Description:TECHNICAL FIELD
[001] This disclosure relates generally to biomanufacturing, and more particularly to manufacturing an organic material-based carpet.
BACKGROUND
[002] The studies conducted on crop residue burning have revealed alarming environmental consequences, shedding light on a pressing issue that affects both air quality and agricultural sustainability. These studies have shown that the practice of crop residue burning has resulted in the release of a staggering number of pollutants into the atmosphere. Specifically, it has contributed to the emission of more than 150 million tons of carbon dioxide (CO2), over 9 million tons of carbon monoxide (CO), 0.25 million tons of sulfur oxides (SOX), 1.28 million tons of particulate matter (PM), and 0.07 million tons of black carbon. Furthermore, crop burning is an unsustainable agricultural practice with far-reaching implications. Beyond its impact on air quality, it has detrimental effects on the environment and agricultural productivity. The practice of burning crop residue results in the production of soot, which settles on fields and infrastructure, further exacerbating pollution levels. Additionally, it depletes valuable nutrients in the soil, which are essential for the health and fertility of agricultural land.
[003] In response to these challenges, various efforts have been made to find alternative uses for crop stubble. These endeavors aim to address the issue of crop residue without resorting to harmful burning practices. However, it's important to acknowledge that these alternative uses of crop stubble are not without their limitations. One significant limitation is the capacity to handle the vast quantities of crop residue produced during harvest seasons. Effective management of such large volumes requires substantial infrastructure and resources. Additionally, some of these approaches may necessitate significant manual labor, which can be a logistical challenge. Furthermore, the efficient management of crop stubble requires the development of appropriate infrastructure, which may not be readily available in all regions. Addressing these limitations is crucial to ensuring the widespread adoption of sustainable practices for crop residue management.
[004] Accordingly, there is a requirement to optimally utilize the crop stubble in an effective manner.
SUMMARY
[005] In one embodiment, a method of manufacturing a carpet is disclosed. The method may include depositing at least one layer of wheat-crop based organic material in between two layers of linear low-density polyethylene (LLDPE) material. In an embodiment, the wheat-crop based organic material and the LLDPE material may be in a weight ratio of about 30:70. The method may further include forming at least one composite sheet by heating the at least one layer of wheat-crop based organic material and the two layers of LLDPE material at a predefined temperature using infrared (IR) heating.
[006] In another embodiment, a carpet is disclosed. The carpet may include at least one composite sheet that may include one layer of wheat-crop based material in between two layers of linear low-density polyethylene (LLDPE) material. In an embodiment, the at least one composite sheet may be formed by heating the layer of wheat-crop based organic material and the two layers of LLDPE material at a predefined temperature using infrared (IR) heating. In an embodiment, the wheat-crop based organic material and the LLDPE material may be in a weight ratio of about 30:70.
[007] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS
[008] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles.
[009] FIG. 1 illustrates a cross-sectional view of a carpet, in accordance with an embodiment of the present disclosure.
[010] FIG. 2 is a flowchart of a method of manufacturing a carpet using plant based organic matter, in accordance with an embodiment of the present disclosure.
[011] FIG. 3 is a flowchart of a method of manufacturing a carpet using wheat crop based organic matter, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[012] The foregoing description has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which forms the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying other devices, systems, assemblies and mechanisms for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that, such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, to its device or system, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
[013] The terms “including”, “comprises”, “comprising”, “comprising of” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a system or a device that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
[014] Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
[015] References in the specification and concluding claims to parts by weight of a particular element or component in a composition or article, denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a composition or a selected portion of a composition containing 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the composition.
[016] A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.
[017] Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals have been used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to FIGs. 1-3. As summarized above, in one broad aspect, the present invention provides a method of manufacturing a carpet and a carpet thereof.
[018] Referring now to FIG. 1, a cross-sectional view of a carpet 100 is illustrated, in accordance with an embodiment of the present disclosure. The carpet 100 may include one or more alternate layers 104A, 104B, 104C of polymer material and plant based organic material 106A, 106B respectively. The carpet 100 may include a top substrate layer 102B and a bottom substrate layer 102A made of a non-woven fabric material such as, but not limited to, rayon, polyethylene terephthalate (PET), polypropylene, etc. In an embodiment, the carpet 100 may include at least one composite sheet 108 that may include at least one layer of plant based organic material 106A deposited between two layers of polymer material 104A, 104B.
[019] In an embodiment, at least one composite sheet 108 may be formed by depositing a first layer of polymer material 104A over the bottom substrate layer 102A. Further, a first layer 106A of plant based organic material may be deposited over the first layer of polymer material 104A. Further, a second layer of polymer material 104B may be deposited over the first layer 106A of plant based organic material. A top substrate layer 102B may be provided over the second layer of polymer material 104B to form the carpet 100. In an embodiment, the subsequent, second layer 106B of plant based organic material may be deposited over the second layer of polymer material 104B and subsequent third layer 104C of polymer material 104C may be deposited over the second layer 106B of plant based organic material. In some embodiments, one or more subsequent layers of the plant based organic material 106B and the polymer material 104C may be deposited to form the carpet 100 having a desired thickness and having the plant based organic material and the polymer material in the weight ratio of about 30:70.
