Description:FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
TITLE OF INVENTION
ENGINEERED PROTECTIVE FILM FOR MICROCLIMATIC CONDITIONING OF
SOIL AND PREPARATION THEREOF
APPLICANT NAME AND ADDRESS
Name: GROWIT INDIA PRIVATE LIMITED
Nationality: INDIAN, Address : 606A, Union Heights, Near Rahul Raj
Mall, Vesu, Surat, Gujarat 39500
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES
THE INVENTION AND THE MANNER IN WHICH IT IS TO BE
PERFORMED
[0001] FIELD OF INVENTION
[0002] The present invention relates to the field of agricultural films, more specifically plastic mulch. More particularly, the invention relates to an engineered multilayer protective film for microclimatic conditioning of soil used in agricultural applications.
[0003] BACKGROUND OF THE INVENTION
[0004] Plastic mulch is a specialized agricultural film used to cover soil around plants. The use of plastic mulch has fundamentally transformed modem farming practices by modifying the microclimate surrounding crops. This technology, first introduced in the 1950s, has become an essential tool in commercial agriculture, particularly in vegetable production and specialty crops.
[0005] The primary functions of plastic mulch include soil temperature regulation, moisture conservation, weed suppression, and improved crop yield and quality. Black plastic mulch, the most commonly used variety, increases soil temperature by absorbing solar radiation and transferring heat to the soil beneath. This warming effect can advance harvest dates by 7-14 days and extend growing seasons in temperate regions. Conversely, white or reflective mulches can cool the soil by reflecting solar radiation, beneficial for late-season planting or hot climates.
[0006] Plastic mulch is also useful for moisture management in the soil. It creates a barrier between soil and atmosphere and reduces evaporation of moisture in the soil by up to 70% compared to bare soil. This water conservation aspect is particularly valuable in regions with limited rainfall or irrigation resources. Additionally, the film reduces the chances and degree of soil coming into contact with fruits and vegetables and reduces the incidence of soil-borne diseases. It also increases the cleanliness of agricultural produce and saves money and efforts spent in cleaning the produce.
[0007] Modern plastic mulch films are engineered with various compositions and properties. Standard polyethylene films range from 15 to 50 micrometers in thickness, with specialized multilayer films incorporating different additives for enhanced performance. These may include UV stabilizers to prevent degradation, infrared-blocking compounds for temperature control, and pigments for specific light management properties.
[0008] The use of plastic mulch has environmental concerns. Biodegradable alternatives are gaining popularity as these environmental concerns grow. Biodegradable alternatives are made from plant-based polymers or specially formulated polyesters, break down into harmless compounds after the growing season, eliminating the need for removal and disposal. However, their higher cost and variable degradation rates currently limit widespread adoption.
[0009] The economic impact of plastic mulch is significant. Despite installation costs, the technology typically provides positive returns through increased yields, reduced irrigation needs, decreased herbicide usage, and earlier harvest premiums. Studies indicate yield increases of 30-50% in various crops, with even higher gains in specific situations. However, challenges exist. Traditional plastic mulch requires removal and disposal after use, contributing to agricultural waste. Mechanical laying of mulch demands specialized equipment and labor. Soil temperature under black mulch can sometimes exceed optimal levels, necessitating careful timing of installation and potentially requiring cooling strategies in hot climates.
[0010] Despite these challenges, plastic mulch remains a cornerstone of intensive vegetable production, continually evolving with new materials and technologies to meet changing agricultural needs while addressing environmental concerns.
[00011] OBJECTS OF THE INVENTION
[0012] The primary objectives of this invention are to engineer a protective film that delivers superior microclimatic soil conditioning while achieving an optimal balance between UV protection and thermal management properties. The film is designed to maintain exceptional durability despite its minimal thickness, offering a cost-effective solution through precisely controlled material composition. The present invention also focuses on increasing manufacturing efficiency through a streamlined co-extrusion process, ensuring consistent production quality while minimizing manufacturing complexity and associated costs.
[0014] DESCRIPTION OF THE DRAWINGS
[0014] Fig. IA illustrates a conventional film comprising a single layer.
Fig. 1B illustrates a conventional film comprising two layers.
Fig. 2 illustrates the present invention which is an engineered protective film comprising three distinct layers (1, 2, 3) of equal thickness.
Fig. 3 illustrates an exemplary film having holes through which plants can grow when the film is deployed.
[0015] DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention relates to an engineered protective film comprising three distinct layers (1, 2, 3) of equal thickness, manufactured through a sequential co-extrusion process. The film's total thickness ranges from 17-30 micrometers, optimized for both performance and material efficiency.
