Field of the Invention

The present invention relates to a novel coated knitted or woven textile material made substantially from natural, plant-based fibres; to uses thereof and to methods of manufacturing such materials.

More particularly, the present invention relates to a coated knitted or woven textile material made substantially from natural, plant-based fibres; said material being stretchable.

Background to the Invention

The present invention is based on the use of a wide range of natural leaf or stem fibres, including, but not limited to, pineapple leaf fibre (PALF).

The main sources of pineapple originate from Brazil, Thailand and the Philippines.

In Brazil, Thailand, the Philippines and elsewhere, when the pineapple fruit is harvested, the pineapple leaves are mostly left to rot. Hitherto, a small amount has been used to extract pineapple leaf fibre, which is used as a filament or blended with cotton, nylon or similar natural or synthetic based fibres and spun into yarn. The yarn produced may be used in the making of woven textiles, etc.

In 2008 the top 20 pineapple producing countries produced more than 17 million MT of pineapple as is illustrated in Table I: The pineapple leaf fibres used to make the new natural knitted or woven material hereinafter described are a by-product of the pineapple fruit harvest. Currently they are left to decompose after the fruit harvest. Thus, the income of pineapple farmers in Bangladesh, Ivory Coast, the Philippines and elsewhere, would be enhanced by the fibre extraction processes needed in the production of this new natural knitted or woven material hereinafter described. The technology, when completed, will be transferable to other regions of the world which are large producers of pineapple. A suitable use of pineapple leaf fibre would be economically beneficial to pineapple farmers, it would also provide a material from renewable resources that is otherwise often discarded as waste material.

The natural material is environmentally advantageous because, inter alia, it does not require additional land, energy and fertiliser for the crop, as is the case for other natural, plant-based fibres such as cotton. Nor does it compete for land resources used in the food industry which contrasts to cotton.

International Patent application No. WO 2011/148136 describes a composite nonwoven material comprising a natural leaf or stem fibre and a polymer material. The composite nonwoven material described therein provides a good natural coated textile material. However, the composite nonwoven material will generally have a density of 300g m" ² or greater and a thickness of about 2.5-3.0 mm. Furthermore, the composite nonwoven material is generally inelastic and is not considered to be stretchable.

Thus, there is a need for a more stretchable coated textile material that is generally biodegradable. Furthermore, the natural knitted or woven material may be suitable for, inter alia, use in automotive industries and the like.

Summary of the Invention

Thus, according to a first aspect of the present invention, there is provided a stretchable coated textile material comprising a natural knitted or woven material made substantially from plant-based yarns including natural fibres and wherein said natural knitted or woven material is coated with a stretchable polymer material.

According to one aspect of the invention the material comprises a knitted material.

According to another aspect of the invention the material comprises a woven material.

More particularly, the present invention relates to coated knitted or woven material made substantially from plant based yarns; said material resembling leather and being stretchable.

The natural plant-based yarns will generally comprise plant based fibres. More particularly, the plant based yarns comprise natural leaf or stem fibres. Leaf fibres generally comprise naturally occurring or cultivated fibres that have a high cellulose content, e.g. about 70% w/w or more. The natural, plant-based knitted or woven material used in the present invention may comprise a yarn from a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres. The natural knitted or woven material may comprise leaf fibre or a stem fibre and mixtures thereof. Preferably, the natural fibre comprises a leaf fibre. When the natural material comprises only leaf fibre, it may be based on a single source of leaf, e.g. PALF, or a mixture of leaves. The knitted or woven material used in the present invention may comprise a blend of a natural plant-based fibre and a biobased synthetic fibre. Biobased fibres are produced from renewable sources, they are generally biodegradable, compostable and eco-friendly. Biobased fibres include, but shall not be limited to, PLA (poly-lactic acid) fibre, chitosan fibre, algae based fibre, bacterial cellulose fibre, collagen fibre, spider silk fibre, milk-weed fibre, milk fibre and bio-wash/enzyme fibre; including combinations thereof.

