Description:Brief Description of the Drawings

Generally, the present disclosure relates to polymer production methods. Particularly, the present disclosure relates to a method for producing a biodegradable translucent polymer sheet.
Background
The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
In the current landscape of materials science and environmental sustainability, the quest for alternatives to conventional plastics has become imperative due to the alarming rates of plastic pollution globally and its detrimental impact on the environment. Plastic pollution, characterized by the accumulation of plastic products in the Earth's environment, has emerged as a global concern. Ordinary plastics, known for their longevity, can persist in the environment for up to a thousand years, contributing significantly to environmental destruction. India, in particular, faces alarming levels of plastic pollution, with an estimated generation of 7,300,752 tonnes of plastic waste and an additional 3,30,764 tonnes of microplastics by 2023. The Indian plastic industry, valued at 110,000 crore rupees, consumes 13 million tonnes of plastic annually, recycling only 60% of this amount. Despite India's per capita plastic consumption being lower than the global average, the country generates 16 lakh tonnes of plastic waste annually, posing significant environmental challenges.
To combat the rising issue of plastic pollution, India introduced the Plastic Waste Management Rules (PWR) in 2011, which were revised in 2016. These regulations advocate for measures such as banning plastic bags smaller than 50 microns and gradually eliminating non-recyclable multi-layered plastics. Despite the economic potential of plastic recycling, estimated at Rs. 5600 crore a year, the opportunities within this sector remain largely untapped.
The problem of plastic pollution is not confined to India alone. Globally, approximately 300 million tonnes of plastic products are generated each year, with only 9% being recycled. The environmental impact of plastic pollution is profound, harming approximately 600 marine species, 80% of which suffer injuries or deaths due to plastic ingestion. Furthermore, plastics have been found in the blood of newborns, linking them to adverse health effects such as cancer, hormonal disruptions, and heart damage.
Amidst this backdrop, the exploration of agricultural waste as a raw material for producing biodegradable polymers offers a glimmer of hope. India's agricultural sector generates over 500 million tonnes of crop residues annually, including stubble. Stubble burning, a common practice in northern India, contributes significantly to air pollution, with an estimated 101 million tonnes of CO2 emissions during the stubble burning season. The utilization of agricultural waste, such as corn stubble and husks, in the production of biodegradable polymers presents an innovative solution to managing agricultural waste while addressing the issue of plastic pollution. Bioplastics derived from agricultural waste have shown accelerated rates of biodegradation, with some formulations breaking down in a matter of months, offering a sustainable alternative to conventional plastics.
Given the environmental challenges posed by plastic pollution and the underutilization of agricultural waste, there exists an urgent need for solutions that not only mitigate the environmental impact of plastics but also harness the potential of agricultural waste for sustainable materials production. Such solutions should aim to enhance the scalability and economic viability of producing biodegradable polymers from agricultural waste, thereby contributing to environmental conservation and sustainable development.
Summary
The following presents a simplified summary of various aspects of this disclosure in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements nor delineate the scope of such aspects. Its purpose is to present some concepts of this disclosure in a simplified form as a prelude to the more detailed description that is presented later.
The following paragraphs provide additional support for the claims of the subject application.
In an aspect, the present disclosure provides a method for producing a biodegradable translucent polymer sheet. The method encompasses several steps starting with the procurement of corn stubble and husks from post-harvest farms, which are then processed through chopping, cooking, and bleaching to prepare a pulp. This pulp is combined with a mixture containing corn starch, glycerin, vinegar, and distilled water, which is subsequently heated and molded to form a translucent polymer sheet. The final product is achieved after drying and demolding the material, resulting in a biodegradable translucent natural polymer sheet. This method employs agricultural waste as a raw material, presenting an innovative approach to polymer production that not only addresses environmental concerns related to plastic pollution but also utilizes renewable resources efficiently.
Furthermore, the present disclosure introduces a system for producing a biodegradable translucent natural polymer, comprising various units designed for collecting, processing, and transforming corn stubble and husks into polymer sheets. This system includes a collection unit equipped with a conveyor system, a grinding unit with an adjustable mechanism, a cooking and bleaching unit integrated with temperature control and pH monitoring capabilities, a mixing unit, and a heating unit. Additionally, the system features a molding unit capable of adjusting polymer thickness, a drying unit enhanced with UV lights for faster drying and antimicrobial treatment, and a demolding unit designed to remove the dried polymer efficiently. The inclusion of a packaging unit further facilitates the handling and distribution of the final biodegradable polymer sheets.
