FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION (See section 10, rule 13)
“A COMPOSITE MATERIAL FOR AUTOMOBILE TRIM
PARTS”
Name and Address of the Applicant:
a) Name: TATA MOTORS LIMITED
b) Nationality: Indian
c) Address: Bombay House, 24 Homi Mody Street, Hutatma Chowk, Mumbai 400001, Maharashtra, India
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
The present invention relates to a composite material and a process of preparing thereof. In particular, the present invention relates to a composite material for automobile trim parts.
BACKGROUND OF THE INVENTION
Sustainability and increased ecological awareness have encouraged engineers to develop effective and novel materials by utilizing natural resources in the automotive sector. Natural fibre has recently caught the attention of the OEMs due to their ease of availability, environmental friendliness, and biodegradability. Most of the components produced by natural fibres are interior components such as inner door panels, seat covers and insulations and so forth and most commonly used fibres are flax, hemp and kenaf. Moreover, the matrix used in combination with these natural fibres is polypropylene, acrylonitrile butadiene styrene, epoxy, and polycarbonate etc. Thus, the automobile trim parts are produced by a combination of natural fibers and/or synthetic fibers with synthetic polymer. The different kinds of natural fibers reinforced polymer composite have received great importance in different automotive applications by many automotive companies.
SUMMARY OF THE INVENTION
The present invention relates to a composite material for an automobile trim part comprising: a natural fiber and a binder fiber, wherein the natural fiber is in the range of 40 wt.% to 70 wt.% and the binder fiber is in the range of 25 wt.% to 35 wt.%. The composite material further comprises cotton felt, and polyethylene terephthalate felt.
The present invention also relates to the process of preparing the composite material from the natural fiber.
BRIEF DESCRIPTION OF DRAWINGS
The present invention is accompanied by following drawings, wherein:
Figure 1 illustrates the automobile trim parts prepared with composite material of the present invention: a) Rear wall trim and b) Engine cover carpets.
Figure 2 illustrates the perspective view of the thermo forming molding.

Figure 3 illustrates the trim part obtained from the composite material in Example 1 by Thermoforming process.
Figure 4 illustrates the flammability test for the composite material of the present invention.
Figure 5 illustrates the environment test for the composite material of the present invention.
DETAILED DESCRIPTION OF THE OF THE INVENTION
At the very outset of the detailed description, it may be understood that the ensuing description only illustrates a particular form of this invention. However, such a particular form is only an exemplary embodiment, and without intending to imply any limitation on the scope of this invention. Accordingly, the description is to be understood as an exemplary embodiment and teaching of invention and not intended to be taken restrictively.
Throughout the specification and claims, the following terms take the meanings explicitly associated herein unless the context clearly dictates otherwise. The meaning of "a", "an", and "the" include plural references. The meaning of "in" includes "in" and "on." Additionally, a reference to the singular includes a reference to the plural unless otherwise stated or inconsistent with the disclosure herein. Thus, for example, reference to "natural fiber” may include “natural fibers”.
As used herein, the terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a method that comprises a list of acts does not include only those acts but may include other acts not expressly listed or inherent to such method. In other words, one or more acts in a method proceeded by “comprises… a” does not, without more constraints, preclude the existence of other acts or additional acts.
It is an aim of the present invention to provide a composite material which is sustainable, environmentally friendly, recyclable, and inexpensive. The present invention substitutes the synthetic fibers with specific amount of natural fibers in automotive vehicles to enhance product sustainability quotient for the Interior parts at a lower cost without compromise in value. This will improve recyclability, circularity, and waste management.
The present invention provides a composite material for automobile trims parts with natural fiber. The composite material includes banana fibre as natural fibre for its good specific strength and lower density to develop automobile trims parts like Rear wall trim, Engine cover