A preferred yarn is made from a leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF. Alternatively, fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF. Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc. When a stem fibre is included in a composite material of the invention may comprise a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp. An especially preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), pineapple. However, it will be understood by the person skilled in the art that mixtures of leaf and stem fibres, for example, fibres that may have a relatively high content of pineapple leaf fibres, may be used in the yarns of this aspect of the invention. When the yarn comprises a composite material including leaf and stem fibres, preferably a majority of the material comprises a leaf fibre, such as PALF. Thus, in the yarn used in the knitted or woven material of the invention the leaf fibre may comprise at least 20% w/w of the leaf/ stem fibre content, preferably at least 30% w/w of the leaf/ stem fibre content, preferably at least 40% w/w of the leaf/ stem fibre content, preferably at least 50% w/w of the leaf/ stem fibre content, preferably at least 60% w/w of the leaf/ stem fibre content, preferably at least 70% w/w of the leaf/ stem fibre content preferably at least 80% w/w of the leaf/ stem fibre content, preferably at least 90% w/w of leaf/ stem fibre content and especially at least 95% w/w of the leaf/ stem fibre content. When a mixture of leaf fibres is used it is desirable that a major part of the leaf fibre is PALF. Thus, at least 50% w/w of the leaf fibre content is PALF, preferably at least 60% w/w of the leaf fibre content is PALF, preferably at least 70% w/w of the leaf fibre content is PALF, preferably at least 80% w/w of the leaf fibre content is PALF, preferably at least 90% w/w of the leaf fibre content is PALF and especially at least 95% w/w of the leaf fibre content is PALF. In one aspect of the present invention when the leaf fibre is PALF, the natural fibre element of the knitted or woven material may comprise about 100% w/w leaf fibre, i.e. no stem fibre is present. Preferably the leaf or stem fibre is delignified prior to use using conventional delignification methods known in the art or other delignification methods described herein.

It will be understood by the person skilled in the art that any of the known pineapple cultivars may be used in the materials or processes of the present invention. The pineapple, Ananas comosus, has several cultivars and other subspecies taxa. Here they are pomologicaly (by fruit characteristics) sorted into three groups:

• Spanish group - is a group which can be recognized by white flesh and leaves with spines on the edge o Red Spanish o Singapur Spanish o Sugar Loaf

• Queen group - they can be recognized by yellow and/or golden yellow flesh and leaves with spines on the border o Abacachi o Cabazoni o Pernambuca o Queen o Victoria

Cayenne group - can by recognized by yellow flesh and leaves without spines on the borders o Baronne Rothschild o Cayenne

■ Hilo o Monte Lirio

The knitted or woven material may comprise a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres.

A preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Lirm), e.g. PALF. Alternatively, fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF. Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc.

When a stem fibre is included in the PALF composite, a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp.

The knitted or woven material will generally comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre or other natural cellulosic derived fibres. For the avoidance of doubt, the percentage of natural leaf or stem fibre is based on the weight of the uncoated knitted or woven material. The knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres. The remainder of the knitted or woven material will comprise a biobased fibre, which shall include, but shall not be limited to, PLA (poly-lactic acid) fibre; or a semi-synthetic fibre, such as, viscose, lyocell, tencel, recycled cotton, etc. Thus, the amount of biobased fibre or a semi- synthetic fibre may be from about 70 to about 95% w/w of the knitted or woven yarn material. It should be understood that the semi-synthetic fibre, such as, viscose, lyocell, tencel, recycled cotton, etc. may be present in the yarn itself and/or in the knitted or woven material. In a particular aspect of the invention the semi-synthetic fibre may be tencel.

Thus, according to one aspect of the invention there is provided a yarn comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi-synthetic fibre.

According to another aspect of the invention there is provided a knitted or woven material comprising such a yarn, i.e. comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi-synthetic fibre.

It is within the scope of the present invention for the knitted or woven material to comprise a blend of yarns. The knitted or woven material may be produced using conventional knitting methods known per se. Thus, the knitted or woven material may be produced by employing a continuous yarn or set of yarns to form a series of interlocking loops. Knitted fabrics can generally be stretched to a greater degree than woven fabrics. It will be understood that the knitted material may be produced as a weft knit (also known as a filling knit) or warp knit, or any combination thereof. A warp knit is usually closer, flatter, and less elastic than a filling knit. They are made on a chain loom, with each warp controlled by a separate needle. The loops interlock along the length of the fabric. When the material of the invention comprises a knitted material it may optionally comprise a 3D knitted material.

The polymer coating comprises a stretchable polymer coating. The amount of polymer coated onto the natural knitted or woven material may vary, but will generally be from about 1 to 40% w/w of a polymer, based on the weight of the total composite coated material; or from about 1 to 20% w/w of a polymer.

