WO2020136626A1

WO2020136626A1 - Yarn made up of 100% banana pseudostem fibers

Info

Publication number: WO2020136626A1
Application number: PCT/IB2019/061418
Authority: WO
Inventors: Raghavan Parthasarathy; Venkatsubba Reddy CHOWDAVARAM
Original assignee: Raghavan Parthasarathy; Chowdavaram Venkatsubba Reddy
Priority date: 2018-12-29
Filing date: 2019-12-28
Publication date: 2020-07-02

Abstract

A process for the manufacturing of 100% banana yarn, said process comprises steps of harvesting banana pseudostem, peeling, fibre extraction/separation, washing, sun drying, cutting of fibers, carding and spinning; and a wearable fabric consisting of said 100% banana fiber.

Description

Yarn made up of 100% Banana Pseudostem Fibers

FIELD OF INVENTION

1. The present invention relates generally to obtaining fabric from bio waste.

In particular, the invention relates to extraction and conversion of plant fibre in waste banana stems to textile fabric of superior quality.

BACKGROUND OF THE INVENTION

2. 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.

3. In recent years, people have shown interest in forest preservation and finding a sustainable way to use agricultural and forest residues. Cellulose fibre from the forest and agricultural residues has many advantages, such as environmental friendliness, recyclability, and lower cost. Of the different kinds of tree/plants, banana plant is considered to be one of the world’s most useful and the most versatile plant. Almost all the parts of this plant, including the fruit, peel, leaf, pseudo-stem, stalk, and inflorescence (flower), can be utilized.

4. The banana pseudo-stem is also used for use as pulp and paper raw material, fibre for textiles, and filler or structural reinforcement in composites materials. The pseudo-stem of banana plant is the stem of banana plant that provides and transports nutrients from the soil to the fruits. The pseudo-stem is a part of the banana plant that looks like a trunk, which consists of a soft central core and tightly wrapped up to 25 leaf sheaths. These leaf sheaths unwrap from the stem and transform to recognizable banana leaves when they have matured. Usually, this pseudo stem is cut and disposed after the banana fruit is harvested for the season. After harvesting the fruit, farmers have to cut and remove the‘banana tree/ stem’ after every harvest. While the stem can be composted and used as fertilizers, it is most often burnt or dumped into water bodies due to its redundancy and null economic value. Additionally, they are unusable for the next harvest. Instead, farmers often focus on raising a new plant which will produce yield, i.e. the banana fruit in approximately one year time. For every ton of banana fruit harvested, about 100 kg of the fruit is rejected (i.e., rotten fruit) and approximately 4 tons of biomass wastes (e.g., leaf, pseudo-stem, rotten fruit, peel, fruit-bunch-stem, rhizome, etc.) is produced. This means that the amount of biomass wastes is nearly four times the amount of bananas produced in each harvest.

Based on another literature, it can be estimated that one hectare of banana farm could produce approximately 220 tons of biomass wastes. These wastes are usually disposed by dumping them into lakes and rivers, composting or simply through incineration. These methods cause obvious damage to the environment. Irrespective of the means of disposal, greenhouse gases carbon-dioxide and methane are released into the air. Today, despite rapid innovation in sustainable technology, not much attention is being given to elimination of bio-wastes through the productive utilization of the same.

The potential use of such stem fibers in textiles is becoming increasingly apparent every day. Much research is currently being undertaken in the textile sector to design new fibers, fabrics and threads with carefully controlled properties to meet the needs of niche markets. Furthermore, research is being conducted to fit the aforementioned needs in model which provides sustainability to the industry.

When compared resultant fabric made from the fibre extracted from other plants, banana stem is much better option as they are economical and have desirable mechanical properties. Additionally, while any other tree traditionally used for extracting fiber take nearly 30 years to grow, a banana tree only takes one year. Further, although the important ingredient in both tree fabric, banana stems contain very strong fibre.

Care and caution needs to be taken during the extraction of natural fibres from plants to avoid damage. Traditionally, pseudo stems from banana plants were manually cut from the main stem of the plant and then rolled lightly to remove the excess moisture. Further, any impurities such as pigments, broken fibers, coating of cellulose etc. were manually removed by combing the rolled-up fibre, after which the fibers were cleaned and dried. This method, however, is tedious, time consuming and risky as it may cause damage to the fibres, thereby making the entire process economically unviable. Consequently, this type of technique cannot be recommended for industrial application. Additionally, this method is inefficient as it does not enhance or even fully utilize the mechanical and chemical properties of banana fibre.

Furthermore, only 30-40% of banana fibre is used in most textiles and is often blended with cotton or other materials. This is done to increase its strength, wear resistance, etc. However, a method to make cloths solely out of banana fibers while overcoming such defects does not exist.

In the light of the aforementioned there exists a need to obtain 100% textile fabric from banana plant waste. The present invention is meant to overcome certain limitations of conventionally obtaining fabric from waste banana tree.

All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

In some embodiments, the numbers expressing quantities or dimensions of items, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual 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 with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims. OBJECTS OF THE INVENTION

17. The primary objective of the invention is to provide a process/method to extract fibre from pseudo banana stems and convert the said fibre into fabric.

18. Another objective of the invention is to provide a process/method to produce textiles that is 100% from banana fibre.

19. Yet another objective is to use banana fibers to produce fabrics of superior quality.

20. Another objective of the invention is that the fabric so produced has medicinal properties and can be used for manufacture of medical clothing such bandages, wraps, masks and other medically used clothing.

21. Yet another objective of the invention is to produce fabrics from biomass wastes from pseudo stems of banana plants.

22. The other objects and advantages of the present invention will be apparent from the following description when read in conjunction with the accompanying drawings, which are incorporated for illustration of preferred embodiments of the present invention and are not intended to limit the scope thereof.

SUMMARY OF THE TNVENTTON

23. The following information presents a simplified summary of the disclosure in order to provide a basic understanding of the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

One aspect of the present invention discloses a process for extracting fibre from the disposable wastes from banana plant harvests, and converting the said fibre into wearable fabric.

The most important aspect of this invention is that it utilizes the biodegradable banana stem (which is considered as wastes and is often disposed through environmentally harmful methods) for the production of fabrics, thereby providing an additional source of income for banana producers and saving environmental hazards.

Another aspect of this invention is that fibre is extracted from the banana stem which is of high quality compared to conventional fibre sources. The fabric obtained by using banana fibre is as smooth as silk and cotton. Thus the fabric obtained from banana stem fibre is an alternative and economical way to get a fabric of superior quality as equivalent to silk and cotton. In accordance with another aspect of this invention, fibre from waste banana stem is useful for production of paper cardboard, tea bags, currency note paper and many other products.

In accordance with another aspect of this invention, fibre from waste banana stem is useful as natural absorbent. The use of banana fibre as natural absorbent has promising potential to absorb oil spilling in oil refinery. It also can be used as absorbent in coloured wastewater from the dyes of textile industry.

The first step involves the harvesting of banana stem. Banana pseudo stems is harvested on a periodical basis, usually matching the rate at which each pseudo stem matures. Then, the stems are peeled to extract sheaths in the second step. The fibre can be separated from the bundles through a process called tuxing. Here, the leaves or sheaths are stripped from the cut pseudo stems.

In the third step, fibers from the banana pseudo-stem leaves (sheaths) are separated. The extraction process is conducted as soon as the pseudo-stem’s leaves are cut.

The extraction can also involve the process of retting to soften and then separate the fiber bundles from the cortex or the wood.

Then, gum and other non-fibrous residual components are removed, washed thoroughly and dried under the sun for a day.

After softening of fibre, the fibre is cut into a predetermined size through a cutting machine and thereafter, the fibre is fed into carding machine to produce sliver, which in-tum is the spun into yam.

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 embodiment herein include all such modifications. BRIEF DESCRIPTION OF DRAWINGS

35. The detailed description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items.

36. Fig. l illustrates steps involved in the extraction of banana fibres from banana plant wastes and conversion of the same into textiles, according to an embodiment of the present invention herein.

DETATEED DESCRIPTION OF THE PREFERRED EMBODIMENTS

37. In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

38. If the specification states a component or feature“may”,“can”,“could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

39. As used in the description herein and throughout the claims that follow, the meaning of“a,”“an,” and“the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of“in” includes“in” and“on” unless the context clearly dictates otherwise.

40. Throughout this specification, the use of the word "comprise" and“include”, and variations such as "comprises", "comprising", “includes”, and “including” may imply the inclusion of an element or elements not specifically recited.

Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this invention will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

While embodiments of the present invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the invention, as described in the claim.