[0017] The outer layer (1) of the film comprises:
[0018] LLDPE: 70.65 - 40.65%
LDPE: 15 -
White pigment: 0 — 30%
Red pigment: 0 — 23%
Yellow pigment 0 —
Green pigment: 0 — 18% Silver pigment: 0 — 10.5% UV absorber: 3.6 —4.5%
Antioxidant: 0.75 — 1.25%
[0019] The middle layer (2) comprises:
LLDPE: 41.65 - 58.00%
LDPE: 15-25%
White pigment: 0 — 32%
Black pigment: 0 — 27%
UV absorber: 0.6 - 0.75%
Antioxidant: 0.75 — 1.25%
[0020] The inner layer (3) comprises:
[0021] LLDPE: 35.45 - 62.45%
LDPE: 15 -
Black pigment: 15 — 37% UV absorber: 1.8 - 2.25%
Antioxidant: 0.75 — 1.25%
[0022] One embodiment of the engineered protective film has silver/black appearance and contains 5-15.5% silver pigment in the outer layer (1), 15-32 % black pigment in the middle layer (2), 10-35 % black pigment in the inner layer (3).
[0023] Another embodiment of the engineered protective film has a white/black appearance and contains 25-37 % white pigment in the outer layer (1) and the middle layer (2).
[0024] Yet another embodiment of the engineered protective film has a red/black appearance and contains 18-28 % red pigment in the outer layer (1), 27-37% white pigment in the middle layer (2), and 27-37 % black pigment in the inner layer (3).
[0025] Yet another embodiment of the engineered protective film has a yellow/black appearance and contains 12-22 % yellow pigment in the outer layer (1), 27-37% white pigment in the middle layer (2), and 27-37 % black pigment in the inner layer (3).
[0026] Yet another embodiment of the engineered protective film has a green/black appearance and contains 13-23 % green pigment in the outer layer (1), 22-32 % white pigment in the middle layer (2), and 10-20 % black pigment in the inner layer (3).
[0027] The engineered protective film can be manufactured by extrusion process involving the following steps:
[0028] Manufacturing an outer layer by combining: 70.65 — 40.65% LLDPE, 15 — 25% LDPE, 0 — 30% white pigment, 0 — 23% red pigment, 0 — 17% yellow pigment, 0 — 18% green pigment, 0 — 10.5% silver pigment, 3.6 — 4.5% UV absorber, 0.75 — 1.25% antioxidant;
[0029] Manufacturing a middle layer by combining: 41.65 - 58.00% LLDPE, 15 - 25% LDPE, O - 32% white pigment, O - 27% black pigment, 0.6 - 0.75% UV absorber, 0.75 1.25% antioxidant;
[0030] Manufacturing an inner layer by combining: 35.45 — 62.45% LLDPE, 15 — 25% LDPE, 15 — 37% black pigment, 1.8 — 2.25% UV absorber, 0.75 — 1.25% antioxidant; and
[0031] Co-extruding the three layers wherein: the middle layer is extruded along with the outer layer and the inner layer is extruded along with the middle layer on the opposite side of the outer layer and all three layers are extruded to equal thickness and the total thickness of the combined layers is controlled to range from 17-30 micrometers.
[0032] A variation of the method of manufacture involves the addition of 5 - 15.5 % silver pigment in the outer layer, 15-32 % black pigment in the middle layer, 10-35 % black pigment in the inner layer, thereby producing a film having silver/black appearance.
[0033] Another variation of the method of manufacture involves the addition of 25-37 % white pigment in the outer layer and the middle layer, thereby producing a film having a white/black appearance.
[0034] Yet another variation of the method of manufacture involves the addition of 18-28 % red pigment in the outer layer, 27-37% white pigment in the middle layer, and 27-37% black pigment in the inner layer, thereby producing a film having a red/black appearance.
[0035] Yet another variation of the method of manufacture involves the addition of 12-22% yellow pigment in the outer layer, 27-37% white pigment in the middle layer, and 27-37% black pigment in the inner layer, thereby producing a film having a yellow/black appearance [0036] Yet another variation of the method of manufacture involves the addition of 13-23% green pigment in the outer layer, 22-32% white pigment in the middle layer, and 10-20% black pigment in the inner layer, thereby producing a film having a green/black appearance.