The amount of polymer may be from about 1 to 40% w/w, or from about 2 to 40% w/w, or from about 3 to 40% w/w, or from about 4 to 40% w/w, or from about 5 to 40% w/w, or from about 5 to 20% w/w, from about 5 to 20% w/w; based on the weight of the total composite coated material.

The polymer coating comprises a fusible polymer. The fusible polymer may be applied at a temperature of about 180°C or less, preferably about 170°C or less, preferably about 160°C or less, preferably about 150°C or less, preferably about 140°C or less, preferably about 130°C or less, preferably about 120°C or less, preferably about 110°C or less, preferably about 100°C or less, more preferably about 90°C, more preferably about 80°C or less, more preferably about 60°C or less. Thus, the polymer may be applied at a temperature of from about 50 to 120°C, preferably from about 60 to 110°C, preferably from about 60 to 110°C, preferably from about 70 to 100°C, more preferably from about 70 to 80°C. The application of the polymer can be conducted at room temperature, but then is cured at a higher temperature.

The stretchable polymer material may comprise a curable material, such as a resin. The curable material may be cured by any conventional means, thus, it may be temperature curable, e.g. heat curable; light curable, e.g. UV curable; chemically curable; etc. Thus, a suitable curable material may comprise a resin, such as an olephinic resin, e.g. a polyurethane (PU). Any polyurethane conventionally used in textiles may be used, including hydrophilic polyurethanes. However, in one aspect of the invention a polyurethane derived from renewable resources may be preferred. It will be understood that a variety of renewable polyurethanes may be used. Such polyurethanes include, but shall not be limited to, polyurethanes derived from corn sugars, vegetable oils, including safflower, sunflower, soybean and castor oils, etc. Mixtures of polyurethanes may also be used, including mixtures of conventional (fossil fuel derived) polyurethanes and renewable polyurethanes.

In a further aspect of the invention the curable polymer material may comprise a pigmented curable resin. Thus, for example, a pigmented curable resin may comprise a resin as herein described, including a colour pigment. Alternatively, the pigment may be applied in a different curable material. The choice of such pigments will be well understood by the person skilled in the art and will comprise conventional pigments.

The pigmented curable resin may be applied as a coating to the knitted or woven material, such that the coated knitted or woven material is provided with a colour finishing.

A variety of fusible polymers known to the person skilled in the art may be used in the coating of the material of the present invention. Such polymers may comprise a synthetic polymer or, preferably, a natural, e.g. biodegradable polymer. Such polymers include, but shall not be limited to, acrylonitrile butadiene styrene (ABS); acrylic (PMMA); polyetheretherketone; cellulose acetate; cyclic olefin copolymer (COC); ethylene vinyl acetate (EVA); ethylene vinyl alcohol (EVOH); fluoroplastics, such as, PTFE, FEP, PF A, CTFE, ECTFE and ETFE; ionomers; acrylic/PVC alloy; liquid crystal polymer (LCP); polyoxymethylene (POM or acetal); polyacrylates (Acrylic); polyacrylonitrile (PAN or acrylonitrile); polyamide (PA or Nylon); polyamide-imide (PAI); polyaryletherketone (PAEK or Ketone); polybutadiene (PBD); polybutylene (PB); polybutylene terephthalate (PBT); polycaprolactone (PCL); polychlorotrifluoroethylene (PCTFE); polyethylene terephthalate (PET); polycyclohexylene dimethylene terephthalate (PCT); polycarbonate (PC); polyhydroxyalkanoates (PHAs); polyketone (PK); polyester; polyethylene (PE); polyetheretherketone (PEEK); polyetherketoneketone (PEKK); polyetherimide (PEI); chlorinated polyethylene (CPE); polyimide (PI); polylactic acid (PLA); polymethylpentene (PMP); polyphenylene oxide (PPO); polyphenylene sulphide (PPS); polyphthalamide (PPA); polypropylene (PP); polystyrene (PS); polysulphone (PSU); polytrimethylene terephthalate (PTT); polyurethane (PU); polyvinyl acetate (PVA); polyvinyl chloride (PVC); polyvinylidene chloride (PVDC); and styreneacrylonitrile (SAN); etc. Desirably the polymer is hydrophilic.