Each component of the system and method is meticulously designed to ensure the production of biodegradable polymer sheets is not only environmentally friendly but also scalable and efficient. By leveraging agricultural waste and incorporating advanced processing technologies, this invention aims to provide a sustainable solution to the global issue of plastic pollution, promoting the use of biodegradable materials in various applications.

Field of the Invention

The features and advantages of the present disclosure would be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a method (100) for producing a biodegradable translucent polymer sheet, in accordance with the embodiments of the present disclosure.
FIG. 2 illustrates a block diagram of system (200) for producing a biodegradable translucent natural polymer, in accordance with the embodiments of the present disclosure.
FIG. 3 illustrates the water-resistant properties of biodegradable and translucent polymer sheet that has been developed using corn waste, in accordance with the embodiments of the present disclosure.

Detailed Description
In the following detailed description of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to claim those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims and equivalents thereof.
The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
FIG. 1 illustrates a method (100) for producing a biodegradable translucent polymer sheet, in accordance with the embodiments of the present disclosure. The method (100) for producing a biodegradable translucent polymer sheet, which is outlined through a series of elaborated steps. This method leverages agricultural waste, specifically corn stubble and husks, to fabricate an environmentally friendly material. The method (100) commences with step (102) obtaining corn stubble from farms post-harvest. This step is essential for sourcing raw material that is abundant and renewable. Corn stubble, often considered agricultural waste, is repurposed here, contributing to waste reduction and environmental sustainability. The stubble serves as a primary biomass source for the subsequent production process. Following the collection of corn stubble, the method (100) involves gathering corn husks from the leftover skins of corn cobs in step (104). Similar to corn stubble, corn husks represent a substantial amount of agricultural waste. By incorporating corn husks, the method (100) further utilizes biomass that would otherwise contribute to environmental degradation.
In step (106) collected corn stubble and husks are then chopped into pieces approximately 5 cm in size using an industrial grinder or pulverizer. This process is critical for ensuring uniformity in size, which facilitates more efficient cooking and delignification. The uniform size of the biomass pieces ensures consistent treatment in the subsequent steps of the method. The method (100) proceeds with cooking a mixture of corn stubble and husks in a 1:1 ratio by weight, to which 5% by weight of NaOH is added in step (108). This addition serves for delignification, breaking down the lignin present in the biomass, thereby making the cellulose more accessible for the later stages of polymer sheet formation. The specified water-to-mixture ratio of 5:1 ensures the mixture is adequately hydrated for the cooking process. After cooking, in step (110) the mixture undergoes bleaching with 25% concentrated chlorine bleach for eight hours. This process is aimed at purifying the biomass by removing residual lignin and other impurities, essential for achieving a translucent polymer sheet. A thorough rinse follows to remove chlorine particles and adjust the pH level to 7, preparing the biomass for polymerization.
In step (112), the bleached biomass is then combined with a specific mixture of distilled water, corn starch, food-grade glycerin, food-grade vinegar, and the prepared pulp in a borosilicate glass beaker. This step is pivotal for creating the polymer matrix. Each component plays a crucial role, with corn starch acting as a natural polymer, glycerin as a plasticizer to enhance flexibility, and vinegar to aid in network formation. In step (114), the mixture in the beaker is heated to 250 degrees celsius in a water bath or suitable vessel while being stirred at 60 rpm. This heating process is crucial for achieving a jelly-like slurry consistency, indicative of the initial stages of polymerization. The controlled temperature and stirring rate ensure uniform heat distribution and mixing.
Once the desired consistency is achieved, the jelly-like slurry is poured into a shaping tray or mold in step (116). This step determines the final shape and thickness of the polymer sheet, with the slurry being molded into a pre-defined form. In step (118), adjustments to the consistency of the slurry with additional water may be needed before molding. This ensures the slurry has the appropriate viscosity for even spreading within the mold, critical for uniform thickness and smoothness of the polymer sheet. The slurry is spread evenly within the mold to achieve a thickness of approximately 1mm in step (120). Uniform spreading is essential for producing sheets of consistent thickness and quality. In step (122), drying the molded material is accomplished either naturally under sunlight for about 10 hours or in an oven at 100 degrees Celsius for 40-45 minutes. Drying solidifies the polymer matrix, yielding a durable material. Additionally in step (124), the dried material is demolded to obtain the biodegradable translucent natural polymer sheet. This step marks the culmination of the manufacturing process, with the polymer sheet now ready for application or further processing.
