Algae Bio Textile

Abstract

Bio-textile material from filamentous algae. The invention provides 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 wherein a specific weight ratio of algae and/or seaweed to natural fillers is maintained to achieve different level of thickness in the prepared bio-textile. The prepared bio-textile has good tensile and tearing strength in the range of 100-200 N/mm and 50-80 N/mm, respectively such that it can be used to produce different types of apparels. The process of preparation of the bio-textile using eco-friendly materials comprises the steps of harvesting, pre-treatment, slurry preparation, structural layer and double layer formation, drying and finishing steps.

I claim: 
     
         1 . A non-woven bio-textile comprising
 a single structural layer with a thickness of 0.5-5 mm or   a plurality of layers including a surface layer and a structural layer with a thickness of 1-10 mm;   characterized in that each layer further comprises
 pre-treated algae, natural fillers and other additives; or 
 pre-treated algae, seaweed, natural fillers and other additives; 
 wherein the weight ratio of pre-treated algae and natural fillers is between 3:7 and 7:3; and 
 the weight ratio of pre-treated algae, seaweed and natural fillers is 5:2:3;
 wherein the other additives includes adhesives, binders, lacquers, softeners/plasticizers, preservatives and/or colouring agents; and 
 the weight percentage of other additives is in the range of 0.5-10%. 
 
   
     
     
       2. The non-woven bio-textile fabric as claimed in  claim 1 , wherein the filamentous algae is selected from but not limited to different Classes including Chlorophyceae, Klebsormidiophyceae, Xanthophyceae, Bacillariophyceae (diatoms), Cyanophyceae, and the like; and the seaweed is selected from but not limited to different phylum including Rhodophyta, Cyanobacteria, Chlorophyta, Pheophyta and the like. 
     
     
         3 . The non-woven bio-textile fabric as claimed in  claim 1 , wherein the fillers are selected from but not limited to rice husk, wheat straw, grass, cork powder, starches including tapioca, corn, potato, rice and the like; textile waste including include fabric scraps, leather buffing dust and the like; waxes including bees wax, paraffin wax, carnauba wax and the like; oil, polymer fillers and the like;
 the adhesives are 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; and   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 and 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%, respectively.   
     
     
         4 . The non-woven bio-textile fabric as claimed in  claim 1 , wherein the tensile strength of the single layered and double layered bio-textile is in the range of 100-200 N/mm and 150-200 N/mm, respectively;
 the tearing strength of the single layered and double layered bio-textile is in the range of 50-60 N and 70-80 N, respectively; and   the GSM of the single layered and double layered bio-textile is in the range of 550-600 GSM and 1350-1450 GSM, respectively.   
     
     
         5 . The non-woven bio-textile fabric as claimed in  claim 1 , wherein the distribution of weight % between the surface layer and the structural layer is in the ratio 3:7 and 7:3. 
     
