Algae Bio Textile

The present invention relates to a bio-textile material. In particular, the present invention relates to a bio-textile produced from algae by a unique process.

There is a growing global demand for fashion with the global market expected to reach $157.88 billion by 2032. Currently, the fashion industry contributes 20% of global wastewater, significantly harming marine habitats and biodiversity. The fashion industry is a major contributor to environmental damage, accounting for significant CO2 emissions, water pollution, and the depletion of natural resources. Agriculture, particularly cotton farming, uses large amounts of pesticides, many of which are hazardous and continue to be applied despite being banned globally. These pesticides often make their way into water systems, further polluting the environment. The production of synthetic fabrics also contributes to CO2 emissions through the use of fossil fuels. Additionally, the textile industry discharges harmful solvents, dyes, and pigments, which can be toxic and carcinogenic. Surfactants, which are widely used during production, also contain harmful chemicals that interfere with hormone systems in both humans and aquatic life. The leather industry releases toxic chemicals such as chromium, zinc, cadmium, and other heavy metals into water sources during tanning. That can contaminate ecosystems, harm marine life, and impact human health. Improper disposal of tannery wastewater can also block sunlight from reaching aquatic environments, disrupting photosynthesis and oxygen levels. Similarly, microplastics from synthetic fibers accumulate in oceans, harming marine life and ultimately affecting human health.

The patent document IN202221047455A discloses plant based vegan leather made from banana crop-waste Abstract The present invention relates to compositions for preparing Vegan Leather and Vegan Leather prepared from such compositions wherein such compositions comprise of Banana pulp and at least one adhesive or binder. Further, the invention also relates to processes for preparing compositions and Vegan Leather from compositions containing Banana Pulp. This Vegan leather is a leather like material completely free of any animal product.

The document CN116987302A describes a bio-based pure plain leather as well as a preparation method and application thereof, and belongs to the technical field of synthetic leather. The maple leaf pulp and the Kangpu tea biomass cellulose are extracted on the basis of agricultural wastes, and then the bio-based pure plain leather without any animal component is prepared from the maple leaf pulp and the Kangpu tea biomass cellulose; the bio-based pure plain leather has physical, chemical and mechanical properties similar to those of traditional leather, and has certain air permeability; the bio-based pure plain leather is simple in process, easy to control, low in cost and energy consumption, excellent in processability and good in industrial practicability.

However, in the aforementioned documents, though a part of recyclable biological sources are used, synthetic polymers like polyvinyl acetate, polyvinyl alcohol, polylactic and the like are still used for the preparation of bio-based leather. Also, the backing panel/material is also synthetic in nature which will again add up to the pollution after being used and discarded.

Therefore, there exists a need to address the environmental issues associated with textile and leather production and to produce a bio-textile by replacing harmful, resource-draining materials with eco-friendly, and biological resources.

The principal object of the invention is to reduce pollution and recycle waste or abundant materials from available resources by producing a bio-textile.

Another object of the invention is to prepare a non-woven bio-textile composed of a single or multiple layers, including surface and structural layers, incorporating pre-treated algae, seaweed, natural fillers, and other additives.

Another object of the invention is to establish a specific weight ratio of algae and/or seaweed to natural fillers to achieve different levels of thickness in the prepared bio-textile. In some embodiments, seaweed may serve as the primary biomass, combined with natural fillers and additives as described herein. In other embodiments, algae may serve as the primary biomass, or algae and seaweed may be used in combination. In certain cases, algae may also function as a structural or natural filler when seaweed is the primary biomass.

Another object of the invention is to prepare a bio-textile with good tensile and tearing strength such that it can be used to produce different types of apparels.

Another object of the invention is to provide a process of preparation of the bio-textile using eco-friendly materials including harvesting, pre-treatment, slurry preparation, different layer formation, drying and finishing steps.

These and other objects and characteristics of the present invention will become apparent from the further disclosure to be made in the detailed description given below.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

The invention provides a non-woven bio-textile comprising a single structural layer or a plurality of layers including a surface layer and a structural layer further wherein each further includes including a pre-treated algae, natural fillers and other additives or a pre-treated algae, seaweed, natural fillers and other additives.

One aspect of the present invention is to maintain a weight ratio of pre-treated algae and natural fillers between 3:7 and 7:3 and a weight ratio of pre-treated algae, seaweed and natural fillers is 5:2:3.

Other aspect of the present invention is to prepare a single layered or double layered bio-textile with a tensile strength in the range of 100-200 N/mm and 150-200 N/mm, respectively, and a tearing strength in the range of 50-60 N and 70-80 N, respectively.

Another aspect of the present invention is to distribute the weight ratio between the surface layer and the structural layer in a double layered bio-textile between 3:7 and 7:3 to obtain a fabric with different GSM value ranging between 500-1500.

Yet other aspect of the present invention is to provide a process of preparation of double layered bio-textile comprises the steps of (a) harvesting, cleaning and optional detoxification of the biological source; (b) pre-treatment of the source; (c) preparation of pulp/slurry; (d) preparation of structural layer using algae and seaweed mixture; (e) preparation of double layered non-woven bio-textile/fabric; and (f) drying, curing and finishing the bio-textile/fabric.

These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.

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/or 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 practised 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.

Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in an embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.

Moreover, although the following description contains many specifics for the purposes of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to said details are within the scope of the present disclosure. Similarly, although many of the features of the present disclosure are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present disclosure is set forth without any loss of generality to, and without imposing limitations upon the present disclosure.

The term “bio-textile” or “biofabric” are interchangeably used in the Specification where all these terms have the same context and meaning as it describes the non-woven bio-textile fabric of the invention.

The invention disclosed herein provides a non-woven bio-textile fabric comprising either a single structural layer or a plurality of layers including a surface layer and a structural layer. The surface layer and the structural layer further comprises either pre-treated algae and natural fillers or pre-treated algae, seaweed and natural fillers. The bio-textile fabric further comprises additives including adhesives, lacquers, binders, softeners/plasticizers, preservatives and/or colouring agents. The weight ratio of pre-treated algae and natural fillers in the fabric is between 0.01:10 and 10:0.01, specifically between 3:7 and 7:3. The weight ratio of pre-treated algae, seaweed and natural fillers in the fabric is 5:2:3. The weight percentage of additives in the fabric is in the range of 0.5-10%. The thickness of the single layered and multiple layered bio-textile fabric is in the range of 0.5-5 mm and 1-10 mm, respectively.

In an example embodiment, the filamentous algae is selected from but not limited to Classes Chlorophyceae, Klebsormidiophyceae, Xanthophyceae, Bacillariophyceae (diatoms), Cyanophyceae, and the like. Preferably, the algae are selected from different genera of the Class Chlorophyceae including Spirogyra, Zygnema, Mougeotia, and the like from the Order Zygnematales; Cladophora (especially Cladophora fracta) and the like from the Order Cladophorales, Ulothrix and the like from the Order Ulotrichales; Hydrodictyon and the like from the Order Chlorococcales; and Oedogonium and the like from the Order Oedogoniales. Preferably, the algae are selected from a genera of the Class Klebsormidiophyceae including Klebsormidium and the like. Preferably, the algae are selected from a genera of the Class Xanthophyceae including Vaucheria, Tribonematales, and the like. Preferably, the algae are selected from a genera of the Class Bacillariophyceae including Aulacoseira, Melosira, and the like. Preferably, the algae are selected from a genera of the Class Cyanophyceae including Oscillatoria, Nostocales, and the like.

In an example embodiment, the seaweed is selected from but not limited to different phylum including Rhodophyta, Cyanobacteria, Chlorophyta, Pheophyta and the like. Preferably, the seaweeds are selected from different genera of the Phylum Chlorophyta including Ulva and the like; Phylum Pheophyta including Sargassum, Durvillaea, Saccharina, and the like; Phylum Rhodophyta including Gracilaria, Gelidium, Rhodophyta and the like.

In some example embodiment, the fillers are selected from but not limited to rice husk, wheat straw, jute, grass, cork powder, starch, textile wastes, waxes, oil, polymer fillers and the like wherein starches include tapioca, corn, potato, rice and the like; waxes include bees wax, paraffin wax, carnauba wax and the like; and textile wastes include fabric scraps such as recycled fabrics, recycled fabric blends, leather buffing dust and the like.

In some example embodiment, the adhesive is selected from but not limited to heat-activated adhesives including gum/glue-based adhesives including guar gum, arabic gum, xanthan gum, jackfruit glue, arrow root glue, corn-starch glue and the like; chitosan-based adhesives, starch-based adhesives derived from plant sources including corn, wheat, or potatoes; rosin-based adhesives, natural rubber and polyurethane based adhesives.

In some example embodiment, the wax and oil as plasticiser or for waterproofing is selected from but not limited to carnauba wax, beeswax, vegetable or fruit oil and natural resin in the range of 3-5%, 2-4%, 1-2%, 1-3%, respectively. The colouring agents are selected from but not limited to natural dyes including onion skin, indigo leaves, beetroot, and charcoal powder used in the range of 2-3%, 1-2%, 0.5-1% and 1-2%, provides yellow/orange, red/pink, blue, and black colour, respectively.

In an exemplary embodiment, the tensile strength of the single layer and double layer is estimated using breaking force and elongation strip method as per ASTM D 5035:2011 standards wherein the size used for testing is 3″×1″. The tensile strength of the single layer and double layer bio-textile fabric is in the range of 100-200 N/mm and 150-200 N/mm, respectively. On comparison, the tensile strength of the bio-textile fabric is better than the conventional fabric including cotton, nylon, rayon, polyester and denim. This indicates that the single layered bio-textile is suitable for light wear applications and double layered fabric for heavy duty applications.

In other exemplary embodiment, the tearing strength of the single layer (3″×1″) and double layer (3″×1″) is estimated using IS 6489 (Part 1): 2011 R2021 standards and is in the range of 50-60 N and 70-80 N, respectively. On comparison, this is better than rayon, silk, chiffon and linen fabric. This indicates that both the single layered and double layered bio-textile is resistant to tearing and is suitable durable applications such as workwear, industrial use, and outdoor fabrics.