Hydrophilic polymers include, but shall not be limited to, one or more resins, such as one or more polyurethanes, e.g. polyurethanes derived from renewable resources, etc. or one or more biopolymers, such as polylactic acid (PL A), poly-3 -hydroxybutyrate, etc.

The amount of stretch in the stretchable coated textile material of the invention may generally be measured a Stretch Percentage. For example, a knitted or woven material that measure Im at rest and stretches to 1.5m is said to have a Stretch Percentage of about 100%.

Thus, the stretchable coated textile material of the present invention may have a Stretch Percentage of from about 1% to about 100%; or from about 2% to about 100%; or from about 3% to about 100%; or from about 4% to about 100%; or from about 5% to about 100%; or from about 10% to about 100%; or from about 10% to about 50%; or from about 10% to about 40%; or from about 10% to about 30%; or from about 20% to about 30%; e.g. 25%.

The tensile strength of the stretchable coated textile material may vary depending, inter alia, upon the source of the leaf fibre, the method of delignifying, etc. Pineapple leaf fibre is especially suitable since it produces fibres or yarns which are, inter alia, fine, e.g. they may have a denier or linear density of from about 10 to 20 tex; or from about 14 to 18 tex; or from about 15 to 17 tex, e g. 16 tex.

According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows no cracking after >100,000 flexes dry (determined by BS EN ISO 17694:2016). This compares with about 60,000 cycles to cracking which is exhibited in the nonwoven product described in International Patent application No. WO 2011/148136.

According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows no or little abrasion or very slight - modification of brightness after >51,200 revolutions (determined by BS EN ISO 12947-2:2016 or BS EN 5470- 2:2003).

According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a tear (BS EN ISO 4674-1:2016 Method B) strength of >31 N (Direction I) and/or >46 N (Direction II). According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a tensile strength (BS EN ISO 1421 :2016 Method 1 - Strip) (load at break) of >84 N (Direction I) and/or >65 N (Direction II)

According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows an elongation at break of >200% (Direction I) and/or >77.0 % (Direction II).

According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows a maximum load of >228.0 N (Direction I) and/or >435 N (Direction II).

According to a further aspect of the invention there is provided a stretchable coated textile material wherein the textile material comprises a natural knitted or woven material made substantially from plant-based yarns including natural fibres, wherein the fabric shows an elongation at maximum load of >194% (Direction I) and/or >67.9% (Direction II). This compares with an elongation of about 25% which is exhibited in the nonwoven product described in International Patent application No. WO 2011/148136. The Fabric Weight of the knitted or woven material may vary. The Fabric Weight may be measured in grams per square metre or g/m ² (also abbreviated as GSM). The Fabric Weight of the knitted or woven material may be from about 10 to about 1,000 g/m ² ; or from about 20 to about 1,000 g/m ² ; or from about 30 to about 1,000 g/m ² ; or from about 40 to about 1,000 g/m ² ; or from about 50 to about 1,000 g/m ² ; or from about 50 to about 500 g/m ² ; or from about 50 to about 400 g/m ² ; or from about 50 to about 300 g/m ² ; or from about 50 to about 200 g/m ² ; or from about 100 to about 200 g/m ² .

According to a further aspect of the invention there is provided a method of making a stretchable coated textile material as herein described; said method comprising: a) knitting or weaving a plurality of natural PALF yarns, to form a natural knitted or woven material including natural fibres; b) applying a fusible polymer material to the natural knitted or woven material.

The method according to this aspect of the invention may comprise the use of PALF yarns or a mixture of PALF yarns and other natural plant-based yarns. In particular, the method of the inventions comprises the use of a comprising from about 5 to about 30% w/w natural leaf or stem fibre or other cellulosic derived fibres; and from about 70 to about 95% w/w of a biobased fibre or a semi- synthetic fibre; or a combination thereof. The aforementioned method produces the stretchable coated textile material of the invention.

According to one aspect of the invention the material comprises a knitted material.

According to another aspect of the invention the material comprises a woven material.

The stretchable coated textile material may be produced by following steps a) and b) followed by curing the curable material.

By the term “curing” is meant any method conventionally known to the person skilled for causing a material to set. Thus, the term curing may refer to thermally, e.g. heating, a material, for example, heating a resin at a temperature above the fusing temperature of the resin, visible or non-visible light setting, e.g. UV curing, etc.