     
         6 . A process of preparation of non-woven bio-textile fabric comprises the steps of:
 (a) harvesting, cleaning and optional detoxification of the biological source further including the steps of:
 (i) harvesting algae mats using either an automated netting system or a rotary drum collector and harvesting seaweed using hand harvesting technique; 
 (ii) rinsing the harvested algae and seaweed with filtered water to remove sand, and debris either by hand washing or mechanical washers; 
 (iii) detoxifying on detection of heavy metals and pollutants in the cleaned algae; 
 (iv) soaking the seaweed in cold water for 12-24 hours to soften and desalinate it followed by sorting to remove non-target species, damaged seaweed, and plastic waste, and final rinsing; and 
 (iv) drying each sources separately either by spreading on drying racks or using an oven at 40-50° C.; 
   (b) pre-treatment of the source further including the steps of:
 (i) preparing two sets of enzymatic solution by mixing enzymes with water at 35-40° C. in a temperature controlled vat; 
 wherein the first set of enzymes includes 1-2% cellulase, 1-2% pectinase and 0.5-1% hemicellulose, and the second set of enzymes includes 0.5-1% alginate lyase, 0.3-0.5% carragenase and 0.1-0.3% pectinase; 
 (ii) immersing the cleaned/dried algae in the first set of enzyme solution followed by occasional paddling for even distribution and soaking for 3-4 h such that the selected enzymes softens and breaks down complex material and cell wall components in the algae; 
 wherein the dried algae is rehydrated by soaking in warm water for 1-2 h before adding the enzyme solution; 
 (iii) immersing the first treated algae and cleaned seaweed, separately in the second set of enzyme solution followed by occasional paddling for even distribution and soaking for 3-4 h such that the selected enzymes breaks down alginates, carrageenan and pectin; 
 (iv) rinsing the treated algae and seaweed in clean water to remove excess enzymes and straining through a fine mesh to remove any remaining debris/impurities; and 
 (v) soaking the enzyme treated algae and seaweed, separately with alkaline solution comprising sodium carbonate (5-7%) and calcium hydroxide (2-3%) that neutralizes pH, removes gels, further loosens and softens fiber; 
 wherein the soaked seaweed in alkaline solution is boiled for 2-3 h at 90-100° C. and rinsing in cold water to remove excess gel; 
   (c) preparation of pulp/slurry further including the steps of:
 (i) boiling the pre-treated algae from step (b) in a steam-heated vessel for 2-3 hours in the presence ultrasonic waves (20-40 kHz) to further soften and separate the fibers and enhancing pulp consistency; 
 (ii) rinsing the boiled algae in clean water to remove excess gels and straining through a fine mesh to remove excess water; 
 (iii) preparing algal slurry by
 transferring the boiled algae to a mechanical pulper or industrial blender, adding fillers and required amount of water to achieve a desired consistency; 
 pulverizing the mixture for 30-60 minutes until the pulp reaches a smooth, homogenous consistency; 
 applying ultrasonic processing (20-40 kHz) for 30-60 minutes at 80-90° C. to further refine the pulp and ensure uniform dispersion of algal fibers and fillers; 
 pressing the algal pulp to achieve a slurry with workable consistency; and 
 
 (iv) preparing algal-seaweed slurry by
 stripping the seaweed fibers either manually or by using a fiber extraction machine to separate the cellulose-rich parts; 
 drying the fibers in drying racks drying oven at 40-50° C. until it is slightly damp but pliable; 
 breaking down boiled algae from step (c (i)) into fine fibers using a blender or mechanical pulper; 
 blending the fine fibers of algae and seaweed along with natural fillers evenly using a carding machine or hand carder; 
 
 (v) optionally incubating the slurry in a eco-friendly bleaching agent overnight to achieve light-coloured bio-textile; 
   (d) preparation of structural layer using wet felting or needle felting technique wherein
 (i) the wet felting technique further including the steps of
 layering algae-seaweed fiber mixture onto a felting mat or mesh screen and building up the layers to achieve desired thickness; 
 preparing a soap solution comprising castile soap and hot water (60-70C) at 0.5% w/v and applying on the layered algae-seaweed fibers to moisten the fibers; 
 rolling back and forth over the layered fibers by placing a bamboo mat or rolling pin or hydraulic rollers up to 30 minutes such that the friction causes the fibers to interlock and bond; 
 wherein the pressure of hydraulic rollers is in the range of 200-300 psi; 
 rinsing the felted sheet with cold water and repeating the rolling process multiple times to achieve desired density and strength; 
 drying the felted sheets in air or using oven; and 
 
 (ii) the needle felting technique further including the steps of
 layering algae-seaweed fiber mixture onto a felting mat or foam block; 
 needle punching and poking the layered fibers using a felting needle tool such that the barbs on the needle catch the fibers and entangle them; 
 building a layer on top of felted layer and repeating the needle punching and poking until it reaches desired thickness; 
 heat setting the felted sheet using steam iron or heat press for increasing the durability; 
 
