Method of producing a bio based textile material and materials and products made thereby

Abstract

The present invention is directed to a system and method for creating different bio-based, natural composite textile materials. In the system and method described herein, a non-woven fabric is used as a backing material upon which the bio-based, natural composite materials are applied in one or more coating layers, resulting in a bio-based and substantially biodegradable textile material that provides high performance in consumer industries, such as the footwear industry.

1 . A method for producing a bio-based textile material, comprising:
 applying a first coating to a reinforcement backing material, wherein the first coating includes a slurry containing mushroom material and natural rubber material,   drying the reinforcement backing material with the first coating;   flattening a surface of the reinforcement backing material with the first coating,   applying a second coating to the reinforcement backing material, wherein the second coating includes a slurry containing a natural rubber material and wherein the second coating is applied on top of the first coating;   applying a third coating to the reinforcement backing material, wherein the third coating is applied on top of the second coating; and   adjusting the thickness of the reinforcement backing material.   
     
     
         2 . The method of  claim 1 , wherein the reinforcement backing material is a woven or a non-woven fabric. 
     
     
         3 . The method of  claim 1 , wherein the natural rubber is latex. 
     
     
         4 . The method of  claim 1 , wherein the first, second and third coating comprise separate layers. 
     
     
         5 . The method of  claim 1 , wherein the first coating is a homogenous solution, continuously mixed as it is applied to the reinforcement backing material using at least one of a roller coater machine, doctor blade, Foulard system, brushes or other application devices that spread the first coating. 
     
     
         6 . The method of  claim 1 , wherein the thickness of the reinforcement backing material is adjusted by splitting the reinforcement backing material based at least in part on performance requirements of the No-based textile material. 
     
     
         7 . The method of  claim 1 , wherein a roller coater system is used to apply the at least one of the first coating, the second coating or the third coating, the roller coater system comprising:
 a container for holding the slurry;   a nozzle or valve in the container to control the amount of slurry, the nozzle or valve connected to a controllable pump allowing a user to adjust the amount of slurry coating dispensed;   an application coating roller controllable to rotate to contact the reinforcement backing material with an adjustable amount of pressure, wherein the nozzle or valve dispenses the slurry from the container onto the application coating roller;   one or more scraper blades to remove excess slurry, wherein the thickness of a coating applied to the reinforcement backing material by the application coating roller is based on the amount of slurry released from the nozzle.   
     
     
         8 . The method of  claim 7 , wherein the thickness of the coating applied to the reinforcement backing material by the application coating roller is adjusted based on the distance between the one or more scraper blades and the application coating roller or the amount of pressure applied to the roller by the one or more scraper blades 
     
     
         9 . The method of  claim 1 , wherein at least one of the first coating, the second coating or the third coating is applied on one or both sides of the reinforcement backing material. 
     
     
         10 . The method of  claim 1 , wherein the thickness and amount of the reinforcement backing material, the first coating, the second coating and the third coating is adjusted by trimming or cutting to a shape, size and thickness. 
     
     
         11 . A system for creating a bio-based sheet textile material, comprising:
 a reinforcement backing material;   a roller coater system for applying a first coating, a second coating and a third coating to the reinforcement material,   the first coating including a slurry containing mushroom material and natural rubber material;   a drying mechanism for drying the reinforcement backing material with the first coating;   an embossing machine for flattening a surface of the reinforcement backing material with the first coating;   the second coating including a slurry containing a natural rubber material and wherein the second coating is applied on top of the first coating and the third coating is applied on top of the second coating; and   a splitting device for adjusting the thickness of the reinforcement backing material,   
     
     
         12 . The system of  claim 11 , wherein the reinforcement backing material is a woven or a non-woven fabric. 
     
     
         13 . The system of  claim 11 , wherein the natural rubber is latex. 
     
     
         14 . The system of  claim 11 , wherein the first, second and third coating comprise separate layers. 
     
     
         15 . The system of  claim 11 , wherein the first coating is a homogenous solution, continuously mixed as it is applied to the reinforcement backing material using at least one of a roller coater machine, doctor blade, Foulard system, brushes or other application devices that spread the first coating. 
     
     
         16 . The system of  claim 11 , wherein the thickness of the reinforcement backing material is adjusted by splitting the reinforcement backing material based at least in part on performance requirements of the bio-based textile material. 
     
     
         17 . The system of  claim 11 , wherein the roller coater system is used to apply the at least one of the first coating, the second coating or the third coating, the roller coating system comprising:
 a container for holding the slurry;   a nozzle or valve in the container to control the amount of slurry, the nozzle or valve connected to a controllable pump allowing a user to adjust the amount of slurry coating dispensed;   an application coating roller controllable to rotate to contact the reinforcement backing material with an adjustable amount of pressure, wherein the nozzle or valve dispenses the slurry from the container onto the application coating rollier;   one or more scraper blades to remove excess slurry, wherein the thickness of a coating applied to the reinforcement backing material by the application coating roller is based on the amount of slurry released from the nozzle.   
     
     
         18 . The system of  claim 17 , wherein the thickness of the coating applied to the reinforcement backing material by the application coating roller is adjusted based on the distance between the one or more scraper blades and the application coating roller or the amount of pressure applied to the roller by the one or more scraper blades. 
     
     
         19 . The system of  claim 11 , wherein at least one of the first coating, the second coating or the third coating is applied on one or both sides of the reinforcement backing material. 
     
     
         20 . The system of  claim 11 , wherein the thickness and amount of the reinforcement backing material, the first coating, the second coating and the third coating is adjusted by trimming or cutting to a shape, size and thickness.