As herein described, the manufacture of the natural knitted or woven material according to the present invention desirably utilises leaf and/or stem fibres that have been delignified or partially delignified. Chemical processes of delignifying are known in the art. Chemical products have been used for the conventional delignifying process of PALF. More precisely, conventional delignifying has been made using sodium hydroxide (NaOH) or hydrolysis of small sugars.

A novel process of enzyme delignifying of leaf and/or stem fibres is described in

International Patent application No. WO 2011/148136. According to a further aspect of the invention the step of delignifying comprises enzyme delignifying.

For the enzymatic treatment, various enzymes types may be used, such as a biopectinase (a complex of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase), a pectinase, a hemicellulose, a lactase, a perolase and a cellulase. Those enzymes have been used combined are alone in order to determine the best delignifying formulation. The biopectinase is able to dissolve pectin, hemicellulosic and others materials. Pectinase, hemicellulase and cellulase enzymes can dissolve pectin, hemicelluloses and cellulose materials, respectively. Cellulase enzyme is well known for the polishing of fibrils in the surface of cotton fabrics. However, according to the state of the art, cellulase is not commonly used for fibres treatment has it can degrade fibres and reduce its resistance. In the present invention cellulase may be used in low quantity as an additive to the enzymatic process.

A preferred group of enzymes which may be mentioned are consisting of polygalacturonase, pectinesterase, pectinic lyase, hemicellulase, hypozyme lactase or perolase; and mixtures thereof. Specific mixtures which may be mentioned include a mixture of polygalacturonase, pectinesterase, pectinic lyase and hemicellulase (Biopectinase), a mixture of polygalacturonase and a mixture of hypozyme lactase and perolase. A preferred enzyme is a mixture of polygalacturonase and hemicellulase. A further preferred enzyme is a mixture of hypozyme lactase and perolase. When a mixture of polygalacturonase and hemicellulase is used the mixture may comprise from 1% to 10% w/w polygalacturonase and from 05% to 2% w/w hemicellulase, e.g. a mixture of 5% polygalacturonase and 1% hemicellulase.

The amount of enzymes may vary depending upon, inter alia, the nature of the leaf and/or stem fibre being delignified.

The use of the knitted or woven PALF material in the manufacture of the stretchable coated textile material is novel per se. Thus, according to a further aspect of the invention there is provided the use of a knitted or woven PALF material made substantially from PALF natural plant-based yarns including natural fibres in the manufacture of a stretchable coated textile material as herein described.

According to one aspect of the invention there is provided the use of a knitted PALF material in the manufacture of a stretchable coated textile material as herein described.

According to another aspect of the invention there is provided the use of a woven PALF material in the manufacture of a stretchable coated textile material as herein described.

According to the invention the knitted or woven PALF material will generally comprise yarns comprising from 5 to about 30% w/w natural leaf or stem fibre, the remainder comprising a biobased fibre or a semi- synthetic fibre as herein described. For the avoidance of doubt, the percentage of natural leaf or stem fibre is based on the weight of the knitted or woven material.

According to this aspect of the invention the yarn or the knitted or woven PALF material may comprise yarns comprising from 5 to about 30% w/w natural leaf or stem fibre; or from about 5 to about 25% w/w natural leaf or stem fibre; or from about 10 to about 25% w/w natural leaf or stem fibre; or from about 10 to about 20% w/w natural leaf or stem fibre; or from about 10 to about 15% w/w natural leaf or stem fibre. The knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre. Thus, the amount of biobased fibre or a semi-synthetic fibre, such as, viscose, lyocell, tencel, recycled cotton, etc., may be from about 70 to about 95% w/w of the yarn or the knitted or woven material.

