FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
AND
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; rule 13)
TITLE OF THE INVENTION BANANA FIBRE-BASED AUTOMOTIVE PRODUCTS
APPLICANT(S)
TATA MOTORS LIMITED
Bombay House, 24 Homi Mody Street,
Hutatma Chowk, Mumbai 400 001, Maharashtra, India; an Indian company.
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
[0001] The present invention relates to banana composite fibers, and more specifically related to a banana fibre-based automotive products and parts includes a single composite felt or multiple composite felts.
BACKGROUND OF THE INVENTION
[0002] Automotive industry is working hard on increasing eco-friendliness and fuel efficiency of vehicles by, for example, reducing vehicle weight and using eco-friendly products. Also, there is a need to replace the conventional metal and plastic components in the vehicles with lightweight and environment-friendly products without compromising on the strength, flexibility, modulus, reliability, performance, quality, and life of the components. Interior products in the vehicles, such as parcel shelf, headliner, sidewall trims, and seats, are made of a variety of materials, such as leather, nylon, vinyl chloride, faux leather, or polymers. Such materials cause harmful environmental impacts and may also be expensive. Hence there remains a need for a lightweight composite felt.
SUMMARY OF THE INVENTION
[0003] In one aspect the present invention involves providing a banana fibre-based automotive product having a single composite felt or a plurality of composite felts having identical compositions. The composite felt includes banana fibers and a base material. The composite felt includes 50 % to 90 % of the banana fibers and 10% to 50 % of the base material. The composite felt includes a single layer of uniform composition of the banana fibers and the base material.
[0004] In an embodiment, the predefined range of banana fibres and a base material includes 50 % of the banana fibers (101) and 50% of the base material (102).

[0005] In an embodiment, the predefined range of banana fibres and a base material includes 65% of the banana fibers (101) and 35% of the base material (102).
[0006] In an embodiment, the banana fibers has physical properties comprising a diameter in range of 50-250 mm, a length of 1000-5000 mm, a density of 750-950 kg per meter, a specific gravity of 1.05 and a microfibril angle of 11 degree.
[0007] In an embodiment, the single layer uniform lightweight composite felt is one of banana fibers composite felt with various GSM and banana non-woven composite felt with various GSM.
[0008] In an embodiment, the banana fibre-based automotive product is one of: a roof liner, a parcel self, a side wall trim, a rear wall trim, a seat form, a tail gate, and a head liner.
[0009] In an embodiment, the composite felt has uniform stiffness throughout the single layer uniform lightweight composite felt.
[0010] In an embodiment, the composite felt has density of: 1800GSM, 1500GSM or 2000 GSM.
[0011] In an embodiment, the base material is one of polyolefin fibers, and polypropylene fibers.
[0012] In one aspect the present invention involves providing a process for manufacturing the banana fibre-based automotive product. The process includes receiving banana fibers of a desired length, mixing in the banana fibers with base material in predefined ratio, passing the mixture of the banana fibers and the base material (102) through a carding machine to form fibrous webs; and needle punching the fibrous webs to form a composite felt, wherein the composite felt

formed has a single layer of uniform composition of banana fibers and the base material.
[0013] In an embodiment, the process includes pre-heating the composite felt, and moulding the heated lightweight composite felt on the automotive product to make the banana fiber-based automotive product.
[0014] In an embodiment, the desired length of each of the banana fibers (101) is one of 60 mm length, 80 mm length and 100 mm length, and wherein of the base material (102) is of 100 mm length.
[0015] In one aspect the object is satisfied by providing a banana fiber-based automotive product including a single composite felt or a plurality of composite felts (100) having identical compositions. The automatic product is manufactured from banana fiber using following steps: mixing in the banana fibers of a desired length with base material in predefined ratio by mixing means, carding the mixture of the banana fibers and the base material by passing the mixture through a carding machine to form fibrous webs, needle punching the fibrous webs to form a composite felt using a punching machine, wherein the composite felt formed has a single layer of uniform composition of banana fibers and the base material, pre-heating the single composite felt or the plurality of composite felts having identical compositions using any heating means, and moulding the single composite felt or the plurality of composite felts having identical compositions on desired automotive product mould to make the banana fiber-based automotive product.
[0016] The automotive product according to the present subject matter has a single composite felt or a plurality of composite felts having identical compositions. Therefore, manufacturing of the composite felts of the present subject matter can be achieved in a much simpler manner, as compared to manufacturing of composite felts having multiple layers each having different compositions of banana fibre and base material. Further, the manufacturing of the composite felts does not require

