Composite fabric comprising a biopolymer layer which is obtained from microorganisms
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Solution Overview
Problem
Existing composite fabrics with biopolymer layers, such as bacterial cellulose, face issues with detachment from the base fabric, difficulty in dyeing, and high production costs due to the need for anchoring polymers and chemical cross-linkers, which also hinder the achievement of fashionable visual effects in clothing articles.
Innovation Solution
A composite fabric design featuring a woven base fabric with loop portions that serve as securing means for the biopolymer layer, allowing it to be grown directly on the fabric without the use of chemical binders, enhancing dye uptake and maintaining the biopolymer layer's attachment during dyeing and finishing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If anchoring polymers and chemical cross-linkers are used to attach the biopolymer layer to the base fabric, then the attachment strength is improved, but the dye uptake capability deteriorates and production costs increase
Solution Approach 1:
The invention extracts and removes the harmful chemical cross-linkers and anchoring polymers from the composite fabric structure. By using only physical entanglement through loop portions to attach the biopolymer layer, the patent eliminates substances that would interfere with dye uptake, thereby resolving the contradiction between attachment strength and dye uptake capability
Solution Approach 2:
The loop portions act as an intermediary mechanical structure between the base fabric and the biopolymer layer. These loops provide attachment through physical entanglement without requiring chemical substances, thus maintaining both strong attachment and full dye uptake capability of the biopolymer layer
2Strength
If anchoring polymers and chemical cross-linkers are used to attach the biopolymer layer, then the attachment strength is improved, but the production costs increase
Solution Approach 1:
The invention extracts and eliminates the need for expensive chemical cross-linkers and anchoring polymers. By relying solely on the mechanical loop portions already present in the base fabric, the patent reduces material costs and simplifies the manufacturing process, thereby resolving the contradiction between attachment strength and production costs
Solution Approach 2:
The base fabric's loop portions inherently provide the attachment function without requiring additional chemical substances. The structure serves itself by using its own geometric features to secure the biopolymer layer, eliminating the need for separate anchoring agents and reducing overall production costs
3Adaptability or versatility
If a biopolymer layer is applied to a base fabric, then the functional properties are improved, but the biopolymer layer detaches during dyeing and finishing processes
Solution Approach 1:
The base fabric is pre-equipped with loop portions that are specifically designed to mechanically interlock with the biopolymer layer before dyeing and finishing processes. This preliminary structural preparation ensures that the biopolymer layer remains securely attached during subsequent high-temperature and high-moisture processing, resolving the contradiction between functional properties and attachment stability
Solution Approach 2:
The loop portions create a flexible mechanical interlocking structure that adapts to the biopolymer layer while maintaining secure attachment. This flexible mechanical bond remains effective during the dynamic conditions of dyeing and finishing processes, preventing detachment while preserving the functional properties of the biopolymer layer
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite fabric achieves easy and cost-effective dyeing with low dye consumption, maintains the biopolymer layer's attachment, and allows for fashionable visual effects in clothing articles, reducing production waste and costs.
Implementation Method 1
contacting at least part of at least one of the sides of said base fabric with a culture of biopolymer-producing microorganisms, said at least one of the sides being provided with said additional layer of loop portions; culturing said biopolymer-producing microorganisms, to provide the base fabric with at least one biopolymer layer produced by said biopolymer-producing microorganisms
Data Source
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AI summary
The present invention relates to a composite fabric comprising a base fabric (1)and at least one bacterial biopolymer layer(20). The base fabric is a woven fabric, and comprises warp yarns(2)and weft yarns(3,4). A first plurality of warp yarns and at least one plurality of first weft yarns form a base layer(1a)of the base fabric, and at least one second plurality of warp yarns and/or at least one plurality of second weft yarns forms an additional layer (1b)of loop portions (7) on at least one of the sides(5, 6)of the base fabric. The at least one bacterial biopolymer layer(20)is provided at least on part of the additional layer(1b). The invention further relates to a process for the production of the composite fabric and to a clothing article comprising the composite fabric.