A preferred yarn is made from a leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF. Alternatively, fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF. Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc. When a stem fibre is included in a composite material of the invention may comprise a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp; and other cellulose derived fibres, such as, grass(es) bamboo, straw and cotton. An especially preferred is a leaf fibre, for example, a leaf fibre that comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), pineapple. However, it will be understood by the person skilled in the art that mixtures of leaf and stem fibres, for example, fibres that may have a relatively high content of pineapple leaf fibres, may be used in the yarns of this aspect of the invention. When the yarn comprises a composite material including leaf and stem fibres, preferably a majority of the material comprises a leaf fibre, such as PALF. Thus, in a composite material the leaf fibre may comprise at least 50% w/w of the leaf stem fibre content, preferably at least 60% w/w of the leaf/ stem fibre content, preferably at least 70% w/w of the leaf/ stem fibre content preferably at least 80% w/w of the leaf/ stem fibre content, preferably at least 90% w/w of leaf/ stem fibre content and especially at least 95% w/w of the leaf/ stem fibre content. When a mixture of leaf fibres is used it is desirable that a major part of the leaf fibre is PALF. Thus, at least 50% w/w of the leaf fibre content is PALF, preferably at least 60% w/w of the leaf fibre content is PALF, preferably at least 87% w/w of the leaf fibre content is PALF, preferably at least 80%w/w of the leaf fibre content is PALF, preferably at least 90% w/w of the leaf fibre content is PALF and especially at least 95% w/w of the leaf fibre content is PALF. In one aspect of the present invention when the leaf fibre is PALF, the yarn or knitted or woven material may comprise about 80% w/w leaf fibre. Preferably the leaf or stem fibre is delignified prior to use using conventional delignifying methods known in the art or other delignifying methods described herein. The knitted or woven material may comprise a natural knitted or woven yarn, wherein the knitted or woven yarn will comprise from about 5 to about 30% w/w natural leaf or stem fibre. The remainder of the knitted or woven material will comprise a biobased fibre, such as, PLA (poly-lactic acid) fibre, or a semi-synthetic fibre, such as, such as, viscose, lyocell, tencel, recycled cotton, etc.. Thus, the amount of biobased fibre or semisynthetic fibre may be from 70 to about 95% w/w of the yarn or knitted or woven material. The knitted or woven material may comprise a single source of leaf fibre or a composite of leaf fibres or a composite of one or more leaf fibre and one or more stem fibres.

A preferred leaf fibre comprises the leaves of one or more plants of the Bromeliaceae family, such as, Ananas Comosus (Linn), e.g. PALF. Alternatively, fibres such as abaca or sisal (Agave sisalana) may be used either alone or as a composite with PALF. Abaca fibres are leaf fibres from banana plants, such as, Musa acuminata or Musa balbisiana, etc.

When a stem fibre is included in the PALF composite, a variety of conventionally known stem fibres may be used, for example, flax, jute, ramie and hemp.

The knitted or woven material will generally comprise a natural knitted or woven fibre, wherein the knitted or woven fibre material will comprise from about 5 to about 30% w/w natural leaf or stem fibre. For the avoidance of doubt, the percentage of natural leaf or stem fibre is based on the weight of the uncoated knitted or woven material.

The invention will now be described by way of example only and with reference to the accompanying figures in which:

Figure 1 illustrates yarns of different sizes; all with composition of 30% PALF, 70% TENCEL™ lyocell; Figure 2 illustrates a sample of plain jersey knitted fabric, using a yarn of figure 1; and

Figures 3 and 4 illustrate the finished coated knitted fabric of figure 2.

Example 1

Yarn Production

The PALF (pineapple leaf fibre) was processed into a textile grade standard through purification, cutting and carding processes. The PALF fibres were then mixed and blended with other cellulose based fibres (e.g. lyocell). Both types of fibres are taken through an opener and carding machine where the fibres are weighed to the correct percentage ratio (e.g. 30% w/w PALF 70% w/w Lyocell). The fibres were then taken through a cottonised carding process and through a draw frame before being spun. Once the sliver had been through the draw frames (this process gives the fibres a more homogeneous alignment and is the first stage of identifying the yam’s thickness), the sliver was taken through the first spinning stage where the yarn twist and spinning speed was controlled, this establishes the yarn characteristics (e.g. strength, size, hairiness, elongation). The yarn was spun with a technology, (e.g. ring spinning) giving the yarn the final outcome. Once the spinning was complete the yarn was wound onto a cone ready for shipment.

Example 2

Fabric Production (plain jersey knited fabric)

The yarn was distributed onto the amount of cones needed for the specific machine for the knitting manufacturing.

The construction was chosen and the gauge of machine and needle alignment is chosen accordingly. The machine gauge was highly dependent on the yarn size (e.g. Ne20/2 will use a machine gauge of approx. 10 - 14 depending on the desired weight and handle). The fabric was inspected once produced, removed from the knitting machine and moved to the finishing facility, where it was washed and stented. In some cases the fabric underwent an enzymatic wash or special finishing (e.g. a hydrophilic wash). Once the fabric has been finished it was dried and then assessed for chemical and physical performance characteristics.

