Method of forming a cellulose web
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Solution Overview
Problem
Current methods for producing cellulose fabrics are limited to two-dimensional formats, requiring sewing of flat fabrics together to create clothing, whereas there is a need for a method to form cellulose fabric directly on three-dimensional objects.
Innovation Solution
A method involving the application of cellulose-producing bacterial and/or fungal cultures to a three-dimensional object, followed by repeated spraying with a nutrient solution in a controlled environment to deposit a cellulose layer, which is then thermally processed to stabilize and remove the cellulose fabric, allowing for seamless formation on complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat cellulose fabrics are grown and sewn together to create garments, then traditional textile production methods are used, but the fabrics cannot be formed directly on three-dimensional objects and require additional sewing steps
Solution Approach 1:
The patent transitions from two-dimensional flat fabric growth to three-dimensional object coating. Cellulose-producing cultures are applied directly to 3D objects (shoes, clothing, accessories) and grow conformally to the object's shape, eliminating the need to flatten, cut, and sew separate fabric pieces together.
Solution Approach 2:
The bacterial cultures autonomously grow and deposit cellulose directly on the three-dimensional object surface when provided with nutrient solution. The system self-assembles the fabric structure conformally to the object shape without requiring external manipulation, patterning, or assembly steps.
2Manufacturing precision
If cellulose cultures are applied to three-dimensional objects with repeated spraying of nutrient solution, then seamless fabric formation is achieved, but the process requires controlled environment and multiple processing steps
Solution Approach 1:
The patent employs periodic spraying of nutrient solution onto the cellulose cultures at controlled time intervals. This periodic nourishment allows the cultures to grow in controlled increments, ensuring uniform cellulose deposition and fabric thickness while maintaining productivity through automated spraying cycles.
Solution Approach 2:
The patent controls the growth process by adjusting parameters including nutrient solution concentration, spraying frequency, humidity levels (at least 90%), and temperature. These parameter changes enable precise control over cellulose deposition rate and fabric properties while maintaining efficient production.
3Adaptability or versatility
If different bacterial and fungal cultures are applied to different areas of the object, then customized fabric properties are achieved, but the application process becomes more complex
Solution Approach 1:
The patent applies different cellulose-producing cultures to different regions of the three-dimensional object to create localized variations in fabric properties. For example, different cultures can produce varying thickness, density, texture, or functional characteristics in specific areas, allowing customization without complex application machinery.
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
Enables the creation of seamless cellulose fabrics on three-dimensional objects, offering a sustainable alternative to traditional textile production methods and allowing for the integration of additional materials or objects within the fabric, resulting in materials similar to leather, paper, or wood, with customizable properties.
Implementation Method 1
at least one cellulose-producing bacterial and/or fungal culture is applied to the surface of a three-dimensional object... the bacterial and/or fungal culture has deposited a cellulose layer
Implementation Method 2
the cellulose layer on the three-dimensional object is thermally processed in order to obtain the cellulose fabric in a stabilized form
Data Source
Figure 1~4
Figure 5~7
Figure 8~11
AI summary
The invention relates to a method for forming a seamless cellulose tissue (9), comprising the steps of applying at least one cellulose-producing bacterial and/or fungal culture (4) to the surface of a three-dimensional object (1) in a first step, repeatedly spraying the three-dimensional object (1) with a nutrient solution (5) in a closed environment (3) until the bacterial and/or fungal culture (4) has deposited a cellulose layer (7) of the desired thickness, and thermally processing the cellulose layer (7) on the three-dimensional object in order to obtain the cellulose tissue (9) in a stabilized form.