[020] Accordingly, the carpet 100 may include a composite layer 108 sandwiched between a top substrate layer 102B and the bottom substrate layer 102A. It is to be noted that the carpet 100 may include the plant based organic material and the polymer material in a weight ratio of about 30:70. Accordingly, the plant based organic material may act as a reinforcement to enhance the mechanical properties of the polymer material.
[021] In an embodiment, the polymer material may be include, but is not limited to, polyethylene polymers such as a low density polyethylene (LDPE), heterogeneously branched linear low density polyethylene (LLDPE), high density polyethylene (HDPE), heterogeneously branched ultra-low density polyethylene (ULDPE), heterogeneously branched very low density polyethylene (VLDPE), heterogeneously branched linear low density polyethylene (LLDPE), heterogeneously branched linear very low density polyethylene (VLLDPE), a copolymer of ethylene and alpha olefin, polypropylene, a copolymer of propylene and alpha olefin, a copolymer of propylene and ethylene, ethylene vinyl acetate copolymer (EVA), ethylene methyl acrylate copolymer (EMA), grafted polyethylene polymers (e.g., a maleic anhydride extrusion grafted heterogeneously branched linear low polyethylene or a maleic anhydride extrusion grafted homogeneously branched ultra-low density polyethylene), ethylene acrylic acid copolymer, ethylene ethyl acrylate copolymer, polystyrene, polyolefin, polybutylene, polycarbonate, ethylene propylene polymers, ethylene styrene polymers, and styrene block copolymers.
[022] In an embodiment, the plant based organic material may be obtained from, but not limited to, an agricultural crop, fiber crop, etc. In an embodiment, agricultural crops may include, but are not limited to, paddy, wheat, etc. In an embodiment, the plant based organic material may be obtained from, but not limited to fiber crops such as, but not limited to, cotton, jute, coir, hemp and flax, etc.
[023] In an embodiment, plant based organic material may be selected as, but not limited to, wheat crop based organic material. Further, in some embodiment, the polymer material may be selected as, but not limited to, LLDPE. Further, the wheat crop based organic material and LLDPE may be in a weight ratio of about 30:70 to manufacture the carpet 100. The wheat-crop based organic material may include dried wheat crop stubble. The dried wheat crop stubble may be prepared by drying wheat crop stubble at a temperature of about 80º Celsius for a drying period of about 30 minutes. Further, the dried wheat crop stubble may be cut to have an aspect ratio in a range of about 6-27.
[024] In an embodiment, the carpet 100 may be formed by depositing the layer of wheat-crop based organic material 106A between the at least two layers of the LLDPE material 104A, 104B to form the at least one composite sheet 108 and sandwiching the composite sheet between the top substrate layer 102B and the bottom substrate layer 102A. The carpet 100 may be formed by heating the at least one composite sheet sandwiched between the top substrate layer 102B and the bottom substrate layer 102A for a period of about 4 minutes at a predefined temperature using a heating methodology such as, but not limited to, infrared (IR) heating, etc. In an embodiment, the predefined temperature may be equal to about 160º Celsius. Further, upon heating, the at least one composite sheet 108 sandwiched between the top substrate layer 102B and the bottom substrate layer 102A may be cooled and compressed for a period of about 1 minute using a pressure of 50T using a cold compression technique to form the carpet 100. In an embodiment, the carpet 100 may have grams per square meter of about 800. In an embodiment, the carpet 100 may be used as, but not limited to, an automotive load floor carpet, a rug, a household carpet, etc.
[025] Referring now to FIG. 2, a flowchart 200 of a method of manufacturing a carpet using plant based organic matter, in accordance with an embodiment of the present disclosure. In an embodiment, method 200 may include a plurality of steps that may be performed to manufacture the carpet 100.
[026] At step 202, a plant based organic raw material such as, but not limited to, wheat crop stubble may be dried at about 80 º Celsius for about 30 minutes.
[027] At step 204, the dried plant based organic raw material may be cut to form plant based organic material having an aspect ratio in a range of about 6-27.
[028] At step 206, a bottom substrate layer 102A is formed made of a non-woven fabric material.
[029] At step 208, a first layer of polymer material 104A is deposited on the bottom substrate layer 102A. In an embodiment, the polymer material may include, but not limited to, LLDPE material.
[030] At step 210, a second layer 106A of the plant based organic material, formed in step 204, may be deposited over the first layer of polymer material 104A.
[031] At step 212, a third layer 104B of polymer material may be deposited over the second layer 106A of the plant based organic material. In an embodiment, the at least one composite layer 108 may include the layer of plant based organic material 106A between the at least two layers of the polymer material 104A, 104B.
[032] In an embodiment, the plant based organic material and the polymer material are in a weight ratio of 30:70. In an embodiment, to form a carpet 100 of desired thickness and having the plant based organic material and the polymer material in the weight ratio of about 30:70 the carpet 100 may be formed to include one or more alternate layers of plant based organic material and the polymer material as shown in FIG. 1.
[033] At step 214, a top substrate layer made of non-woven fabric material may be provided on top of the third layer 104B of polymer material.
[034] At step 216, the layers 102A, 104A, 106A, 102B may be heated at a predefined temperature using infrared (IR) heating to form a composite sheet of the carpet 100.
[035] At step 218, the composite sheet may be cooled and compressed for 1 minute using a pressure of 50T to form the carpet 100. In an embodiment, the composite sheet may be compressed using cold compression techniques. In an embodiment, the carpet 100 may have grams per square meter of about 800.
[036] Referring now to FIG. 3, a flowchart 300 of a method of manufacturing a carpet using wheat crop based organic matter, in accordance with an embodiment of the present disclosure.
[037] At step 302, at least one layer of wheat-crop based organic material may be deposited in between two layers of linear low-density polyethylene (LLDPE) material. In an embodiment, the wheat-crop based organic material and the LLDPE material may be in a weight ratio of 30:70.
[038] Further at step 304, a composite sheet may be formed by heating the at least one layer of wheat-crop based organic material and the two layers of LLDPE material at a predefined temperature using infrared (IR) heating.
[039] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[040] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[041] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
[042] It is intended that the disclosure and examples be considered as exemplary only, with a true scope of disclosed embodiments being indicated by the following claims.