“System” refers to an integrated apparatus designed for manufacturing biodegradable translucent natural polymer sheets, incorporating units for collecting, processing, and treating agricultural by-products, specifically corn stubble and husks, through a series of mechanical and chemical operations to form and finalize the polymer product.
The term "collection unit " as used throughout the present disclosure relates to a mechanism designed for the acquisition of agricultural by-products, specifically corn stubble and husks, from post-harvest fields. The collection unit serves the initial and crucial step in the process of producing a biodegradable translucent natural polymer by securing the raw materials necessary for the subsequent production stages. The effectiveness of collection unit in gathering adequate and suitable biomass is vital for ensuring a consistent supply of raw materials for the polymer production process.
The term "grinding unit" as used throughout the present disclosure relates to an apparatus configured to chop corn stubble and husks into pieces of approximately 5 cm in size. Grinding unit is instrumental in preparing the biomass for cooking and bleaching by reducing the size of the raw materials to ensure uniform treatment during the process. The capability of grinding unit to produce uniformly sized pieces facilitates efficient delignification and bleaching, thereby enhancing the quality of the polymer produced.
The term "cooking and bleaching unit" as used throughout the present disclosure relates to a system capable of processing the chopped biomass by mixing corn stubble and husks in a 1:1 ratio, adding NaOH and water for delignification, cooking the mixture, and subsequently bleaching it with chlorine bleach followed by rinsing. Cooking and bleaching unit plays a critical role in purifying the biomass and preparing it for polymerization, with the delignification and bleaching processes being essential for removing lignin and other impurities from the biomass.
The term "mixing unit" as used throughout the present disclosure relates to a component that includes a borosilicate glass beaker for combining corn starch, glycerin, vinegar, distilled water, and the bleached corn stubble and husk pulp. Mixing unit is responsible for creating the polymer matrix by thoroughly mixing the specified components. The mixture prepared by mixing unit is critical for the formation of the biodegradable translucent natural polymer, with each component playing a specific role in the polymerization process and the final properties of the polymer sheet.
The term "heating unit" as used throughout the present disclosure relates to a mechanism capable of heating the mixture prepared by mixing unit in a water bath or a similar vessel to degrees Celsius while stirring the mixture at a constant 60 rpm. Heating unit is crucial for achieving the gelation and polymerization of the mixture, transforming it into a jelly-like slurry ready for molding. The precise control of temperature and stirring speed by heating unit ensures the uniform consistency and quality of the polymer slurry.
The term "molding unit" as used throughout the present disclosure relates to an apparatus designed for pouring and evenly spreading the heated mixture into a shaping tray or mold. Molding unit determines the shape and thickness of the biodegradable polymer sheet, making it a key component in defining the dimensions and appearance of the final product. The ability of molding unit to evenly spread the mixture is essential for achieving uniform thickness and quality in the produced polymer sheets.
The term "drying unit" as used throughout the present disclosure relates to a system designed for either naturally drying or oven-drying the molded material. Drying unit solidifies the polymer matrix, transitioning the material from a gel-like state to a solid, durable sheet. The choice between natural drying and oven-drying offers flexibility in the process, allowing for adjustments based on environmental conditions and production needs.
The term "demolding unit" as used throughout the present disclosure relates to a mechanism for retrieving the biodegradable polymer sheet from the mold after the drying process is complete. Demolding unit is essential for the final step of the production process, ensuring that the polymer sheet is carefully removed from the mold without damage. The functionality of demolding unit is critical for maintaining the integrity and quality of the biodegradable translucent natural polymer sheet, preparing it for further use or processing.
