is made by mechanical spinning by means of a tri axial spinning device, which twists the outer layer of seaweed fiber on an intermediate layer of Spandex fiber and an inner layer of hemp fiber.

[0011] Patent CN 110318269 B describes a dyeing method without salt and without seaweed fiber alkalis, which allows a reduced loss of mass per unit area. Cationic viscose fiber is also used in said patent.

[0012] Patent EP 3276053 Al describes a regenerated fireproof cellulose fiber with organic si 1 icon-ni trogen , having a higher limit oxygen index and improved fireproof performance, in particular, the described fiber comprises an amount of silicon between 5-15% by weight, nitrogen between 0.1-5% by weight, oxygen between 30-60% by weight, carbon between 20-40% by weight, hydrogen between 1-7% by weight, titanium between 1-7% by weight and calcium between 1-7% by wei ght . uses of alginate fibers are also known for producing general items of clothing. For example, the company in question uses a type of seaweed of nonfireproof origin for producing textiles intended for the civil and sports sector.

[0013] The finding aims to overcome the limits of the prior art highlighted above, by providing a fireproof eco- sustainable and environmentally friendly textile structure, with high mechanical resistance, usable for creating garments and linen in general.

[0014] The suggested solution is a textile structure, and production process, usable for producing IPD garments, provided with intrinsically fireproof properties, made with yarns of various counts, created from the intimate mix of 100 % biodegradable, compostable, eco-sustainable plant fibers in percentages varying according to the specific needs required by the type of protective garment made for users who may come into contact with flames and / or suffer the effect of other sources of heat.

[0015] A better understanding of the finding will be achieved with the following detailed description of a preferred embodiment.

[0016] As previously said, the finding consists of a textile structure and relative manufacturing process, made from a plurality of plant fibers, which are eco- sustainable and environmentally friendly, compostable and biodegradable, in which the features of said fibers give the textile fireproof properties and the selection and dosage of which allow high mechanical resistance to be achieved.

[0017] According to the finding, the exclusive use of plant fibers allows overcoming the limits of the prior art, avoiding the addition of chemical products, making the disposal of the garment easy and non-polluting because when the product has reached its end of use, it is not intended for differentiated waste collection, but can serve as vegetable compost for the ground as it is a 100% biodegradable and compostable product. Furthermore, a textile of this type does not create deposits of polluting substances in the subsoil, and if disposed of, for example by combustion, causes no harm to the atmosphere since no harmful substances are present in the fumes.

[0018] The garments made from the described textile structure are classifiable as IPD (HI category); said garments are thus composed of 100% biodegradable, compostable and eco-sustainable plant-based fibers.

[0019] Furthermore, besides satisfying the current requirements of environmental sustainability, they ensure the protection provided by the European standard UNI EN ISO 11612:2015, having undergone specific testing to evaluate the functional protective features.

[0020] More specifically, according to the present invention the use of plant fibers is provided, deriving from seaweed, in percentages greater than, or equal to 40% of the composition, and other plant fibers, such as hemp fibers, viscose fibers, beech fibers, for example and the like.

[0021] Said plant fibers are added in percentages varying according to the needs; nonetheless, all the fibers used are 100% biodegradable, compostable and eco-sustainable.

[0022] As said, the textile according to the finding is used for manufacturing protective clothing for users who may come into contact with flames and / or suffer the effects of other sources of heat by contact with radiation and convection, such as, Fire Brigade, civil Protection forces and / or the like.

[0023] Besides producing yarns with various thread counts, which are intrinsically fireproof, eco-sustainable, 100% biodegradable, compostable and of plant origin, the use of said plant fibers allows obtaining yarns with which to make fireproof textile structures having a uniform coloring, high mechanical resistance and that are highly resistant to uv rays, washing and rubbing.

[0024] Said features can be experimentally determined and measured with tests provided in the industry standards; therefore, said garments are included among the equipment called “individual Protective Devices”, acronym IPD, III category.

[0025] A 100% biodegradable and compostable textile structure is the object of the present invention, made from a plurality of fibers, obtained by mixing a main matrix consisting of seaweed fibers with other plant fibers, such as hemp fibers, viscose fibers, beech fibers or the like, for example, for manufacturing garments or linen usable as individual protective devices and having fireproof properties.

[0026] According to the finding, the fiber deriving from seaweed, or alginate fiber, consists of calcium alginate, a metal salt of alginic acid deriving from a copolymer; such fiber is added in a mixture with percentages not less than 25%, preferably (but not exclusively) equal to at least 40%.

[0027] For producing said fiber, alginate acid is extracted from the cell wall of the seaweed and solubilized in the form of sodium alginate by known processes; then, the flosses of the yarn are extruded and coagulated in a bath of calcium salt-based aqueous solution.

[0028] The result leads to the formation of a calcium alginate with reduced solubility and this allows using the alginate fibers as natural fibers for manufacturing yarns for textiles.

[0029] The known process of producing such alginate fibers takes place in closed cycle, without release of chemical substances, hence the European union’s decision to grant this procedure the environmental award in the category “technology for sustainable development”.

[0030] A 100% biodegradable and compostable fiber derives from the aforesaid seaweed, having a wide range of performance advantages: in fact, besides the intrinsically fireproof properties, said fibers have reduced weight, hypoallergenic and non-allergenic properties, high breathability with 50% higher absorbency to sweat with respect to normal cotton fiber, good thermal insulation, skin-protecting, antiinflammatory, anti-oxidant, re-mineralizing effects, softness, resistance to uv rays, to washing and ironing, as the yarns of alginate fibers can be washed at high temperatures and ironed as any other cotton garment.

[0031] Therefore, as regards the fireproof properties, only the alginate fiber boasts a LOI Limit Oxygen index) reaching 47.2%.

[0032] According to the finding, the addition of other plant fibers to the alginate matrix allows increasing the final mechanical resistance of the structure, enabling the use thereof as an IPD. The addition of other plant-based fibers ensures compliance with tenacity performance and possibly further contributing to flameretardant properties.

[0033] According to the finding, the percentage of alginate fibers in the yarn must be comprised between 25% and 60% to ensure the fire-proof properties of the final yarn.

[0034] According to the present invention, hemp fibers are added to said alginate fibers in a percentage varying between 5% and 25% and beech fibers in a percentage varying between 5% and 50%. in addition to hemp fiber, beech fiber or possibly another fiber of plant origin is added. in a preferred, but non-limiting embodiment, the alginate fibers in the yarn are present at 45%, the hemp fibers are present at 15% and the beech fibers are present at 40%.

[0035] Other types of biodegradable and / or organic fibers other than the previously described hemp or beech fibers, for example further plant fibers (e.g. bamboo, cotton, viscose, etc.), mineral and / or animal fibers can also be added to the base matrix of the yarn, consisting of alginic fibers in the above indicated percentage range; nonetheless, the addition of said fibers does not compromise the features of the final yarn and allows ensuring fireproof and biodegradable properties of the final product.

[0036] Consequently, the textiles obtained from the fireproof yarn according to the finding are fire-proof and with high mechani cal -type properties. in particular, high resistance to traction, tear and fire has been found, in compliance with the corresponding European standards:

[0037] • UNI EN ISO 13934-1 / 2013 (TRACTION RESISTANCE)

[0038] • UNI EN ISO 13937-2 / 2002 (TEAR RESISTANCE) • UNI EN ISO 15025 / 2003 (FIRE RESISTANCE)

[0039] The textiles described so far can be subjected to repeated washing, between 10 °C and 90 °C with spin cycle, using natural cleaning solutions and avoiding soaps with high alkaline and / or salt content.

[0040] Therefore, according to the invention, the composition made with seaweed fibers and other plant fibers ensures 100% biodegradability of the yarn in all natural and industrial environments, such as the ground, compost, fresh water and sea water, and therefore the textiles obtained therefrom have the same features.

[0041] Advantageously, the process used for producing the textile structure described so far allows maintaining the properties of the single yarns in the final textile structure, without needing to add other external chemical components, which may jeopardize the features of environmental friendliness, biodegradability, compostability and the final fireproof and high mechanical resistance properties.

[0042] The production process provides that, before spinning, i.e. before being transformed into yarn, the fibers undergo a coloring process of the organic type using natural and / or organic colorants therefore completely environmentally friendly (100% green); specifically, each fiber is colored separately from the others to ensure greater uniformity of the color and to obtain a final textile not showing any changes in color.

[0043] At the end of the coloring process, the fibers are subjected to an intimate mixture processing, which involves different successive mixing steps to obtain a single uniform yarn, in fact, the term “mixing” indicates that the fibers of a different type and / or origin are intimately mixed creating a unique mixture. in the first step, the fibers are inserted into an intimate mixing chamber provided with heating and humidification means for maintaining a constant temperature .

[0044] The fibers are then introduced into a loading funnel, allowing the fibers to enter the extruder connected to a static mixer carrying them to a mixing pump where they are completely mixed, successively crossing a sort of centrifuge for further mixing.

[0045] Following this step, the intimate mixture of the fibers reaches a cooling chamber.

[0046] The final step is a step of spinning and winding the yarn.

[0047] Thus produced, the textile structure is ready to be used for producing clothing and / or underwear.

Claims

CLAIMS1. A textile structure for manufacturing protective fireproof clothing and / or linen with high mechanical resistance, highly resistant to uv rays, washing and rubbing, for military use for users who may come into contact with flames and / or suffer the effects of other sources of heat by contact, radiation and convection, such as, Fire Brigade, civil Protection forces and / or the like, and having the features of equipment known as “individual Protective Devices” (IPD HI category), said textile structure being characterized in that it is made from a plurality of plant fibers that are eco-sustainable and envi ronmental ly-f riendly, compostable and biodegradable, wherein, a main matrix is consisting of seaweed fibers, or alginate fibers, which are processed in intimate mixture together with other plant fibers, said matrix of alginate fibers being present in the final textile structure in a range between 25% and 60%, the remaining part being compensated by plant-based fibers, such as hemp fibers, viscose fibers, beech fibers, bamboo, cotton, viscose or the like.

2. A textile structure according to claim 1, characterized in that said alginate fibers consist of calcium alginate, a metal salt of alginic acid deriving from a copolymer, said calcium alginate having intrinsic properties, such as: reduced weight, hypoallergenic and anallergic properties, high breathability with absorbency 50% higher than sweat with respect to normal cotton fiber, good thermal insulation, skin-protecting, anti-inflammatory, anti-oxidant, re-mineralizingeffects, softness, resistance to uv rays, to washing and ironing, and an LOI Limit Oxygen index) of 47.2%.

3. A textile structure according to one or more of the preceding claims, characterized in that it provides adding other plant fibers to said alginate matrix to increase the final mechanical resistance of the structure.

4. A textile structure according to one or more of the preceding claims, characterized in that it is environmentally friendly, 100% biodegradable, compostable in all natural and industrial environments, such as the ground, fresh water and sea water, for example, provided with fire-proof properties and high mechanical resistance and therefore, the textiles obtained therefrom have the same features.

5. A textile structure according to one or more of claims 1 to 3, characterized in that it is of the eco-sustainable type, 100% biodegradable and compostable, of plant origin, intended for organic-type disposal, i.e. used as land compost and / or if disposed of differently, it ensures the absence of harmful and chemical fumes in the air.

6. A textile structure according to one or more of the preceding claims, characterized in that it consists of 45% alginate fiber, 15% hemp fibers and 40% beech fibers.

7. A process for producing the textile structure according to claim 1, characterized in that the fibers are subjected to intimate mixture processing, wherein the fibers of different type and / or origin are intimately mixed, creating a unique mixture, saidprocessing being characterized by a plurality of steps, in which:• in the first step, the fibers are inserted into one or more mixing chambers provided with heating and humidification means for maintaining a constant temperature ;• The fibers are then introduced into a loading funnel, allowing the fibers to enter an extruder connected to a static mixer;• The fibers pass from the static mixer to a mixing pump where they are completely mixed;• The fibers are directed to a rotation disk by said mixing pump for a further mixing;• Then, the intimate mixture of fibers reaches a cooling chamber to allow the final cooling;• Finally, the fibers, thus mixed and cooled, are subjected to a step of spinning and winding of the yarn thus obtained.

8. A process of producing the textile structure according to claim 7, characterized in that the fibers used undergo a preliminary coloring step using organic and / or plant colorants and therefore completely environmentally friendly (100% green); said coloring step being carried out before spinning, and that is, before being transformed into yarn, wherein each fiber is colored separately from the others to ensure greater uniformity of the color and to obtain a final textile not showing any changes in color.

9. A process for producing the textile structure according to claims 7 and 8, wherein the succession of steps allows obtaining a final homogenous textilestructure in terms of coloring, without changes in the properties of the original fibers from which it originates, ensuring that the final structure has substantially fireproof properties, with high mechanical resistance.