[0037] TECHNICAL CHARACTERISTICS
[0038] The technical characteristics of the engineered film were found to have the following specifications:
COLOR:
IYpe of Film Engineered film
Process Analysis
Sr.N
O. Units n
1 Width Scale
Measurement mm 1200 1200 - 1203
2 Length Meter counter meter 400 401
3 Density ASTM
D4397-16 g/cm2 0.98 0.98
4 Tensile
Strength
@ Break MD ASTM-D882 Kgf/c
2 200 260 - 280
200 210 - 240
5 Elognation
@ Break MD ASTM-1)882 300 490 _ 520
400 520 - 545
6 Tear Strength ASTM 1)1424 g/micr on 2 25 - 30
4 35 - 40
7 Dart impact
failure ASTM-1)1709 g/micr on 2.5 & Above 3.9 - 4.2
SILVER BLACK:
Type of Film Engineered film
Process Analysis
Sr.N
o. Properties Testing Method Units Specificatio n Test Result
1 Width Scale
Measurement mm 1200 1200 - 1203
2 Length Meter counter meter 400 401
3 Density ASTM
D4397-16 g/cm2 0.98 0.98
4 Tear Strength MD ASTM D1424 g/micron 2 20 - 25
4 28 - 34
5 Dart impact
failure ASTM-D1709 g/micron 2.5
Above 3.9 - 4.0
WHITE BLACK:
TYpe of Film Engineered film
Process Analysis
Sr.N
o. Properties Testing Method Units Specificatio n Test Result
1 Width Scale
Measurement mm 1200 1200 - 1203
2 Length Meter counter meter 400 401
3 Density ASTM D4397-16 g/cm2 0.98 0.98
4 Tensile
Strength @
Break MD ASTM-1)882 Kgf/c
2 200 250 - 270
200 200 - 235
5 Elognation
@ Break MD ASTM-D882 300 490 _ 520
400 520 - 545
6 Tear Strength MD ASTM D1424 g/micr
on 2 25 - 30
4 35 - 40
7 Dart failure impact ASTM-DI 709 g/micr
on 2.5
Above 4.0 - 4.2
[0039] The efficacy of the engineered protective film has been studied in various agricultural crops.
[0040] Study/Examp1e 1:
[0041] One study involved banana (Musa sp.) cultivation. In the said study, the production of bananas with and without the use of the engineered film which is the subject of the present application was compared.
[0042] The plant cultivation parameters were found to be as follows:
Parameters With Engineered Film Without Engineered Film
Plant Height/Mtr 2.25 Mfr 2.00 Mfr
Plant girth/cm 53.69 48.23
Days taken for Maturity 305 336
No. of finger/bunch 128 112
Cost of Mulching 18000 Nil
Weeding cost/ sucker removing Nil 5000
Yield/acre/ ton 34 30
Rate/kg 11 10
Revenue/acre
[0043] Overall a noticeable improvement in the yield was observed.
[0044] Study/Example 2:
[0045] Another study involved cotton (Gossypium hirsutum) cultivation. In the said study, the production of cotton with and without the use of the claimed engineered film was compared.
The plant cultivation parameters were found to be as follows:
Parameter With Engineered Film Without Engineered Film
Plant growth Excellent Average
No. ofB011s/P1ant 65 55
Flowering initiation (DAS) 38 49
Water saving 98% Nil
Cost of mulching 13000 Nil
Pesticide+Fungicide+fertilis er + Weeding cost 12000 25000
Yield/acre/quintal 16 11
Rate/quintal (Price depends upon market) 8000 7800
Revenue/acre 128000 85800
[0046] Overall a noticeable improvement in the yield was observed.
[0047] Study/Example 3:
[0047] Another study involved Papaya (Carica papaya) cultivation. In the said study, the production of papaya fruit with and without the use of present engineered film was compared.
The plant cultivation parameters were found to be as follows:
Parameter With Engineered Film Without Engineered Film
Plant Height/cm 171.81 158.00
Stem girth/cm 36 32
Days to flowering 125 140
No. of fruit/tree 29 24
Cost of mulching 18000 Nil
Weeding cost Nil 6000
Yield/acre/ton 50 46
Rate/kg 12 10
Revenue/acre 58200 50000
[0048] Study/Example 4:
[0049] Another study involved tomato (Solanum lycopersicum) cultivation using colored engineered film in Mukhed, Nanded, Maharashtra. The plant cultivation parameters were found to be as follows:
Parameter Regular Usage (SIB) Special Recommendation
(RIB)
Plant height 87 cm 110 cm
No. of branches (90 days) 8 11
Avg. fruit weight 90 grams 125 grams
Fruit ripening Late Early
Yield increase Average
[0050] Overall the use of colored engineered film in tomato cultivation was found to increase the yield of the produce by a significant margin.