The present invention discloses a process for extracting fibre from the disposable wastes from banana plant harvests, and converting the said fibre into wearable fabric. The process is simple in operation, industrially viable and economical. The first step (101) involves the harvesting of banana stem. Banana pseudo stems is harvested on a periodical basis, usually matching the rate at which each pseudo stem matures. Usually, the outer 3-4 pseudo-stems are stripped in intervals of 6-12 months, while the entire plant is harvested when the inflorescence blossom.

Then, the stems are peeled to extract sheaths in the second step (102). The fibre can be separated from the bundles through a process called tuxing . Tuxing can be done either manually or mechanically using machine. Here, the leaves or sheaths are stripped from the cut pseudo-stems. Afterwards, a knife is put at the butt end between the outer and middle layers of the leaf shaft, and then the outer part is held firmly and pulled out.

In the third step (103), fibres from the banana pseudo-stem leaves (sheaths) are separated. The extraction process is conducted as soon as the pseudo stem’s leaves are cut.

The extraction can also involve the process of retting, which is the separation of the fibre bundles from the cortex or wood, which effects on partial digestion of the cementing material (such as lignin and hemicelluloses) between the fibers in the bundles. Retting involves a two stage process comprising a first stage wherein the fibers are hydrated to cause swelling in order to extract water soluble substances; and a second stage wherein the fibre undergoes aerobic and anaerobic processes by bacteria or fungi respectively.

In the fourth step (104), gum and other non-fibrous residual components are removed. This process can be also be done either manually or mechanically. Then, the fibers are thoroughly washed and dried under the sun for a day. After softening of fibre, the fibre is cut into a predetermined size through a cutting machine in the fifth step (105). Thereafter, the fibre is fed into carding machine in the sixth step (106) to produce sliver, which is the spun into yam through a spinning machine in the seventh step (107).

It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms“comprises” and“comprising” should be interpreted as referring to elements, components, or steps in a non exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C .... and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc., While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

List of Reference Numerals:

101 - Harvesting of Banana Stem

102 - Stems are Peeled to Extract Sheaths

103 - Fibre is separated from the Extracted Sheaths

104 - Extracted Fibres are Washed and Sun Dried

105 - Dry Fibre is cut to the Required Size

106 - Fibre is fed into a Carding Machine

107 - Sliver Spun into yam in a Spinning Machine

Claims

CLAIMS We Claim:

1. A process to obtain textile fabric from 100% banana fibre, comprising the steps:

Harvesting of Banana Stem (101) which includes the gathering of ripened banana crop;

Peeling of stems to Extract Sheaths (102) through a means to separate the sheaths from the banana stem;

Separation of Fibre from the sheaths (103) to extract the fibre from the sheath;

Washing and sun-drying of the said fibre (104) wherein the fibre is separated from gum or any other residual components, and dried under the sun;

Cutting the dried fibre into a predetermined size (105) through a cutting machine;

Feeding of the cut fibre for carding (106) through a carding machine to produce sliver; and

Spinning of sliver into yarn (107) through a spinning machine.

2. A process to obtain textile fibre from 100% banana fibre as claimed in claim 1, wherein extracted sheaths are the leaves of banana plant which packed tightly and make pseudo-stem.

3. A process to obtain textile fibre from 100% banana fibre as claimed in claim 1, wherein the sheaths are separated from the banana plant pseudo stem which then strips the bark, skin, wood, stalk, and grain from the said sheath.

4. A process to obtain textile fibre from 100% banana fibre as claimed in claim 1, wherein extracted fibre are dried at room temperature.

5. A process to obtaining textile fibre from 100% banana fibre as claimed in claim 1, wherein fibres are cut into predetermined sizes using a cutting machine.

6. A process to obtain textile fibre from 100% banana fibre as claimed in claim 1, wherein is a mechanical process that breaks up locks and unorganized clumps of fibre and then aligns the individual fibres so that they are more or less parallel with each other.

7. A process to obtain textile fibre from 100% banana fibre as claimed in claim 1, wherein the said yarn is capable of being processed and converted into wearable fabrics.

8. A process to obtain textile fibre from 100% banana fibre as claimed in claim 1, wherein step (103) or (104) may require the fibre to undergo retting.

9. A process to obtain textile fibre from 100% banana fibre as claimed in claim8, wherein, retting involves a two stage process comprising a first stage wherein the fibers are hydrated to cause swelling in order to extract water soluble substances; and a second stage wherein the fibre undergoes aerobic and anaerobic processes by bacteria or fungi respectively.

10. A wearable fabric consisting of 100% Banana Fibre.