, Claims:I/We claim:
1. A method (200) of manufacturing a carpet (100), comprising:
depositing (210) at least one layer (106A) of wheat-crop based organic material in between two layers (104A, 104B) of linear low-density polyethylene (LLDPE) material,
wherein the wheat-crop based organic material and the LLDPE material are in a weight ratio of about 30:70; and
forming (216) at least one composite sheet (108) by heating the at least one layer (106A) of wheat-crop based organic material and the two layers (104A, 104B) of LLDPE material at a predefined temperature using infrared (IR) heating.

2. The method (200) as claimed in claim 1, comprising sandwiching the deposited at least one layer (106A) of wheat-crop based organic material in between the two layers (104A, 104B) of LLDPE material between two substrate layers (102A, 102B) of a non-woven fabric material to form the at least one composite sheet (108).

3. The method (200) as claimed in claim 2, comprising heating the composite sheet for about 4 minutes at the predefined temperature.

4. The method (200) as claimed in claim 3, wherein the predefined temperature is about 160º Celsius.

5. The method (200) as claimed in claim 4, comprising compressing (218) the composite sheet for 1 minute using a pressure of 50T.

6. The method (200) as claimed in claim 5, wherein the composite sheet is compressed using cold compression techniques.

7. The method (200) as claimed in claim 6, comprising compressing the composite sheet to form the carpet having grams per square meter of about 800.

8. The method (200) as claimed in claim 1, wherein the wheat-crop based organic material is prepared by:
drying (202) wheat crop stubble at about 80 º Celsius for about 30 minutes; and
cutting (204) the dried wheat crop stubble to form the wheat-crop based organic material having an aspect ratio in a range of about 6-27.

9. A carpet (100), comprising:
at least one composite sheet (108) comprising one layer (106A) of wheat-crop based material in between two layers (104A, 104B) of linear low-density polyethylene (LLDPE) material,
wherein the at least one composite sheet is formed by heating the layer of wheat-crop based organic material and the two layers of LLDPE material at a predefined temperature using infrared (IR) heating, and
wherein the wheat-crop based organic material and the LLDPE material are in a weight ratio of about 30:70.

10. The carpet (100) as claimed in claim 9, wherein the at least one composite sheet is formed by sandwiching the at least one layer (106A) of wheat-crop based organic material and the two layers (104A, 104B) of LLDPE material between two substrate layers (102A, 102B) of a non-woven fabric substrate and heating for about 4 minutes at the predefined temperature.

11. The carpet (100) as claimed in claim 10, wherein upon heating, the at least one composite sheet (108) is cold compressed for 1 minute using a pressure of 50T upon heating.

12. The carpet (100) as claimed in claim 11, wherein the at least one composite sheet is compressed to have grams per square meter of about 800.

13. The carpet (100) as claimed in claim 9, wherein the at least one composite sheet is formed by heating the layer of wheat-crop based organic material and the two layers of LLDPE material for 4 minutes at the predefined temperature.

14. The carpet (100) as claimed in claim 13, wherein the predefined temperature is about 160º Celsius.

15. The carpet (100) as claimed in claim 9, wherein the wheat-crop based organic material is prepared by drying wheat crop stubble at 80 º Celsius for 30 minutes.

16. The carpet (100) as claimed in claim 15, wherein the dried wheat crop stubble is cut to have an aspect ratio in a range of about 6-27.