carpet, Headliner and Mats etc. Thus, the present invention provides unique composite material to develop the parts to make it feasible for automotive application.
In an embodiment, the present invention provides a composite material comprising a natural fiber and a binder fiber, wherein the natural fiber is in the range of 40 wt.% to 70 wt.% and the binder fiber is in the range of 25 wt.% to 35 wt.%.
In an embodiment, the present invention provides the composite material, wherein the natural fiber is a banana fiber. The banana fiber has good specific strength and lower density to develop automobile trim parts.
In an embodiment, the present invention provides the composite material, wherein the length of the banana fiber is equal or less than 100 mm.
In an embodiment, the present invention provides the composite material, wherein the binder fiber is a low melt fiber. The low melt fiber utilizes sheath-core fiber that melts at high temperature and bonds with other fiber to provide excellent matrix stability and handling characteristics. The low melt fiber also enhances cushioning product quality and is more compatible with the environment. The low melt fiber is homogeneous with other types of fibers, blend easily, and is recyclable. Further, the low melt fiber has a remarkable heat bonding property.
In an embodiment, the present invention provides the composite material, wherein the low melt fiber comprises polyester.
In an embodiment, the present invention provides the composite material, wherein the composite material further comprises a cotton felt. Cotton felt is a non-woven textile that can be made of natural fiber such as wool or synthetic fiber such as acrylic. Cotton felt can vary in terms of fiber content, colour, size, thickness, density, and more factors depending on the use of the cotton felt. Cotton felt is used for its acoustic properties, softness, and reliability. The content of cotton felt is in the range of 10 wt.% to 20 wt.% based on the total weight of the composite material.
In an embodiment, the present invention provides the composite material, wherein the composite material further comprises polyethylene terephthalate (PET) felt. The PET Felt is a material that absorbs sound while offering a new palette for both visual and acoustic design.

The PET felt is used for its elasticity, acoustic properties and is recyclable. The content of the PET felt is in the range of 30 wt.% to 40 wt.% based on the total weight of the composite material.
In an embodiment, the present invention provides the composite material, wherein the composite material is thermoformable.
In another embodiment, the present invention provides a process of preparing a composite material. The process comprises the steps of:
a) Mixing banana fiber in the range of 40 wt.% to 70 wt.% and low melt fiber in the range of 25 wt.% to 35 wt.%, thereafter converting into sheet as per GSM requirement;
b) putting at least two sheets crossed or parallel (based on output GSM) to each other and passing through needle punching machine to obtain a composite material; and
c) the composite material is directly taken up for thermoforming or optionally passing through hot rollers to activate the low melt followed by thermoforming.
In the present process, the banana fiber is obtained by extracting a sheath by peeling a banana stem, followed by extracting a banana fiber from the sheath, and followed by drying the banana.
In an embodiment, the present invention provides the process of preparing the composite material, wherein the temperature of the heated roller is in the range of 100 ℃ to 200 ℃.
In an embodiment, the present invention provides the process of preparing the composite material, wherein the low melt fiber layer is prepared from a low melt polymer that comprises polyester.
In an embodiment, the present invention provides a process of preparing a composite material, wherein the process of preparing a composite material further comprises the thermoforming of composite material in the presence of cotton felt. The content of cotton felt is in the range of 10 wt.% to 20 wt.% based on the total weight of the composite material.
In an embodiment, the present invention provides a process of preparing a composite material, wherein the process of preparing a composite material further comprises the thermoforming of composite material in the presence of PET felt. The content of the PET felt is in the range of 30 wt.% to 40 wt.% based on the total weight of the composite material.

Certain specific aspects and embodiments of the present application will be explained in greater detail with reference to the following examples, which are provided only for purposes of illustration and should not be construed as limiting the scope of the application in any manner. While particular aspects of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
EXAMPLES
The following examples are for the purpose of illustration of the invention and are not intended in any way to limit the scope of the invention.
Process of preparation of the composite material
The preparation of the composite material is divided into two segments.
1. Fibre Extraction Process
2. Composite material preparation
Fibre Extraction Process: Carefully extracting the natural fiber from the banana plant to avoid damages. A special machine is designed and developed for such extraction in a mechanically automated manner. It mainly consists of two horizontal beams whereby a carriage is attached with a specially designed comb that could move back and forth. This technique is performed by placing a cleaned part of the banana stem on the fixed platform of the machine and clamped at the ends by jaws. This eliminates relative movement of the stem and avoids premature breakage of the fibers. This is followed by cleaning and drying of the fibers.
Composite material preparation: The banana fibres along with low melt fiber are arranged as per gram per square meter (GSM) requirement. With these fibres layers are knitted either in crossed or parallel. These layers are passed through the rollers and then pass through the needle punching machine where fibres are binding with each other, and banana fabric layer is prepared. Then, as per final requirement of product, these layers pass through the hot roller etc. Once the banana fabric layer sandwich gets prepared, it is fed through the heated rollers and from bottom side roller low melt layer is passed. These two layers run parallel with each other and pass through various rollers and to finally obtain the composite material in the form of roll.