In yet other exemplary embodiment, the pH of both single and double layered bio-textile is in the range of 6-7. The GSM of the single layer (3″×1″) and double layer (3″×1″) bio-textile fabric with cotton scraps as fillers is estimated using IS 19864:2001 method A standard and is found to be in the range of 550-600 GSM and 1350-1450 GSM. Fabrics with a high GSM tend to provide better thermal insulation due to their thickness. This makes them suitable for winter clothing (like heavy jackets or coats), blankets, or heavy-duty outdoor gear. The distribution of weight between the surface layer and the structural layer is in the ratio 3:7 and 7:3 based on the weight of algae and algae/seaweed.

Thus, the physical properties of the bio-textile fabric is based on the number of layers and the amount of algae or algae/seaweed that is packed within each layers. On changing the weight of material added, the fabric can be changed for manufacturing different apparels.

In another embodiment, a process of preparation of bio-textile as shown incomprises the steps of (a) harvesting, cleaning and optional detoxification of the biological source; (b) pre-treatment of the source; (c) preparation of pulp/slurry; (d) preparation of structural layer using algae and seaweed mixture; (e) preparation of double layered non-woven bio-textile/fabric; and (f) drying, curing and finishing the bio-textile/fabric.

In an exemplary embodiment, the first step of harvesting, cleaning and and optional detoxification of the biological source including algae and seaweed in the preparation of bio-textile further comprises the steps of:

In an exemplary embodiment, the second step in the preparation of bio-textile further comprises the steps of:

In an exemplary embodiment, the third step in the preparation of bio-textile further comprises the steps of:

In some example embodiment, the consistency of the slurry is dependent on the method of preparation of the structural layer or the non-woven bio-textile including spray gun, felting or vat lifting technique. For spray gun technique, a thin slurry is desirable wherein the pulp content ranges between 5-8%. For vat lifting and felting technique, a medium and thick slurry is required, respectively wherein the pulp content ranges between 8-12% and 12-15%, respectively. The slurry can also be stored in an air tight container up to 2 days at room temperature and has to be remixed before using for the next step.

In an exemplary embodiment, the optional fourth step in the preparation of bio-textile includes incubating the pulp/slurry in an eco-friendly bleaching agent overnight. This step is performed only when light-coloured bio-textile is required. The eco-friendly bleaching agents include hydrogen peroxide, ozone, sodium percarbonate, citric acid, lemon juice, sodium bicarbonate, peracetic acid and enzyme-based bleaches. In a specific embodiment, hydrogen peroxide is used.

In an exemplary embodiment, the fifth step in the preparation of bio-textile including preparation of structural layer by felting technique further comprises the steps of:

In an exemplary embodiment, the sixth step in the preparation of bio-textile including preparation of non-woven double layered bio-textile is performed either using a vat-lifting technique or spray-gun technique.

The vat lifting technique further comprises the steps of:

In a specific embodiment, the number of layers are decided based on the thickness of the bio-textile. For medium thickness bio-textile, 3-4 layers are required whereas for thick bio-textile, 5-6 layers are required.

The spray gun technique further comprises the steps of:

In a preferable embodiment, the slurry consistency loaded in the gun reservoir is in the range of 5-15% that is selected based on the required thickness of the bio textile wherein a slurry of 5%, 10% and 15% indicates 5 kg, 10 kg, and 15 kg of pulp dispersed in 95 L, 90 L and 85 L of water, respectively. Also, a slurry of low, medium, and high consistency is suitable to produce thin/flexible sheets, medium-thickness sheets and thick/durable sheets, respectively. The table given below indicates the relationship between various parameters that is required to be followed for a specific thickness of the bio-textile.

In an exemplary embodiment, the seventh step in the preparation of bio-textile including pressing, drying and curing of single layered and double layered bio-textile further comprises the steps of:

In a preferable embodiment, the pressing equipment includes but not limited to hydraulic press, roller press, vacuum press, and hand press that is ideal for small scale, large scale, achieving even thickness, and artisanal production, respectively. While using a heated press, the temperature is maintained between 40-60° C. to fasten the drying process during pressing. In an example embodiment, non-stick separators used between sheets are selected from but not limited to silicone-coated paper, Teflon sheets, parchment papers, polypropylene fabric wherein except parchment paper other separators are reusable that are used for multiple cycles.

In another embodiment, the adhesive is also be added before pressing process. In such cases, the pressure in the press is gradually increased from 50 psi applied for 1-2 min up to 200 psi applied for 2-3 min such that it avoids seepage of adhesives.

In a preferable embodiment, the heat-activated adhesive is selected from but not limited to gum/glue-based adhesives, chitosan-based adhesives, starch-based adhesives, rosin-based adhesives, natural rubber and polyurethane based adhesives. The gum-based adhesives are activated at relatively low temperatures, around 50° C. to 80° C. whereas the chitosan-based, rosin-based and starch-based adhesives are usually activated from 60° C. to 120° C. PU-based adhesives that are activated in the temperature range of 100-180° C. are chosen when high flexibility, durability and water resistance are desired.