heating the banana fibres and/or base material to very high temperatures for melting them. Still further, pressurizing the raw materials to extreme pressures is also not required according to the present subject matter. Accordingly, the present subject matter provides a simple and cost-effective method for manufacturing composite felts and automotive product.
[0017] 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 scope thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0018] The proposed lightweight composite felt are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding part in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0019] FIG. 1 illustrates a lightweight composite felt of various GSM for
automotive interior part, according to embodiments as disclosed herein;
[0020] FIG. 2 illustrates a process for manufacturing the lightweight composite felt,
according to embodiments as disclosed herein;
[0021] FIG. 3 illustrates a compression moulding process for moulding the
lightweight composite felt onto the automotive interior part, according to
embodiments as disclosed herein;

[0022] FIG. 4 illustrates a parcel shelf with the proposed lightweight composite felt
manufactured using the compression moulding process, according to embodiments
as disclosed herein;
[0023] FIG. 5 illustrates Left-hand (LH) and Right-hand (RH) side wall trims with
the proposed lightweight composite felt, according to embodiments as disclosed
herein;
[0024] FIG. 6 illustrates rear side wall trims with the proposed lightweight
composite felt, according to embodiments as disclosed herein;
[0025] FIG. 7 illustrates tailgate trims with the proposed lightweight composite felt,
according to embodiments as disclosed herein;
[0026] FIG. 8 illustrates headliner with the proposed lightweight composite felt,
according to embodiments as disclosed herein;
[0027] FIG. 9 illustrates seats with the proposed lightweight composite felt,
according to embodiments as disclosed herein; and
[0028] FIG. 10 illustrates some roof liners with the proposed lightweight composite
felt (100), according to embodiments as disclosed herein.
[0029] It may be noted that to the extent possible, like reference numerals have been used to represent like elements in the drawing. Further, those of ordinary skill in the art will appreciate that elements in the drawing are illustrated for simplicity and may not have been necessarily drawn to scale. For example, the dimension of some of the elements in the drawing may be exaggerated relative to other elements to help to improve the understanding of aspects of the invention. Furthermore, the one or more elements may have been represented in the drawing by conventional symbols, and the drawings may show only those specific details that are pertinent to the understanding the embodiments of the invention so as not to obscure the drawing with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF THE INVENTION
[0030] The implementations herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting implementations that are illustrated in the accompanying drawings and detailed in the following description. It should be understood, however, that the following descriptions, while indicating preferred implementations 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 implementations herein without departing from the spirit thereof, and the implementations herein include all such modifications. The examples used herein are intended merely to facilitate an understanding of ways in which the implementations herein can be practiced and to further enable those skilled in the art to practice the implementations herein. Accordingly, the examples should not be construed as limiting the scope of the implementations herein.
[0031] Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the implementations herein. Also, the various implementations described herein are not necessarily mutually exclusive, as some implementations can be combined with one or more other implementations to form new implementations.
[0032] Referring now to the drawings, and more particularly to FIGS. 1 through 10, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0033] FIG. 1 illustrates a lightweight composite felt (100) of various GSM for automotive interior part, according to embodiments as disclosed herein. The lightweight composite felt (100) includes banana fibers (101) and base material (102). The banana fibres (101) is a natural fibre, extracted from banana stem. The

banana fibers (101) are mixed with the polypropylene fibers (102) in a predefined range to form the lightweight composite felt (100).
[0034] In an embodiment, the base material (102) includes polyolefin fibers, and polypropylene fibers.
[0035] In an embodiment, the predefined range is 50 % to 90 % of the banana fibers (101) and 10% to 50 % of the base material (102).
[0036] In an embodiment, the predefined ratio preferably includes 65% of the banana fibers (101) and 35% of the polypropylene fibers (102).
[0037] In an embodiment, the predefined ratio more preferably includes 50% of the banana fibers (101) and 50% of the polypropylene fibers (102).
[0038] The proposed lightweight composite felt (100) can be used to produce automotive products made using the banana fibres (101). The automotive products made using the proposed lightweight composite felt (100) are eco-friendly, lightweight, and cost-effective.
[0039] In an embodiment, the banana fibers (101) has tensile properties having a tensile strength of 175-915 Mpa, an elongation in a range of 1-4%, and Young’s modulus of 12-32 Gpa.
[0040] In an embodiment, the banana fibers (101) has physical properties having a diameter in range of 50-250 mm, a length of 1000-5000 mm, a density of 750-950 kg per meter, a specific gravity of 1.05 and a microfibril angle of 11 degree.
[0041] Unlike the conventional composite felt, the proposed non-woven composite felt is developed and produced using various compositions of the banana fibers (101) and the polypropylene fibres (102). This composite felt is a suitable material

for replacing the current synthetic materials. The advantages of the natural fibre over synthetic fibre are abundance, less damage to processing equipment, low weight, and low cost. Added benefits are that this material has good mechanical properties, such as tensile and flexural modulus, and improved surface finish of moulded parts without increasing part thickness. This material is eco-friendly, biodegradable, and can be recycled twice.
[0042] In the proposed lightweight composite felt (100) is used as a raw material for manufacturing of interior parts such as a roof liner, a parcel self, a side wall trim, a rear wall trim, a seat form, a tail gate, and a head liner. The proposed lightweight composite felt (100) can be produced using existing tooling. The proposed composite felt (100) having good relative mechanical properties, light in weight, and becomes strong with smaller elongation. The proposed composite felt (100) provides improved surface finish of molded parts and less damage to processing equipment. Using the proposed lightweight composite felt (100), in an example, weight savings of about 3 kg can be achieved per vehicle. In some examples, parts produced are 30-35% lighter than their conventional counterparts. Further, since the banana fibres (101) are produced out of agricultural waste, waste utilization is achieved. Also, additional revenue is generated for farmers by sale of the banana stems.
[0043] FIG. 2 illustrates a process for manufacturing the lightweight composite felt (100), accordingly to embodiments as disclosed herein. The proposed process includes the following steps:
[0044] At step S201, the process includes extracting banana fibers (101) from banana stems by extracting means. The extracting means hearing can be machines that are used to extract the banana fibers (101) from banana stems.
[0045] At step S202, the process includes cutting the banana stems into banana fibers (101) of a desired length for lightweight composite felt using cutting means. The cutting means can be a cutter, a blade or a cutting machine. The banana fibres

(101) are extracted and cut to required cut length, such as 60 mm, 80 mm, and 100 mm.
[0046] At step S203, the process includes mixing in the banana fibers (101) with polypropylene fibers (102) in the predefined ratio using a mixing means. The mixing means can be a machine that mixes the banana fibers (101) with polypropylene fibers (102) in the predefined ratio. In an embodiment, the predefined range includes 50 % to 90 % of the banana fibers (101) and 10% to 50 % of the base material (102), 65% of the banana fibers (101) and 35% of the polypropylene fibers (102), 50% of the banana fibers (101) and 50% of the polypropylene fibers (102), and 100% of the banana fibers (101) and the polypropylene fibers (102).
[0047] At step S204, the process includes passing the mixture of the banana fibers (101) and the polypropylene fibers (102) through a carding machine to form fibrous webs. The carding machine cards the mixture of the banana fibers (101) and the base material (102) and form fibrous webs.
[0048] At step S205, the process includes needle punching the fibrous webs using punching machine. The non-woven banana felt composite materials of various GSM and thickness required for various product development are developed. For this, punching machines are used.
[0049] At step S206, the process includes making the lightweight composite felt (100) of various GSM. The lightweight composite felt can be molded on the automotive interior part such as a roof liner, a parcel self, a side wall trim, a rear wall trim, a seat form, a tail gate, and a head liner. The composite felt (100) comprises a single layer of uniform composition of the banana fibers (101) and the base material (102).There can be a single composite felt (100) or a plurality of composite felts (100) having identical compositions in an automotive part.

[0050] FIG. 3 illustrates a compression moulding process (in addition to the steps described in the FIG. 2) for moulding the lightweight composite felt (100) to make the banana fiber-based automotive product, according to embodiments as disclosed herein. The proposed process includes the following steps:
[0051] At S301, the process includes pre-heating the lightweight composite felt (100) using heating means. The heating means described herein can be a heater or any heating machine used to pre-hearing the lightweight composite felt (100).
[0052] At S304, the process includes moulding the heated lightweight composite felt on the automotive interior part to make the automotive interior part with lightweight composite felt (100). A single composite felt (100) or multiple composite felts (100) having identical compositions are moulded to make the banana fiber-based automotive product.
[0053] The manufacturing processes of automotive products and the related parameters are defined with reference to automotive product specification and testing requirements. The manufacturing of the various automotive products or parts are explained below:
[0054] FIG. 4 illustrates a parcel shelf with the proposed lightweight composite felt (100) manufactured using the compression moulding process, according to embodiments as disclosed herein. In the case of parcel shelf, weight saving of 30% with composite banana felt of 2000 GSM can be achieved. In case of headliner, weight saving of 20% with composite banana felt of 1500 GSM can be achieved. In the case of side wall trims, weight saving of 20% with composite banana felt of 1800 GSM can be achieved. In the case of rear wall trims, weight saving of 20% with composite banana felt of 1800 GSM can be achieved. Some parcel shelves produced are illustrated the FIG. 4.
[0055] In an example, the parcel shelf of 1800 GSM weighed 1.4 kg, and the parcel shelf of 1500 GSM weighed 1.25 kg. These are lighter than the conventional parcel

shelves, which weigh 2.25 kg. Due to the lighter weight, vehicle fuel efficiency and NVH (noise, vibration, and harshness) performance of the vehicle improves.
[0056] FIG. 5 illustrates Left-hand (LH) and Right-hand (RH) side wall trims with the proposed lightweight composite felt (100), according to embodiments as disclosed herein. The LH and RH side wall trims with proposed lightweight composite felt (100) can be manufactured using the compression moulding process. The trims may be of 1500 GSM.
[0057] FIG. 6 illustrates rear side wall trims with the proposed lightweight composite felt (100), according to embodiments as disclosed herein. The rear side wall trims with the proposed lightweight composite felt (100) can be manufactured using the compression moulding process. The trims may be of 1500 GSM or 1800 GSM.
[0058] FIG. 7 illustrates tailgate trims with the proposed lightweight composite felt (100), according to embodiments as disclosed herein. The tailgate trims the proposed lightweight composite felt (100) can be manufactured using the compression moulding process. The trims may be of 1000 GSM. The trims of the present subject matter are lightweight, and improve NVH and fuel efficiency performance of the vehicle.
[0059] FIG. 8 illustrates headliner with the proposed lightweight composite felt (100), according to embodiments as disclosed herein. The headliners with the proposed lightweight composite felt (100) can be manufactured using the compression moulding process. The headliners may be of 1500 GSM. The aluminium tooling required for manufacturing the headliners is produced through compression moulding. The headliners of the present subject matter are lightweight, and improve NVH and fuel efficiency performance of the vehicle.

[0060] FIG. 9 illustrates seats with the proposed lightweight composite felt (100), according to embodiments as disclosed herein. The seats with the proposed lightweight composite felt (100) and reduced foam content can be manufactured. In an example, foam content in the seats can be reduced by 30%. The seats can be manufactured using aluminium tooling by foam moulding and using Poly+ Iso cyanide raw material with banana fibre non-woven felt. The provision of banana fibres in the above regions can improve lateral support to the occupant during cornering and can achieve better surface treatment with reduced foam density. The seats of the present subject matter may be lighter in weight, and improve fuel efficiency and NVH performance of the vehicle.
[0061] FIG. 10 illustrates some roof liners with the proposed lightweight composite felt (100), according to embodiments as disclosed herein.
[0062] The automotive products of the present subject matter have passed various tests including performance and durability tests, such as thermal cyclic resistance test, long-term heat ageing test, load carrying capacity test, Flexion rigidity test, Shock Resistance Test, Pull Test, Creep Resistance Test, Flexion resistance to rupture, connection resistance, Endurance test, and Extraction force test for mounting clips, and Load Test (75kg on a piece of 300mm x 300mm) as per their standard specification as provided below:

Sr. No. Test Specification
1 Shock Resistance Test As per C1. 5.16 of TST/TS/TI156
2 Pull Test As per TST/TS/TI156, 8.9
3 Creep Resistance Test As per drawings
4 Flexion rigidity test As per TST/TS/TI156, 8.8
5 Flexion resistance to rupture As per TST/TS/TI156, 8.7

6 Connection resistance Shelf is loaded with 25 kg load at the connections end in car mounted condition. Shelf should not show any breakage.
7 Endurance test As per TST/TS/TI156, 8.12
8 Extraction force test for mounting clips As per TST/TS/TI156, 8.8/As per drawing
9 Load Test (75kg on a piece of 300mm x 300mm) As per TST/TS/TI156, 8.10
[0063] The foregoing description of the specific implementations will so fully reveal the general nature of the implementations herein that others can, by applying current knowledge, readily modify and/or adapt for various applications without departing from the generic concept, and, therefore, such modifications and adaptations should and are intended to be comprehended within the meaning and range of equivalents of the disclosed implementations. 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 implementations herein have been described in terms of preferred implementations, those skilled in the art will recognize that the implementations herein can be practiced with modification within the spirit and scope of the implementations as described herein.
[0064] List to reference numerals:

Sr. No. Description
100 lightweight composite felt
101 banana fibers
102 polypropylene fibers
103 banana fibers composite felt
104 banana non-woven composite felt

We Claim:
1. A banana fibre-based automotive product comprising:
a single composite felt (100) or a plurality of composite felts (100) having identical compositions, wherein the composite felt (100) comprises:
banana fibers (101); and
a base material (102), wherein the composite felt (100) comprises 50% to 90% of the banana fibers (101) and 10% to 50 % of the base material (102), and wherein the composite felt (100) comprises a single layer of uniform composition of the banana fibers (101) and the base material (102).
2. The banana fibre-based automotive product as claimed in claim 1, wherein the predefined range includes 50 % of the banana fibers (101) and 50% of the base material (102).
3. The banana fibre-based automotive product as claimed in claim 1, wherein the predefined range includes 65% of the banana fibers (101) and 35% of the base material (102).
4. The banana fibre-based automotive product as claimed in claim 1, wherein the banana fibers (101) has physical properties comprising a diameter in range of 50-250 mm, a length of 1000-5000 mm, a density of 750-950 kg per meter, a specific gravity of 1.05 and a microfibril angle of 11 degree.
5. The banana fibre-based automotive product as claimed in claim 1, wherein the single layer uniform lightweight composite felt (100) is one of banana fibers composite felt (103) with various GSM and banana non-woven composite felt (104) with various GSM.
6. The banana fibre-based automotive product as claimed in claim 1, wherein the banana fibre-based automotive product is one of: a roof liner, a parcel self, a side wall trim, a rear wall trim, a seat form, a tail gate, and a head liner.

7. The banana fibre-based automotive product as claimed in claim 1, wherein the composite felt (100) has uniform stiffness throughout the single layer uniform lightweight composite felt (100).
8. The banana fibre-based automotive product as claimed in claim 1, wherein the composite felt has a density of: 1800GSM, 1500GSM or 2000 GSM.
9. The banana fibre-based automotive product as claimed in claim 1, wherein the base material (102) is one of polyolefin fibers, and polypropylene fibers.
10. A process for manufacturing the banana fibre-based automotive product, the process comprising:
receiving banana fibers (101) of a desired length;
mixing in the banana fibers (101) with base material (102) in predefined ratio;
passing the mixture of the banana fibers (101) and the base material (102) through a carding machine to form fibrous webs; and
needle punching the fibrous webs to form a composite felt, wherein the composite felt formed has a single layer of uniform composition of banana fibers and the base material.
11. The process as claimed in claim 14, wherein the process comprises:
pre-heating the composite felt (100); and
moulding the heated lightweight composite felt on the automotive product to make the banana fiber-based automotive product.
12. The process as claimed in claim 14, wherein the desired length of each of the
banana fibers (101) is one of 60 mm length, 80 mm length and 100 mm length,
and wherein of the base material (102) is of 100 mm length.

13. An automotive product, wherein the automatic product is manufactured from banana fiber using following steps:
mixing in the banana fibers (101) of a desired length with base material (102) in predefined ratio by mixing means;
carding the mixture of the banana fibers (101) and the base material (102) by passing said mixture through a carding machine to form fibrous webs; and
needle punching the fibrous webs to form a composite felt using a punching machine, wherein the composite felt formed has a single layer of uniform composition of banana fibers and the base material;
pre-heating the single composite felt (100) or the plurality of composite felts (100) having identical compositions using any heating means; and
moulding the single composite felt (100) or the plurality of composite felts (100) having identical compositions on desired automotive part mould to make the banana fiber-based automotive product.