FIG. 2 illustrates a block diagram of system 200 for producing a biodegradable translucent natural polymer, in accordance with the embodiments of the present disclosure. System (200) comprises a collection unit (202), which is configured for obtaining agricultural by-products, specifically corn stubble and husks, from post-harvest fields. Said collection unit (202) may incorporate a conveyor system for efficient material transfer to grinding unit (204). Said grinding unit (204) is structured to chop the received corn stubble and husks into uniformly sized pieces, approximately 5 cm in length, and may include an adjustable mechanism allowing for variation in the size of the chopped biomass. The size-adjusted material is then conveyed to cooking and bleaching unit (206), where the biomass undergoes a delignification process with NaOH and is subsequently bleached with chlorine bleach. A temperature control unit and a pH meter within said cooking and bleaching unit (206) ensure precise conditions are maintained for optimal processing of the biomass. Further included in system (200) is a mixing unit (208), equipped with a borosilicate glass beaker for the preparation of the polymer matrix by combining various ingredients with the treated biomass. Heating unit (210) is provided to bring the mixture to the necessary polymerization temperature, and molding unit (212) ensures accurate shaping and thickness control of the biodegradable polymer. System (200) also encompasses drying unit (214), possibly enhanced with UV lights for both drying and antimicrobial treatment, and demolding unit (216), which facilitates the release of the polymer sheet from the molds without inflicting damage. Additionally, a packaging unit may be included for the final packaging of the polymer sheets post-demolding, thus completing the process flow depicted in the figure.
In an embodiment, the collection unit (202) of the system (200) comprises a conveyor system designed for the efficient transportation of corn stubble and husks from a designated storage area to the grinding unit (204). This integration of a conveyor system within the collection unit (202) significantly enhances the operational efficiency of the system (200) by automating the initial stage of the raw material handling process. The conveyor system facilitates a continuous and consistent supply of corn stubble and husks to the grinding unit (204), thereby ensuring that the production process of the biodegradable translucent natural polymer can be carried out without unnecessary delays or interruptions. The automation provided by the conveyor system not only reduces the labor intensity associated with manual handling of the biomass but also minimizes the risk of contamination or loss of raw materials during transportation. This embodiment underscores the commitment to improving the sustainability and efficiency of the polymer production process by leveraging advanced material handling technologies.
In another embodiment, the grinding unit (204) within the system (200) is enhanced by incorporating an adjustable mechanism that allows for the variation in the size of the chopped pieces of corn stubble and husks based on their type. This adjustable mechanism enables the grinding unit (204) to adapt to the physical characteristics of different varieties of corn stubble and husks, which may vary in terms of density, moisture content, and fibrous structure. By adjusting the size of the chopped pieces, the system (200) can optimize the subsequent cooking and bleaching processes, ensuring that the biomass is uniformly processed for the production of the polymer. The flexibility provided by the adjustable mechanism in the grinding unit (204) contributes to the overall versatility and efficiency of the system (200), allowing for the processing of a wide range of biomass types while maintaining high-quality standards in the production of the biodegradable translucent natural polymer.
In a further embodiment, the cooking and bleaching unit (206) of the system (200) is equipped with a temperature control unit and a pH meter. The temperature control unit is responsible for maintaining the optimal cooking temperature throughout the delignification process, ensuring that the corn stubble and husks are properly cooked without degrading the essential properties required for polymer production. Simultaneously, the pH meter plays a critical role during the bleaching process by continuously monitoring and adjusting the pH level of the mixture. This ensures that the bleaching process effectively removes impurities and lignin from the biomass while preserving the structural integrity necessary for the formation of the polymer matrix. The integration of these advanced control systems into the cooking and bleaching unit (206) significantly enhances the precision and reliability of the polymer production process, leading to the consistent production of high-quality biodegradable translucent natural polymer sheets.
In an embodiment, the molding unit (212) of the system (200) is designed to be configurable, allowing for the adjustment of the thickness of the polymer layer from 0.5 mm to 2 mm. This feature provides the system (200) with the flexibility to produce polymer sheets of varying thicknesses, catering to diverse application requirements. By enabling precise control over the thickness of the polymer layer, the molding unit (212) ensures that the produced polymer sheets meet specific performance criteria, such as flexibility, strength, and translucency, suitable for a range of uses from packaging materials to biodegradable agricultural films. The ability to adjust the thickness of the polymer layer underscores the adaptability of the system (200) in producing customized polymer solutions, enhancing its applicability in different industrial sectors seeking sustainable material options.
In another embodiment, the drying unit (214) of the system (200) incorporates ultraviolet (UV) lights to enhance the drying process and provide antimicrobial treatment to the molded material. The use of UV lights accelerates the drying process by efficiently removing moisture from the polymer sheets, thereby reducing the overall production time. Additionally, the antimicrobial treatment conferred by the UV lights ensures that the polymer sheets are free from microbial contaminants, enhancing their suitability for applications requiring high standards of hygiene and safety. This embodiment highlights the integration of advanced drying technologies in the system (200), contributing to the efficiency, safety, and quality of the biodegradable translucent natural polymer sheets produced.
In a further embodiment, the demolding unit (216) within the system (200) includes a remover unit specifically designed to remove the dried polymer from the molds without causing deformation or damage to the sheets. This remover unit is crucial for preserving the integrity and aesthetic quality of the biodegradable polymer sheets during the demolding process. By ensuring gentle and precise removal of the polymer sheets from the molds, the remover unit plays a vital role in maintaining the consistency and quality of the final product. This embodiment reflects the attention to detail in the design of the system (200), emphasizing the importance of every stage in the production process in achieving the highest standards of product quality.
In an embodiment, the system (200) is directed to a further aspect of the production apparatus that includes a packaging unit configured to package the biodegradable polymer sheets after demolding. Said packaging unit is integrated into system (200) to ensure that, subsequent to the release of the polymer sheets from demolding unit (216), the sheets are immediately protected from environmental exposure and contamination. The packaging unit is tailored to accommodate the dimensions and sensitivity of the biodegradable polymer sheets, providing a means to maintain the sheets in pristine condition until they reach the end user. This step is crucial for preserving the integrity of the biodegradable polymer sheets, especially important if the sheets are intended for applications requiring stringent hygiene standards. The inclusion of such a packaging unit in system (200) underscores the comprehensive nature of the production process, highlighting the attention to preserving product quality from manufacture to final delivery.
FIG. 3 illustrates the water-resistant properties of biodegradable and translucent polymer sheet that has been developed using corn waste, in accordance with the embodiments of the present disclosure. The environmentally friendly polymer can withstand considerable thermal stress, evidenced by its ability to resist deformation when subjected to water temperatures as high as 80 degrees Celsius. The stability of biodegradable and translucent polymer sheet against water ingress is further demonstrated through a water droplet test, wherein the sheet effectively prevents the water from seeping through, thereby highlighting its impermeability. In an experiment assessing the biodegradability of the material, a small section of the polymer sheet, measuring 2 by 2 centimeters, was immersed in 25 milliliters of water. Over a period of 60 days, the sample was left exposed to the ambient conditions of the open atmosphere. The results of this test were significant; the material showed a high rate of dissolution into the water, with more than 70% of it disintegrating, which emphasizes the polymer's capacity to break down in aquatic environments and indicates its potential as a sustainable alternative to traditional plastics. In an embodiment, the biodegradable polymer sheets can degrade more than 70% within 45 to 75 days when immersed in water. Additionally, the biodegradable polymer sheets are characterized by their stability in water temperatures up to 80 degrees Celsius. This property enables that that the biodegradable polymer sheets offer significant environmental benefits, particularly in reducing waste and facilitating recycling processes where temperature fluctuations are a concern.
In an embodiment, the biodegradable and translucent polymer sheet offers a sustainable solution to the environmental problems posed by traditional plastics. By utilizing stubble, an agricultural residue often disposed of through burning, contributing to pollution, the biodegradable and translucent polymer sheet provides an eco-friendly alternative but also utilises waste materials effectively.
Example embodiments herein have been described above with reference to block diagrams and flowchart illustrations of methods and apparatuses. It will be understood that each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations, respectively, can be implemented by various means including hardware, software, firmware, and a combination thereof. For example, in one embodiment, each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations can be implemented by computer program instructions. These computer program instructions may be loaded onto a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions which execute on the computer or other programmable data processing apparatus create means for implementing the functions specified in the flowchart block or blocks.
Operations in accordance with a variety of aspects of the disclosure is described above would not have to be performed in the precise order described. Rather, various steps can be handled in reverse order or simultaneously or not at all.
While several implementations have been described and illustrated herein, a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein may be utilized, and each of such variations and/or modifications is deemed to be within the scope of the implementations described herein. More generally, all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific implementations described herein. It is, therefore, to be understood that the foregoing implementations are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, implementations may be practiced otherwise than as specifically described and claimed. Implementations of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

Claims

I/We Claims

A method (100) for producing a biodegradable translucent polymer sheet, comprising:
(a) obtaining corn stubble from farms post-harvest;
(b) gathering corn husks from the leftover skins of corn cobs;
(c) chopping the corn stubble and husks into pieces approximately 5 cm in size using an industrial grinder or pulverizer;
(d) cooking a mixture of corn stubble and husks in a 1:1 ratio by weight, adding 5% by weight of NaOH to the mixture for delignification and a water-to-mixture ratio of 5:1;
(e) bleaching the cooked mixture with 25% concentrated chlorine bleach for eight hours, followed by a thorough rinse to remove chlorine particles and achieve a pH level of 7;
(f) combining 100 ml of distilled water, 10 g of corn starch, 10 ml of food-grade glycerin, 10 ml of food-grade vinegar, and 15 g of the cooked and bleached corn stubble and husk pulp into a borosilicate glass beaker;
(g) heating the mixture in the beaker to 250 degrees Celsius in a water bath or suitable vessel, while stirring at 60 rpm until the mixture reaches a jelly-like slurry consistency;
(h) pouring the jelly-like slurry into a shaping tray or mold;
(i) adjusting the consistency of the slurry with additional water if needed before molding;
(j) spreading the mixture evenly within the mold to a thickness of approximately 1mm;
(k) drying the molded material either naturally under sunlight for about 10 hours or in an oven at 100 degrees Celsius for 40-45 minutes;
(l) demolding the dried material to obtain the biodegradable translucent natural polymer sheet.
A system (200) for producing a biodegradable translucent natural polymer, comprising:
(a) a collection unit (202) for obtaining corn stubble and husks;
(b) a grinding unit (204) configured to chop corn stubble and husks into approximately 5 cm sized pieces;
(c) a cooking and bleaching unit (206) capable of mixing corn stubble and husks in a 1:1 ratio, adding NaOH and water, cooking the mixture, and subsequently bleaching it with chlorine bleach followed by rinsing;
(d) a mixing unit (208) including a borosilicate glass beaker for combining corn starch, glycerin, vinegar, distilled water, and the bleached corn stubble and husk pulp;
(e) a heating unit (210) capable of heating the beaker in a water bath or a similar vessel to 250 degrees Celsius while stirring the mixture at a constant 60 rpm;
(f) a molding unit (212) for pouring and evenly spreading the heated mixture into a shaping tray or mold;
(g) a drying unit (214) for either naturally drying or oven-drying the molded material;
(h) a demolding unit (216) for retrieving the biodegradable polymer from the mold.
The system (200) of claim 2, wherein the collection unit (202) comprises a conveyor system for transporting corn stubble and husks from a storage area to the grinding unit (204).
The system (200) of claim 2, wherein the grinding unit (204) includes an adjustable mechanism to vary the size of the chopped pieces based on the type of corn stubble and husks processed.
The system (200) of claim 2, wherein the cooking and bleaching unit (206) is equipped with a temperature control unit to maintain the cooking temperature and a pH meter to monitor and adjust the pH level during the bleaching process.
The system (200) of claim 2, wherein the molding unit (212) is configurable to adjust the thickness of the polymer layer from 0.5 mm to 2 mm.
The system (200) of claim 2, wherein the drying unit (214) includes ultraviolet (UV) lights to enhance the drying process and provide antimicrobial treatment.
The system (200) of claim 2, wherein the demolding unit (216) includes a remover unit to remove the dried polymer from the molds without causing deformation or damage.
The system (200) of claim 2, further comprising a packaging unit configured to package the biodegradable polymer sheets after demolding.
The system (200) of claim 2, wherein the biodegradable polymer sheets degrade more than 70% in a water within 45- 75 days, wherein the biodegradable polymer sheets are stable in water up to 80 degree Celsius.

METHOD FOR PRODUCING BIODEGRADABLE TRANSLUCENT POLYMER SHEETS FROM AGRICULTURAL WASTE

The present disclosure provides a method for producing a biodegradable translucent polymer sheet. The method includes obtaining corn stubble from farms post-harvest and gathering corn husks from the leftover skins of corn cobs. The corn stubble and husks are chopped into pieces approximately 5 cm in size using an industrial grinder or pulverizer. A mixture of corn stubble and husks in a 1:1 ratio by weight is cooked, adding 5% by weight of NaOH to the mixture for delignification and a water-to-mixture ratio of 5:1. The cooked mixture is bleached with 25% concentrated chlorine bleach for eight hours, followed by a thorough rinse to remove chlorine particles and achieve a pH level of 7. A combination of 100 ml of distilled water, 10 g of corn starch, 10 ml of food-grade glycerin, 10 ml of food-grade vinegar, and 15 g of the cooked and bleached corn stubble and husk pulp is heated to 250 degrees Celsius in a water bath or suitable vessel, while stirring at 60 rpm until the mixture reaches a jelly-like slurry consistency. The jelly-like slurry is poured into a shaping tray or mold, adjusted with additional water if needed before molding, and spread evenly within the mold to a thickness of approximately 1mm. The molded material is dried either naturally under sunlight for about 10 hours or in an oven at 100 degrees Celsius for 40-45 minutes. Finally, the dried material is demolded to obtain the biodegradable translucent natural polymer sheet.
, Claims:I/We Claims

A method (100) for producing a biodegradable translucent polymer sheet, comprising:
(a) obtaining corn stubble from farms post-harvest;
(b) gathering corn husks from the leftover skins of corn cobs;
(c) chopping the corn stubble and husks into pieces approximately 5 cm in size using an industrial grinder or pulverizer;
(d) cooking a mixture of corn stubble and husks in a 1:1 ratio by weight, adding 5% by weight of NaOH to the mixture for delignification and a water-to-mixture ratio of 5:1;
(e) bleaching the cooked mixture with 25% concentrated chlorine bleach for eight hours, followed by a thorough rinse to remove chlorine particles and achieve a pH level of 7;
(f) combining 100 ml of distilled water, 10 g of corn starch, 10 ml of food-grade glycerin, 10 ml of food-grade vinegar, and 15 g of the cooked and bleached corn stubble and husk pulp into a borosilicate glass beaker;
(g) heating the mixture in the beaker to 250 degrees Celsius in a water bath or suitable vessel, while stirring at 60 rpm until the mixture reaches a jelly-like slurry consistency;
(h) pouring the jelly-like slurry into a shaping tray or mold;
(i) adjusting the consistency of the slurry with additional water if needed before molding;
(j) spreading the mixture evenly within the mold to a thickness of approximately 1mm;
(k) drying the molded material either naturally under sunlight for about 10 hours or in an oven at 100 degrees Celsius for 40-45 minutes;
(l) demolding the dried material to obtain the biodegradable translucent natural polymer sheet.
A system (200) for producing a biodegradable translucent natural polymer, comprising:
(a) a collection unit (202) for obtaining corn stubble and husks;
(b) a grinding unit (204) configured to chop corn stubble and husks into approximately 5 cm sized pieces;
(c) a cooking and bleaching unit (206) capable of mixing corn stubble and husks in a 1:1 ratio, adding NaOH and water, cooking the mixture, and subsequently bleaching it with chlorine bleach followed by rinsing;
(d) a mixing unit (208) including a borosilicate glass beaker for combining corn starch, glycerin, vinegar, distilled water, and the bleached corn stubble and husk pulp;
(e) a heating unit (210) capable of heating the beaker in a water bath or a similar vessel to 250 degrees Celsius while stirring the mixture at a constant 60 rpm;
(f) a molding unit (212) for pouring and evenly spreading the heated mixture into a shaping tray or mold;
(g) a drying unit (214) for either naturally drying or oven-drying the molded material;
(h) a demolding unit (216) for retrieving the biodegradable polymer from the mold.
The system (200) of claim 2, wherein the collection unit (202) comprises a conveyor system for transporting corn stubble and husks from a storage area to the grinding unit (204).
The system (200) of claim 2, wherein the grinding unit (204) includes an adjustable mechanism to vary the size of the chopped pieces based on the type of corn stubble and husks processed.
The system (200) of claim 2, wherein the cooking and bleaching unit (206) is equipped with a temperature control unit to maintain the cooking temperature and a pH meter to monitor and adjust the pH level during the bleaching process.
The system (200) of claim 2, wherein the molding unit (212) is configurable to adjust the thickness of the polymer layer from 0.5 mm to 2 mm.
The system (200) of claim 2, wherein the drying unit (214) includes ultraviolet (UV) lights to enhance the drying process and provide antimicrobial treatment.
The system (200) of claim 2, wherein the demolding unit (216) includes a remover unit to remove the dried polymer from the molds without causing deformation or damage.
The system (200) of claim 2, further comprising a packaging unit configured to package the biodegradable polymer sheets after demolding.
The system (200) of claim 2, wherein the biodegradable polymer sheets degrade more than 70% in a water within 45- 75 days, wherein the biodegradable polymer sheets are stable in water up to 80 degree Celsius.

METHOD FOR PRODUCING BIODEGRADABLE TRANSLUCENT POLYMER SHEETS FROM AGRICULTURAL WASTE