[0051] Study/Example 5:
[0052] Another study involved rice cultivation. The study involved cultivation of rice using drip and the present engineered protective film. It was found that the practice reduced cumulative CH4 (methane) flux by 194% and 69% respectively compared to CF (Conventional Flooding). Emissions of N20 (Nitroxide) was very low and insignificant in this regime whereas, it was high in other regimes. The GWP (Global Warming Potential) of the 2-year average was 89% reduced under this practice compared to conventional flooding (CF). The findings demonstrated that the practice mitigated GHGs (Greenhouse Gas Constitute) while sustaining rice yield as a result of low nitrogen fertilization application and intermittent soil saturation level. Overall the cost saving was found to be more than 40% and water saving was found to be more than 90%.
, Claims:WE CLAIM:
1. An engineered protective film for microclimatic conditioning of soil, said film comprising:
outer(l), middle(2) and inner layers(3) of equal thickness, wherein the middle layer is extruded along with the outer layer, and the inner layer is extruded along with the middle layer on the other side of the outer layer;
characterised in that
the outer layer (1) contains 70.65 - 40.65 % of LLDPE, 15 - 25 % of LDPE, O - 30 % of white pigment, 0 — 23 % of red pigment, 0 — 17 % of yellow pigment, 0 — 18 % of green pigment, 0 — 10.5 % of silver pigment, 3.6 — 4.5 % of UV absorber and, 0.75 — 1.25 % of antioxidant;
the middle layer (2) contains 41.65 - 58.00 % of LLDPE, 15 - 25 % of LDPE, O -32 % white pigment, 0 — 27 % black pigment, 0.6 — 0.75 % UV absorber and, 0.75 - 1.25 antioxidant; and,
the inner layer (3) contains 35.45 - 62.45 % LLDPE, 15 - 25 % LDPE, 15 - 37 % black pigment, 1.8 — 2.25 % UV absorber and 0.75 — 1.25 antioxidant; and
the overall thickness of the film ranges from 17-30 micrometres.
2. The engineered protective film as claimed in claim 1, wherein the said film contains 5—
15.5 % silver pigment in the outer layer (1), 15 — 32 % black pigment in the middle layer (2), 10 — 35 % black pigment in the inner layer (3).
3. The engineered protective film as claimed in claim 1, wherein the said film contains 25-37 % white pigment in the outer layer (1) and the middle layer (2).
4. The engineered protective film as claimed in claim 1, wherein the said film contains 18-28 % red pigment in the outer layer (1), 27-37 % white pigment in the middle layer (2), and 27-37 % black pigment in the inner layer (3).
5. The engineered protective film as claimed in claim 1, wherein the said film contains 12-22 % yellow pigment in the outer layer (1), 27-37% white pigment in the middle layer (2), and 27-37 % black pigment in the inner layer (3).
6. The engineered protective film as claimed in claim 1, wherein the said film contains 13-23 % green pigment in the outer layer (1), 22-32 % white pigment in the middle layer (2), and 10-20 % black pigment in the inner layer (4).
7. A method for manufacturing an engineered protective film for microclimatic conditioning of soil, the method comprising:
Manufacturing an outer layer by combining: 70.65 - 40.65% LLDPE, 15 - 25% LDPE, O 30% white pigment, 0 — 23% red pigment, 0 — 17% yellow pigment, 0 — 18% green pigment, 0 — 10.5% silver pigment, 3.6 — 4.5% UV absorber, 0.75 — 1.25% antioxidant;
Manufacturing a middle layer by combining: 41.65 — 58.00% LLDPE, 15 — 25% LDPE, 0 — 32% white pigment, 0 — 27% black pigment, 0.6 — 0.75% UV absorber, 0.75 - 1.25% antioxidant;
Manufacturing an inner layer by combining: 35.45 — 62.45% LLDPE, 15 - LDPE, 15 37% black pigment, 1.8 — 2.25% UV absorber, 0.75 — 1.25% antioxidant; and
Co-extruding the three layers wherein: the middle layer is extruded along with the outer layer and the inner layer is extruded along with the middle layer on the opposite side of the outer layer and all three layers are extruded to equal thickness and the total thickness of the combined layers is controlled to range from 17-30 micrometers.
8. The method of claim 7, wherein to the film is added 5-15.5 % silver pigment in the outer layer (1), 15-32 % black pigment in the middle layer (2), 10-35% black pigment in the inner layer (3) or 25-37 % white pigment in the outer layer (l) and the middle layer (2) or 18-28 % red pigment in the outer layer (1), 27-37% white pigment in the middle layer (2), and 27-37% black pigment in the inner layer (3) or 12-22% yellow pigment in the outer layer (1), 27-37% white pigment in the middle layer (2), and 27-37% black pigment in the inner layer (3) or 13-23% green pigment in the outer layer (1), 22-32% white pigment in the middle layer (2), and 10-20% black pigment in the inner layer (3).
Date: