Description:BACKGROUND
Technical Field
[0001] The present invention generally relates to an environment-friendly fabric material and, more particularly, to an Eco-Fabric composition and method of preparation thereof. The present invention further relates to a method for manufacturing a fabric material using the Eco-Fabric composition, suitable for different applications.
Description of the Related Art
[0002] The use of High density polyethylene (HDPE)/Polypropylene (PP)woven fabric, Polyvinyl Chloride (PVC)flex, and Biaxially Oriented PolyPropylene (BOPP)films in the production of packaging material, wrapping fabric, and parcel covers, display banners, hoardings, bags for bulk packaging of commodities, Adhesive Tapes etc, has become increasingly popular in recent years due to its durability and cost-effectiveness. However, the downside to these materials is that they cannot be easily recycled, and pose a significant threat to the environment. Once these items are no longer needed or have outlived their usefulness and have been recycled multiple times, they are discarded in landfills where they can remain for hundreds of years without breaking down.
[0003] This is an issue of great concern, as these materials are not biodegradable and their presence in landfills can cause significant environmental damage and can also harm stray animals. As they slowly decompose, they release toxic chemicals and gasses into the surrounding soil, water, and air. These chemicals, such as dioxins and phthalates, can cause serious health problems for both humans and animals. Despite these alarming environmental implications, the use of plastics in the preparation of these items remains prevalent, leading to an increasing accumulation of waste in landfills. The disposal of these items must be handled with great care and caution to prevent further environmental damage.
[0004] The restricted choices for disposing of plastics and PVC Flex are a significant problem. PVC Flex cannot be simply left to decompose naturally in a landfill since it does not biodegrade. Instead, it needs to be treated with extreme caution and care to avoid further harm to the ecosystem. It follows that a significant amount of the waste still finds its way to landfills, where it may continue to produce hazardous chemicals and endanger the environment and the general public's health. Therefore, there is an urgent need for more practical and long-lasting ways to deal with plastic and PVC Flex Waste Management.
[0005] The use of plastics and PVC Flex poses a significant threat to the environment due to its non-recyclable / non-biodegradable nature. It is essential to develop more sustainable alternatives to this material to reduce the amount of plastic waste that ends up in landfills.
[0006] Hence, there is a need for an eco-fabric material, eco-print and eco-tape made up of a very eco-friendly composition.
SUMMARY
[0007] In view of the foregoing, an embodiment herein provides for an eco-fabric with an eco-friendly composition that includes an extruded melt blend of (i) 15% w/w to 60% w/w of high-density polyethylene (HDPE) or Polypropylene (PP), and (ii) 40% w/w to 85% w/w of Calcium Carbonate Granules (CaCO3). The high-density polyethylene (HDPE) or Polypropylene (PP) and Calcium Carbonate Granules (CaCO3) are melt blended at 270 degrees Celsius to 300 degrees Celsius to form eco-fabric composition.
[0008] In some embodiments, the eco-fabric composition includes (i) 0.1% w/w to 10% w/w of at least one ultraviolet (UV) additive, and (ii) 0.1% w/w to 10% w/w of at least one compatibilizer, The at least one ultraviolet (UV) additive is Benzotriazole. The least one compatibilizer is malic anhydride.
[0009] In some embodiments, the eco-fabric composition is provided to at least one circular loom to produce an eco-fabric material.
[0010] In some embodiments, the eco-fabric material is coated with a waterproof film on one or both sides. The waterproof film includes at least one of a Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), Polypropylene (PP). The eco-fabric material is coated with waterproof film is further coated with a chemical to produce an eco-print material.
[0011] In some embodiments, Melt Flow Index (MFI) of the high-density polyethylene (HDPE) or Polypropylene (PP) ranges from 0.1dg/min to3.5dg/min and the Calcium Carbonate Granules (CaCO3) ranges from 0.5dg/min to 1.0dg/min.
[0012] In some embodiments, the eco-fabric material is silt into tapes and gummed on at least one with Hot-Melt EVA glue to form eco-tapes.
[0013] In another aspect, a method of preparing an eco-fabric composition is provided. The method includes melt blending (i) 15% w/w to 60% w/w of high-density polyethylene (HDPE) or Polypropylene (PE), and (ii) 40% w/w to 80% w/w of Calcium Carbonate Granules (CaCO3). The high-density polyethylene (HDPE) or Polypropylene (PP) and Calcium Carbonate Granules (CaCO3) are extruded at 270 degrees Celsius to 300 degrees Celsius to form the eco-fabric composition.
[0014] In another aspect, a method of preparing an eco-fabric material is provided. The method includes (a) melt blending (i) 15% w/w to 60% w/w of high-density polyethylene (HDPE) or Polypropylene (PE), and (ii) 40% w/w to 80% w/w of Calcium Carbonate Granules (CaCO3), (b) extruding the melt blend of HDPE and CaCO3 at 180 degrees Celsius to 335 degrees Celsius through a die to cast a film, (c) quenching the film in a water bath, (d) slitting the quenched film to form a plurality of threads, (e) heating and stretching the plurality of threads at 25 to 1000 m/min at 60 degrees Celsius to160 degrees Celsius and (f) weaving the plurality of threads, using at least one circular loom, to obtain the eco-fabric material. The high-density polyethylene (HDPE) or Polypropylene (PP) and Calcium Carbonate Granules (CaCO3) are melt blended at 270 degrees Celsius to 300 degrees Celsius to form an eco-fabric composition.
[0015] In some embodiments, (i) 0.1% w/w to 10% w/w of at least one ultraviolet (UV) additive, and (ii) 0.1% w/w to 10% w/w of at least one compatibilizer are melt bend along with the HDPE and CaCO3to form the eco-fabric material. The ultraviolet (UV) additive is Benzotriazole. The compatibilizer is maleic anhydride.
[0016] In some embodiments, the method includes coating the eco-fabric material with a waterproof film on one or both sides. The film includes at least one of a Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), Polypropylene (PP). The eco-fabric material that is coated with the waterproof film is further coated with a chemical to produce an eco-print material.
[0017] In some embodiments, Melt Flow Index (MFI) of the high-density polyethylene (HDPE) or Polypropylene (PP) ranges from 0.1dg/min to 3.5dg/min and Calcium Carbonate Granules (CaCO3) ranges from 0.5dg/min to 1.0dg/min.
[0018] In some embodiments, the method includes slitting the eco-fabric material into tapes and gummingthe tapes on at least one side with Hot-Melt EVA glue to form eco-tapes.
[0019] The eco-fabric, eco-print and the eco-tape material is reused and recycled multiple times after its original use, reducing waste and conserving natural resources. The eco-fabric, eco-print and the eco-tape material is suitable for both indoor and outdoor use, making it versatile and practical. The eco-fabric, eco-print and the eco-tape material provides the required durability and strength, depending on the usage, making it reliable and long-lasting. When coated with PP/LDPE lamination, the material becomes water-resistant, protecting against moisture and water damage. The Calcium Carbonate content disintegrates and gets absorbed in the soil easily without harming the environment, making it a more sustainable and soil-friendly material.In some applications, the composition includes (i) 0.1% w/w to 10% w/w of an ultraviolet (UV) additive, and (ii) 0.1% w/w to 10% w/w of a compatibilizer. The ultraviolet (UV) additive is Benzotriazole. The compatibilizer is maleic anhydride. The Melt Flow Index (MFI) of the high-density polyethylene (HDPE) or Polypropylene (PP) ranges from 0.1dg/min to3.5dg/min and Calcium Carbonate Granules (CaCO3) ranges from 0.5 dg/min to 1.0 dg/min. In some embodiments, the eco-fabric is coated with a custom formulated solution, based on waterborne polymer dispersions to make the surface of the material printable (i.e. called as eco-print).In some applications, the composition is used to produce eco-print material using at least one circular loom. The eco-print material is uncoated or coated with a waterproof film on one or both sides. The film includes at least one of a Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), and Polypropylene (PP). In some embodiments, the method includes gumming and slitting of the eco-Fabric on at least one side with Hot-Melt EVA adhesive to make single or double sided adhesive tapes (i.e. called as eco-tape).
[0020] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0022] FIG. 1 illustrates a flow diagram of a method of preparing an eco-fabric composition according to an embodiment herein; and
[0023] FIG. 2 illustrates a flow diagram of a method of preparing an eco-fabric material according to an embodiment herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0025] As mentioned, there remains a need for eco-friendly fabric material that may be used for producing products such as bags, wrapping fabric, banners, and adhesive tapes etc. Referring now to the drawings, and more particularly to FIGS.1 through 2, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0026] FIG. 1 illustrates a flow diagram of a method of preparing an eco-fabric composition according to an embodiment herein. At step 102, (i) 15% w/w to 60% w/w of high-density polyethylene (HDPE) or Polypropylene (PE), and (ii) 40% w/w to 80% w/w of Calcium Carbonate Granules (CaCO3) are obtained. At step 104, the high-density polyethylene (HDPE) or Polypropylene (PP) and Calcium Carbonate Granules (CACO3) are melt blended at 270 degrees Celsius to 300 degrees Celsius to form eco-fabric composition.
[0027] The eco-fabric composition may include (i) 0.1% w/w to 10% w/w of an ultraviolet (UV) additive, and (ii) 0.1% w/w to 10% w/w of a compatibilizer. The ultraviolet (UV) additive is Benzotriazole and the compatibilizer is malic anhydride. In some embodiments, the eco-fabric composition is provided to at least one circular loomto produce an eco-fabric material.The eco-fabric material may be coated with a waterproof film on one or both sides. The waterproof film includes at least one of a Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), Polypropylene (PP). The eco-fabric material is coated with a water proof film and further coated with a chemical to produce an eco-print material. The Melt Flow Index (MFI) of the high-density polyethylene (HDPE) or Polypropylene (PP) ranges from 0.1dg/min to3.5dg/min and Calcium Carbonate Granules (CaCO3) ranges from 0.5dg/min to 1.0dg/min. In some embodiments, the eco-fabric material is silt into tapes and gummed on at least one with Hot-Melt EVA glue to form eco-tapes.
[0028] Table. 1 shows eco-fabric compositions for preparing the Eco-Fabric, Eco-Print and the Eco-Tape according to the embodiments of the invention.
MATERIAL TYPE HIGH-DENSITY POLYETHYLENE (HDPE) OR POLYPROPYLENE (PP) CALCIUM CARBONATE GRANULES (CaCO3) ULTRAVIOLET (UV) ADDITIVES COMPATIBILIZER
ECO-FABRIC 15% w/w to 60% w/w of 40% w/w to 85% w/w 0.1% w/w – 10% w/w 0.1% w/w – 10% w/w
ECO-PRINT 15% w/w to 60% w/w 40% w/w to 85% w/w 0.1% w/w – 10% w/w 0.1% w/w – 10% w/w
ECO-TAPE 15% w/w to 60% w/w 40% w/w to 80% w/w 0.1% w/w – 10% w/w 0.1% w/w – 10% w/w

[0029] FIG. 2 illustrates a flow diagram of a method of preparing an eco-fabric material according to an embodiment herein. At step 202,(i) 15% w/w to 60% w/w of high-density polyethylene (HDPE) or Polypropylene (PE), and (ii) 40% w/w to 80% w/w of Calcium Carbonate Granules (CaCO3)at 270 degrees Celsius to 300 degrees Celsius to form the eco-fabric composition.
[0030] At step 204, the melt blend of HDPE and CaCO3is extruded at 180 degrees Celsius to 335 degrees Celsius through a die to cast a film.At step 206, the film is quenched in a water bath.At step 208, the quenched film is slitto form a plurality of tapes.At step 210, the plurality of tapes is heated and stretched at 25 to 1000 m/min at 60 degrees Celsius to 160 degrees Celsius.At step 212, the tapes are woven using at least one circular loom to obtain the eco-fabric material. The melt bend may include (i) 0.1% w/w to 10% w/w of at least one ultraviolet (UV) additive, and (ii) 0.1% w/w to 10% w/w of at least one compatibilizer are melt bend along with the HDPE and CaCO3to form the eco-fabric material. The ultraviolet (UV) additive is Benzotriazole, and the compatibilizer is maleic anhydride.The method may include coating the eco-fabric material with a waterproof film on one or both sides. The film includes at least one of a Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), Polypropylene (PP).The method may include coating the eco-fabric material with the chemical to make the surface of the fabric printable.The Melt Flow Index (MFI) of the high-density polyethylene (HDPE) or Polypropylene (PP) ranges from 0.1dg/min to 3.5dg/min and Calcium Carbonate Granules (CaCO3) ranges from 0.5dg/min to 1.0dg/min.The method includes slitting the eco-fabric material into tapesand gummed on at least one side with Hot Melt Eva glue to form eco-tapes.
[0031] The eco-fabric material that is coated with waterproof film is further coated with a chemical to produce an eco-print material. In some embodiments, theeco-tapestapes are wounded on a plurality of bobbins before weaving. The eco-tapes are woven for multiple applications such as woven cloth, packages, wrapping fabrics, bags, FIBC bags, shipping sacks, dunnage bags, ground cover, geo-textiles, straps, ropes, adhesive tapes and any other possible application.
[0032] In some embodiments, the concentration of the Calcium Carbonate Granules (CaCO3) in the eco-fabric composition varies from 40% w/w to 85% w/w based on the lifetime of products. For example, the concentration of the Calcium Carbonate Granules (CaCO3) is 40% w/w if the eco-fabric material is used for making banners that require a lifetimeof more than 6 months. The concentration of the Calcium Carbonate Granules (CaCO3) in the eco-fabric composition may vary from 60% w/w to 85% w/w for preparing banners for short-time usage. In some embodiments, the eco-fabric material is extruded with at least one of Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), Polypropylene (PP) at 250 to 300 degrees Celsius. In some embodiments, the Melt Flow Index (MFI) for the high-density polyethylene (HDPE) is 3.5g/10 min, Calcium Carbonate Granules (CaCO3) is 1 g/10 minand the Low-Density Polyethylene (LDPE) is 0.9g/10 min.
[0033] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope.
, Claims:We Claim:
1. An eco-fabric composition comprising:
an extruded melt blend of (i) 15% w/w to 60% w/w of high-density polyethylene (HDPE) or Polypropylene (PP), and (ii) 40% w/w to 85% w/w of Calcium Carbonate Granules (CaCO3), wherein the high-density polyethylene (HDPE) or Polypropylene (PP) and Calcium Carbonate Granules (CaCO3) are melt blended at 270 degrees Celsius to 300 degrees Celsius to form the eco-fabric composition.
2. The eco-fabric composition as claimed in claim 1, wherein the eco-fabric composition comprises (i) 0.1% w/w to 10% w/w of at least one ultraviolet (UV) additive, and (ii) 0.1% w/w to 10% w/w of at least one compatibilizer, wherein the at least one ultraviolet (UV) additive is Benzotriazole, wherein the least one compatibilizer is malic anhydride.
3. The eco-fabric composition as claimed in claim 1, wherein the eco-fabric composition is provided to at least one circular loom to produce an eco-fabric material.
4. The eco-fabric composition as claimed in claim 3, wherein the eco-fabric material is coated with a waterproof film on one or both sides, wherein the waterproof film comprises at least one of a Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), Polypropylene (PP), wherein the eco-fabric material that is coated with waterproof film is further coated with a chemical to produce an eco-print material.
5. The eco-fabric composition as claimed in claim 1, wherein Melt Flow Index (MFI) of the high-density polyethylene (HDPE) or Polypropylene (PP) ranges from 0.1dg/min to3.5dg/min and the Calcium Carbonate Granules (CaCO3) ranges from 0.5dg/min to 1.0dg/min.
6. The eco-fabric composition as claimed in claim 3, wherein the eco-fabric material is silt into tapes and gummed on at least one with Hot-Melt EVA glue to form eco-tapes.
7. A method of preparing an eco-fabric composition, comprising: melt blending (i) 15% w/w to 60% w/w of high-density polyethylene (HDPE) or Polypropylene (PE), and (ii) 40% w/w to 80% w/w of Calcium Carbonate Granules (CaCO3), wherein the high-density polyethylene (HDPE) or Polypropylene (PP) and Calcium Carbonate Granules (CaCO3) are extruded at 270 degrees Celsius to 300 degrees Celsius to form the eco-fabric composition.
8. A method of preparing an eco-fabric material comprising:
melt blending (i) 15% w/w to 60% w/w of high-density polyethylene (HDPE) or Polypropylene (PE), and (ii) 40% w/w to 80% w/w of Calcium Carbonate Granules (CaCO3), wherein the high-density polyethylene (HDPE) or Polypropylene (PP) and Calcium Carbonate Granules (CaCO3) are melt blended at 270 degrees Celsius to 300 degrees Celsius to form an eco-fabric composition;
extruding the melt blend of HDPE and CaCO3 at 180 degrees Celsius to 335 degrees Celsius through a die to cast a film;
quenching the film in a water bath;
slitting the quenched film to form a plurality of threads;
heating and stretching the plurality of threads at 25 to 1000 m/min at 60 degrees Celsius to160 degrees Celsius; and
weaving the plurality of threads, using at least one circular loom, to obtain the eco-fabric material.
9. The method as claimed in claim 8, wherein (i) 0.1% w/w to 10% w/w of at least one ultraviolet (UV) additive, and (ii) 0.1% w/w to 10% w/w of at least one compatibilizer are melt bend along with the HDPE and CaCO3to form the eco-fabric material, wherein the ultraviolet (UV) additive is Benzotriazole, wherein the compatibilizer is maleic anhydride.
10. The method as claimed in claim 8, wherein the method comprises coating the eco-fabric material with a waterproof film on one or both sides, wherein the film comprises at least one of a Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), Polypropylene (PP), wherein the eco-fabric material that is coated with waterproof film is further coated with a chemical to produce an eco-print material.
11. The method as claimed in claim 8, wherein Melt Flow Index (MFI) of the high-density polyethylene (HDPE) or Polypropylene (PP) ranges from 0.1dg/min to 3.5dg/min and Calcium Carbonate Granules (CaCO3) ranges from 0.5dg/min to 1.0dg/min.
12. The method as claimed in claim 8, wherein the method comprises slitting the eco-fabric material into tapes andgummingthe tapes on at least one side with Hot-Melt EVA glue to form eco-tapes.
Dated this 09thMarch, 2023
Signature of the Patent Agent:
Signature:
Name: Arjun KarthikBala
IN/PA No.1021