Process for manufacturing fabric and the resulting product

Abstract

The present invention relates to a fiber manufactured, for example, by the viscose process or by the lyocell process, said fiber comprising a blend of soluble cellulose pulp and soluble pulp made up of other lignocellulosic components derived from plant residue, for manufacturing sustainable fabrics.

Description

FABRIC MANUFACTURING PROCESS AND THE RESULTING PRODUCT. DESCRIPTIVE REPORT FIELD OF THE INVENTION

[0001] The present invention falls within the field of materials for the textile industry and more specifically in a process for manufacturing yarns from lignocellulosic vegetables and the product derived from this manufacturing.

[0002] This type of product also allows for the identification of the lignocellulosic plant material used in its manufacture.

[0003] The process consists of 3 modules, where the first two are carried out in parallel and produce the inputs used in the third module. PREVIOUS EDITIONS

[0004] In the textile industry, it is common to use cellulose to manufacture yarns that are then transformed into fabrics. Cellulose production for the textile industry is largely based on cotton cultivation, which requires large areas of land and produces waste. Cotton plantations are large consumers of water.

[0005] Another alternative used by the textile industry is the manufacture of fabric from synthetic fibers, most of which are derived from fossil fuels.

[0006] The dyeing of fabric using cellulose is, in turn, a cause for environmental concern, as it uses solvents and dyes that are pollutants and are often discharged into rivers.

[0007] A number of inventions have sought to utilize fibrous residues from other plants in the production of fabric, however, so far with little success.

[0008] The invention is registered under number WO22194323, Textile product and use of textile product, 2022.

[0009] This involves obtaining a filament with a core composed of natural fibers, such as cocoa, to create a product in the form of a textile filter.

[0010] The invention in this case utilizes raw fibers from natural products and does not treat the fiber for fabric transformation.

[0011] The invention filed under number WO2012057684, Cellulose derivatization process, 2012

[0012] This presents a process for derivatizing cellulose. The cellulose, which should not have very high viscosity, is subjected to high pH and low temperature, after which the pH is increased and / or the temperature is increased. Then the cellulose is derivatized.

[0013] This process does not allow for the achievement of high viscosity.

[0014] The invention filed under number WO2015077807, Process for pre-treating recovered cotton fibers for use in the production of molded bodies from regenerated cellulose, 2015.

[0015] A process is used for pre-treating recovered cotton fibers for the manufacture of molded bodies from regenerated cellulose.

[0016] The process used comprises a metal removal step and an oxidative bleaching step, which differs from the process presented here by not using lignocellulose fiber in the production of the fabric.

[0017] The invention is registered under number WO2018104330, Cellulose fibers, 2018.

[0018] A method is presented for producing regenerated cellulose fiber using the Lyocell process from a mixture of dissolved cellulose pulp with specially treated recycled cellulose fabrics.

[0019] Viscose is a regenerated cellulose fiber, structurally similar to cotton. To produce viscose, dissolved pulp is treated with an aqueous solution of sodium hydroxide (16-19% by weight) to obtain alkaline cellulose. Then, the alkaline cellulose is treated with carbon disulfide to form sodium cellulose xanthate.

[0020] In the Lyocell process, wood is chipped and undergoes chemical digestion to soften it by removing lignin, allowing for mechanical grinding to form wet pulp. The wet pulp can then be bleached. The pulp is then dried into continuous sheets and rolled. N-methylmorpholine N-oxide is the solvent most frequently used in the Lyocell process. The pulp is dissolved in N-methylmorpholine N-oxide, resulting in a solution called spinning solution. The cellulose solution is filtered and then pumped through spinnerets, devices used to produce a variety of artificial fibers. The spinneret is composed of small holes, like a showerhead, and when the solution is forced through it, continuous filament strands emerge. The fibers are pulled to align the cellulose molecules, giving Lyocell fibers their characteristic high mechanical strength.The fibers are then immersed in another amine oxide solution, this time diluted, which coagulates the fiber strands. Next, the strands are washed with demineralized water. The Lyocell fiber then goes through a drying system where the water evaporates. The strands then undergo a finishing step where a lubricant is applied, which can be a soap or a silicone, or another agent depending on the future use of the fiber. This step is only to prevent the filaments from tangling before the conventional carding and spinning processes.

[0021] Dry, finished fibers, in the form of tow, consist of a large, untwisted bundle of continuous filament lengths. The tow bundles are fed into a crimping machine; a machine that combs the fiber, giving it texture and volume. The crimped fiber is carded by mechanical cards, which perform a combing-like action to separate and order the yarns. The carded yarns are cut and baled to be sent to a textile mill. The entire manufacturing process, from unwinding the raw cellulose to baling the fiber, takes about two hours. After that, Lyocell can be processed in various ways. It can be spun with another fiber, such as cotton or wool. The resulting yarn can be woven or knitted, like any other fabric, and can receive a variety of finishes, from soft and suede-like to silky.

[0022] A process for the production of Lyocell fibers is described, for example, in patent document 4246221, Process for molded cellulose article prepared from a solution containing cellulose dissolved in a tertiary amine N-oxide solvent. Lyocell fibers are distinguished by high tensile strength, high wet modulus and high tie strength.

[0023] Nevertheless, there is a need for improvements, such as the reuse of agro-industrial waste, resulting in a fiber manufactured using a solvent spinning process, such as the Lyocell process, where the biomass is, for example, cocoa husk, replacing wood. Furthermore, this process should not be solely based on purified soluble cellulose pulp, but should also include lignin in its composition, which acts as a structural reinforcing component to improve tensile strength, in addition to providing multifunctional characteristics such as antimicrobial action.

[0024] The invention filed under number CN107338528A, Semi-combed cocoa fiber yarn for health care, 2017.

[0025] This document describes a method for obtaining a blended yarn using calcined cocoa fibers. The calcined fibers They are transformed into a nanometric powder and added to artificial fibers, such as polyester fibers, to improve some of their properties, such as benefits for the skin, quick drying, odor control, thermal insulation, among others.

[0026] In this case, the cocoa residue is not used in fiber form, but rather as a powdered filler for fiber production. GENERAL DESCRIPTION

[0027] Given the gaps identified in the state of the art and the existing demands regarding the production of biomass fabric, it was necessary to create a new technique, as revealed below.

[0028] This technique aims to expand the use of a process that utilizes a compound of regenerated cellulose and lignin, called lignocellulose.

[0029] This process will be carried out in two parallel stages, designated A and B, and will subsequently be finalized in a single stage, designated C.

[0030] The stages consist of the following phases:

[0031] Stage A

[0032] 1 - Biomass Crushing

[0033] 2- Treatment of lignocellulosic material

[0034] 3- Whitening

[0035] 4- Regrinding

[0036] Stage B

[0037] 1 - Biomass Crushing

[0038] 2- Treatment of lignocellulosic material

[0039] Stage C

[0040] 1 - Mixing of steps A and B

[0041] 2- Creating the thread

[0042] 3- Weaving.

[0043] As described below:

[0044] Stage A

[0045] A.1 - Lignocellulosic biomass, in a formulation of 4 to 10% fiber, is ground to a particle size of 0.25 to 2.00 mm;

[0046] A.2- Treatment of lignocellulosic material is carried out in an alcoholic solution in the range of 30-70% (v / v) with a pressure of 8-13 bar and a temperature between 120-200°C;

[0047] A.3- Bleaching with hydrogen peroxide under alkaline conditions with a pH of 7 to 13.5 and a temperature between 30-70°C yields regenerated cellulose;

[0048] A.4- This regenerated cellulose is crushed to a particle size of 0.2 to 2.0 mm;

[0049] Stage B

[0050] B.1 - Lignocellulosic biomass, in a formulation of 4 to 10% fiber, is ground to a particle size of 0.25 to 2.00 mm;

[0051] B.2- Treatment of lignocellulosic material is carried out in an alcoholic solution in the range of 30-70% (v / v) with a pressure of 8-13 bar and a temperature between 120-200°C, lignocellulosic pulp is obtained;

[0052] Stage C

[0053] C.1 - The regenerated cellulose resulting from step A is mixed with the linocellulosic pulp from Step B, in a formulation of 4 to 10%;

[0054] C.2- Yarn manufacturing using the Lyocell process;

[0055] C.3 - Weaving the fabric.

[0056] One characteristic of the process and product described above is that the final product, in the form of yarn or fabric, allows for the identification of the raw material used in Steps A and B based on the lignin, which is different in the cases of cocoa, cupuaçu, and banana, and even different in the cocoa, cupuaçu, and banana variants. Table 1: Description of the Figures PREFERRED MODALITIES

[0057] The fabric manufacturing process and resulting product consist of 3 stages, where Stage A comprises 4 (four) phases, Stage B comprises 2 phases, in which the mixing of Stage A and Stage B are carried out in parallel, and Stage C comprises 3 phases. This process results in the production of a yarn that is sent for weaving. The formulation contains 4 to 10% of the material from Stage B and the remainder from Stage A.

[0058] The product derived from mixing A and B can be softer depending on the amount of component A used in the mixture. The greater the amount of A in the mixture, the more similar the final product will be to cotton, and the greater the amount of B in the mixture, the more similar the product will be to viscose.

[0059] A process according to claim 1, wherein the mixture of steps A and B has a concentration of 96% of A and a concentration of 4% of B, generating a product similar to cotton.

[0060] A process according to claim 1, wherein the mixture of steps A and B has a concentration of 90% of A and a concentration of 10% of B, generating a product similar to viscose.

[0061] A process according to claim 1, wherein the mixture of steps A and B has a concentration of 90% to 96% of A and a concentration of 4% to 10% of B, wherein the higher the concentration of A, the softer the product becomes.

[0062] Process according to claim 1, wherein the lignocellulosic fiber input is made from cocoa husk.

[0063] Process according to claim 1, wherein the lignocellulosic fiber input is made from cupuaçu husk.

[0064] Process according to claim 1, wherein the lignocellulosic fiber input is made from banana stem.

Claims

CLAIMS 1. A fabric manufacturing process characterized by being composed of 3 stages where Stage A is composed of 4 phases: phase 1 biomass grinding, phase 2 lignocellulosic material treatment, phase 3 bleaching and grinding of the product; Stage B is composed of two phases: biomass grinding and phase 2 lignocellulosic material treatment; and a Stage C where the products derived from stages A and B are mixed in a proportion where the product derived from Stage A accounts for 90% to 96% and the product derived from Stage B accounts for 4% to 10% respectively, are spun and woven.

2. Product resulting from a fabric manufacturing process according to claim 1, characterized by having the proportion of product derived from Step A fixed at 96%.

3. Product resulting from a fabric manufacturing process according to claim 1, characterized by having the proportion of product derived from Step A fixed at 90%.

4. Fabric manufacturing process according to claim 1, characterized in that the input for Steps A and B is cocoa husk.

5. Fabric manufacturing process according to claim 1, characterized in that the input for Steps A and B is cupuaçu peel.

6. Fabric manufacturing process according to claim 1, characterized in that the input for Steps A and B is the banana stem.

7. Product resulting from the manufacture of fabric according to claim 1, characterized by allowing the identification of the input for Steps A and B from the lignin.

8. Product resulting from a fabric manufacturing process according to claim 1, characterized by having the degree of softness of the chosen fabric according to the proportion of the product derived from Step A, with a minimum of 90% and a maximum of 96%, where the higher the proportion of the product derived from Step A, the greater the softness of the fabric.

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