The process optionally uses the cotton felt or the PET felt for the preparation of the composite material.
The composite material was obtained with 500GSM and 1200GSM.
Process of preparing automobile trim part from the composite material
Automobile trim parts are prepared from the above composite material by thermoforming process. Cotton felt and PET felt are optionally introduced during the thermoforming process. Once the part is formed and comes out from the molding machine, then it is kept on the trimming fixtures. In this process, carpet trimming is done with the water jet machine and/or can be done in the tooling itself. If the polyvinyl chloride (PVC) type heel pad or in the dead pedal area, then it will fix with the ultrasonic welding. Once all operations are done, the final part is kept on the finishing fixtures with adequate illumination. Here visual inspection is done and if any fibres or foreign material / particles are found on the carpet, then it gets removed.
Thermo forming moulding is shown in Figure 2.
The invention will now be elucidated by way of the following examples, without however being limited thereto.
Example 1: Banana Fiber 80 wt.% + Low melt fiber 20 wt.%
The composite material was prepared based on the above having 80 wt. % banana fiber and 20 wt. % low melt fibre. The automobile trim part prepared from the composite material got torn as shown in Figure 3.
Example 2: Banana Fiber 30 wt.% + Low melt fiber 70 wt.%
The composite material was prepared based on the above having 30 wt. % banana fiber and 70 wt. % low melt fibre. The automobile trim part prepared from the composite material did not have required stiffness.
Example 3: Banana Fiber 70 wt.% + Low melt fiber 30 wt.%
The composite material was prepared based on the above having 70 wt.% banana fiber and 30 wt.% low melt fibre. This composite material provided the required strength. Headliners and Rear wall Trims were prepared from the composite material.

Example 4: Banana Fiber 55 wt. % + Cotton felt 15 wt. % + Low melt fiber 30 wt. % The composite material was prepared based on the above process having 55 wt. % banana fiber, 15 wt. % cotton felt and 30 wt. % low melt fibre. This composite material provided required strength, acoustic properties, and softness. The composite material was used for insulation
Example 5: Banana Fiber 40 wt. % + PET Felt 35 wt. % + low melt fiber 30 wt. % The composite material was prepared based on the above process having 40 wt. % banana fiber, 35 wt. % PET felt and 30 wt. % low melt fibre. This composite material provided required strength, elasticity, and acoustic properties. Mats & Carpets and Covers were prepared from the composite material.
The automobile trim parts prepared with the composite material of Examples 3 to 5 were tested as per interior trims design validation plan (DVP).
Testing of automobile trim parts
The automobile trim parts prepared with the composite material were tested as per interior trims design validation plan (DVP) like Sound absorption coefficient, Sound transmission rate, Odour test, Flammability test, and Environment test and results are found satisfactorily and parts to be implemented on vehicle. The test results are mentioned as below.
Flammability test: Sample tested meets the Horizontal burning rate test requirement when tested as per FM VSS 302, the composite material is observed self-extinguishing & burn rate is 0 mm/min as referred in Figure 4 and is shown in Table 1 below.
Table 1:

Test lequireinent Testing of sample lor honaxtH fawwnaUMy as per rlMS X>2
Material Description Aesthetic tabnc«70% BF*30% LM * BNW
Pan IJ.«.»- s-jr rValtnm I2O0GSM
Observation Table
SrJto. Test description Specified reojuarement OuservatiorHnuivTrMn)

Testptanel TestpiacaZ TestatooeS Testpiaee4 TeatpieeeS
1 Horwontai Bummf Rateei
per Fail VSS 302 The remit or the tist jh»t be conudered omm/Mn

worst test resuts nto account, the Horuontal bumeic. rate a not more then 100 nwn/nwnute or * the ttame eatrnfuahat before reeefwne. the last maasufmf point.

(-~i < i Sample tested meets tie Horizontal fearing rate test requwement when tested as per FM 7SS 302. observed set e«tmgushed & bum rate « 0 rnrrrYnnute material Is
Sound absorption coefficient (SAC): Sound absorption test is performed, and result was found as per requirement.
Sound transmission rate (STL): Sound transmission test is performed, and result was found as per requirement.
Environment test: The environmental test is performed on the trim parts. No delamination, deformation, and deterioration observed on parts as shown in Figure 5.
Odour test: Odour test is performed as per test methos SAE J 1351:2015. Samples were preconditioned at 23±℃ and 50±10% RH for 24 hrs. Test conditions were as below:
Conditioning Samples are preconditioned at 23*2°C and 50l 10*» RH for 24 hrs

Condition Temperature Duration
Dry «5±3*C 1 hr ♦ r«nm
Wet 65*3*C 1 hr »5min
Container 1 L (Glass bottle)
Spacirrwn Site (250*25) cm1
No. of Specimen* : 0211 specimen for each condition )

Rating Scala

Rat.ng Description
1 No nobceabte odor
2 Sttoht but noboMbto otto
3 M*d otto noboeabte but not offensive
4 Noticeable odor, but not offensive
5 Definite odor, but not strong enough to be
UMMtrtrl
e Durante odor, mikJry offensive
7 Unpleasant odor
8 Strong offensive odor
9 Very stiong offensive odor
10 Odor is painful
Observations

Panal.tt Gredt

Dry War
Pane»st*0i 2 3
Panetet*02 2 2
P*netsi«03 2 2
P.,..., ! SM-1 2 2
PaneastaOS 2 2
Median 2 2
Advantages of the present invention are as follows:
• Cleaner products for a more sustainable future.
• Reduction in cost of & total weight of Cabin as compared to some other composites.
• Acceptable modulus – weight ratio
• Minimal health hazards during processing and low greenhouse gas emissions
• Eco Friendly Products with recyclable waste
• Landfill reduction
The foregoing description of the various embodiments is provided to enable any person skilled in art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein, and instead the claims should be accorded the widest scope consistent with the principles and novel features disclosed herein.

While the invention has been described with reference to a preferred embodiment, it is apparent that variations and modifications will occur without departing the spirit and scope of the invention. It is therefore contemplated that the present disclosure covers any and all modifications, variations or equivalents that fall within the scope of the basic underlying principles disclosed above.

We Claim
1. A composite material for automobile trim parts comprising:
a natural fiber and a binder fiber,
wherein the natural fiber is in the range of 40 wt.% to 70 wt.% and the binder
fiber is in the range of 25 wt.% to 35 wt.%.
2. The material as claimed in claim 1, wherein the natural fiber is a banana fiber.
3. The material as claimed in claim 1, wherein the binder fiber is a low melt fiber.
4. The material as claimed in claim 3, wherein the low melt fiber comprises polyester.
5. The material as claimed in 1, wherein the composite material further comprises a cotton felt.
6. The material as claimed in claim 5, wherein the cotton felt is in the range of 10 wt.% to 20 wt.%.
7. The material as claimed in 1, wherein the composite material further comprises a polyethylene terephthalate felt.
8. The material as claimed in claim 7, wherein the polyethylene terephthalate felt is in the range of 30 wt.% to 40 wt.%.
9. The material as claimed in claim 1, wherein the composite material is thermoformable.
10. A process of preparing a composite material as claimed in claim 1 comprising the steps of:

a) mixing banana fiber in the range of 40 wt.% to 70 wt.% and low melt fiber in the range of 25 wt.% to 35 wt.%, thereafter converting into sheet as per GSM requirement;
b) putting at least two sheets crossed or parallel to each other and passing through needle punching machine to obtain a composite material; and
c) the composite material is directly taken up for thermoforming or optionally passing through hot rollers to activate the low melt followed by thermoforming.
11. The process of preparing a composite material as claimed in claim 10 further comprises
thermoforming of the composite material in the presence of cotton felt or PET felt.

12. The process as claimed in claim 10, wherein the banana fiber is obtained by extracting a sheath by peeling a banana stem, followed by extracting a banana fiber from the sheath, and followed by drying the banana fiber.
13. The process as claimed in claim 10, wherein the low melt fiber layer is prepared from a low melt polymer.
14. The process as claimed in claim 13, wherein the low melt polymer is polyester.