   (e) preparation of double layered non-woven bio-textile/fabric using a vat-lifting technique or spray-gun technique;   (f) pressing, drying, curing the bio-textile further including the steps of:
 (i) placing the air dried bio-textile sheet from step (e) on a pressing bed followed by placing a non-stick separator sheet to avoid sticking of fabric on the pressing plates; 
 (ii) pressing for 2-5 min/sheet at a pressure range of 100-300 psi to remove excess water and improve fiber bonding; 
 wherein the pressing is initiated at low pressure and is gradually increased to prevent uneven pressing and to produce a sheet of consistent thickness; 
 (iii) removing the non-stick separator and applying a layer of adhesive on the surface of pressed sheets; 
 (iv) transferring the adhesive treated sheets from the press to a drying equipment and drying the non-woven bio-textile fabric at 40-60° C. for a time period of 6-24 hours with a relative humidity maintained between 40-50%; 
 wherein time of drying is selected based on the thickness of the bio-textile fabric; 
 (v) the dried bio-textile sheets are pressed again for 2-5 min either in a hydraulic press or a heated press at a pressure range of 150-200 psi to improve bonding between fibers; 
 (vi) cooling the sheets at room temperature for 12-24 h to allow the fibers to settle; and 
   (g) finishing the bio-textile/fabric further including the steps of:
 (i) waterproofing by applying wax or natural oil using a spray gun or roller wherein the wax/oil is completely melted at 50-60° C.; 
 (ii) curing the sheet at room temperature for 12-24 h that allows full absorption of the waterproofing layers; 
 (iii) applying the natural dye solution using spray gun, brush or dip method and drying the sheets at 50-60° C. for 12-24 h; 
 wherein the dye solution is prepared by boiling natural dye source including onion skin, indigo leaves, beetroot, and charcoal powder in water and straining the solution; 
 (iv) placing the dried sheet on a pre-heated embossing plate and applying pressure with a hydraulic press for 30-60 s; 
 (v) allowing the sheet to cool for 12 h to set the pattern and storing in a dry place until further usage. 
   
     
     
         7 . The process of preparation of non-woven bio-textile fabric as claimed in  claim 6 , wherein the structural layer obtained after felting process is further pressed, dried and finished similar to that of step (f) and step (g) such that it acts as a single layered bio-textile fabric comprising algae and seaweed in the ratio 3:7. 
     
     
         8 . The process of preparation of non-woven bio-textile fabric as claimed in  claim 6 , wherein the consistency of the slurry is dependent on the method of preparation of the structural layer or the non-woven bio-textile;
 wherein a thin slurry with a pulp content in the ranges between 5-8% is desirable for spray gun technique and a medium to thick slurry with a pulp content in the ranges between 8-15% is desirable for vat lifting and felting technique.   
     
     
         9 . The process of preparation of non-woven bio-textile fabric as claimed in  claim 6 , wherein the adhesives is alternatively added before the pressing step (f) and 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 to avoid seepage of adhesives. 
     
     
         10 . The process of preparation of non-woven bio-textile fabric as claimed in  claim 6 , wherein the final composition of the single layered bio-textile includes 70-80% of algae/seaweed, 10-15% of natural fillers, 3-5% of softeners/plasticizers and 1-2% of colouring agent, and the double layered bio-textile includes 45-50% of algae, 20-25% of seaweed, 15-20% of natural fillers, 5-8% of softeners/plasticizers and 1-2% of colouring agent. 
     
     
         11 . A non-woven bio-textile comprising a single structural layer or a plurality of layers, each layer comprising pre-treated seaweed, natural fillers, and other additives; wherein the weight ratio of pre-treated seaweed to natural fillers is between 3:7 and 7:3; and wherein the additives are selected from adhesives, binders, lacquers, softeners/plasticizers, preservatives, and/or colouring agents, present in an amount of 0.5-10% by weight. 
     
     
         12 . A non-woven bio-textile comprising a single structural layer or a plurality of layers, each layer comprising pre-treated algae, natural fillers, and other additives; wherein the weight ratio of pre-treated algae to natural fillers is between 3:7 and 7:3; and wherein the additives are selected from adhesives, binders, lacquers, softeners/plasticizers, preservatives, and/or colouring agents, present in an amount of 0.5-10% by weight.