Example 3

Coated Fabric Production

PALF is the base component of the material, the PALF was extracted from the leaves by a semi-automatic mechanical process, then washed with water and dried under the sun, that acts as a natural bleaching agent.

The fibres were then processed to achieve textile grade. First the sugars that act as cement in between the fibres were dissolved by an enzymatic treatment in a batch reactor at temperature around 50 °C. This allowed the fibres to be easily separated in the following steps. PALF fibres were consequently cut to 38 mm, opened and carded mechanically to get smooth textile grade fibres.

The textile grade fibres were then blended with Tencel in a 30:70 w/w ratio of PALF: Tencel, and consequently spun in to an Nel6/1 yarn in a dry process. The yarn was able to be knitted into a jersey construction that provides the necessary elastic property. The fabric was then stabilised by washing to get a consistent knitted fabric substrate.

A transfer paper coated with a finishing resin composition was used to transfer the coating polymer resin onto the surface of the knitted fabric substrate using a calendaring machine, with a thick blade to apply the composition. The paper was not removed at this stage. The coating polymer resin composition adhered to the knitted fabric.

Materials used:

Water based Polyurethane, soft (standard), e.g. polyurethane PKA, 90-97% w/w

Antifoaming agent, e.g. BG-Print ASF - BGH, 0.3-1% w/w

Thickener e.g. Cresaclear TE 1-2% w/w

Other auxiliary chemicals, e g. cross linker, extra finishes, thickener, pigment, metallic powder, etc. 0-7% w/w

The resulting coated fabric was then dried and cured in a press under heat and pressure (with the transfer paper in situ) at a temperature of 90°C to 150°C, and a pressure: of lkg/cm ² to 4kg/cm ² , for 1 to 30 seconds, e.g. 120°C at 1.5kg/cm ² to 2kg/cm ² for 10 seconds or 150°C for 60 seconds.

Then the paper was released to show the knitted coated material.

Example 4

Flex Resistance Test

The flex resistance of the stretchable coated textile material was determined using the test method of ISO 17694:2016. ISO 17694:2016 specifies a test method for determining the flex resistance for footwear, e.g. uppers and linings, irrespective of the material in order to assess the suitability for the end use.

The results of the flex resistance test are shown in Table 1.

Example 5

Abrasion Resistance Test (1)

The abrasion resistance of the stretchable coated textile material was determined using the test method of BS EN ISO 12947-2:2016. BS EN ISO 12947-2:2016 specifies the procedure for the determination of specimen breakdown (end-point of test) by inspection at fixed intervals and is applicable to all textile fabrics (uncoated) including nonwovens apart from fabrics where the specifier indicates the end performance as having a low abrasion wear life. The results of the abrasion resistance test are shown in Table 1.

Example 6

Abrasion Resistance Test (2)

The abrasion resistance of the stretchable coated textile material was determined using the test method of BS EN 5470-2:2003. BS EN 5470-2:2003 specifies the procedure for the determination of resistance of a material to wet and dry abrasion of a coated material.

The results of the abrasion resistance test are shown in Table 1.

Example 7

Tear Strength Test

The tear strength of the stretchable coated textile material was determined using the test method of BS EN ISO 4674-1:2016 Method B. BS EN ISO 4674-1 :2016 specifies two methods for determining the forces necessary to initiate and propagate tearing of a coated fabric using the constant rate of tear method. The methods described are the following:

- method A: tongue tear; and

- method B: trouser tear.

The results of the tear strength test are shown in Table 1. Example 8

Tensile Strength and Elongation Test

The Tensile strength and elongation of the stretchable coated textile material was determined using the test method of BS EN ISO 1421:2016 Method 1 - Strip. BS EN

ISO 1421 :2016 specifies two methods for the determination of the tensile strength of fabrics coated with rubber or plastics.

- Method 1 the strip test method, which is a method for the determination of tensile strength and elongation at break. - Method 2 the grab test method, which is a method for the determination of tensile strength only.

The methods apply to test pieces in equilibrium with specific standard atmospheres for testing and to wet test pieces. Both methods require the use of a constant rate of extension (CRE) tensile-testing machine.

The results of the tear strength test are shown in Table 1.

Table 1