Bio-Based Coated Synthetic Material Using Agricultural Residues
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Solution Overview
Problem
The fashion industry faces significant environmental challenges due to the use of fossil-based materials, leading to issues such as solid waste, toxic chemical effluents, water pollution, and high carbon emissions. Additionally, the management of agricultural waste contributes to air, soil, and water pollution.
Innovation Solution
A synthetic or foamed synthetic material is developed using a bio-based formulation composed of agricultural residues like corn cob, rice husk, and peanut shells, combined with thermoplastic binders, stabilizers, and plasticizers. This formulation is coated onto a base fabric to create a high-value-added biomaterial that is eco-friendly and has a reduced carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fossil-based synthetic materials (PVC, polyurethane) are used to create synthetic leather alternatives, then the material provides durability and functional performance, but it generates toxic chemical effluents, solid waste, water pollution, and high carbon emissions
Solution Approach 1:
The patent changes the chemical composition parameters of the coating formulation by replacing fossil-based polymers with bio-based alternatives derived from agricultural waste. The formulation uses specific ratios of agricultural waste (1-65 wt%), thermoplastic binder (30-90 wt%), stabilizer (1-35 wt%), and plasticizer (3-30 wt%) to achieve both durability and environmental compatibility, resolving the contradiction between performance and toxicity
Solution Approach 2:
The patent creates a composite material system combining agricultural waste particles with thermoplastic binders and functional additives. This composite approach allows the integration of renewable, non-toxic agricultural residues with performance-enhancing polymers, achieving both durability and reduced harmful emissions simultaneously
2Ease of manufacture
If agricultural waste is burnt to prepare fields for sowing, then the process is convenient and low-cost for farmers, but it releases large amounts of carbon dioxide, carbon monoxide, particulate matter, and black carbon into the atmosphere
Solution Approach 1:
The patent converts the harmful practice of agricultural waste burning into a beneficial process by using the same agricultural residues as raw materials for producing bio-based coating formulations. The agricultural waste that would otherwise be burnt is now processed into valuable synthetic leather materials, transforming an environmental hazard into an economic opportunity while eliminating air pollution
Solution Approach 2:
The patent introduces an intermediary processing system that collects and processes agricultural waste before final use. The waste material is gathered, processed into fine particles, and incorporated into the coating formulation through kneading and blending steps, serving as a bridge between the agricultural sector and manufacturing sector while preventing direct burning
3Productivity
If conventional synthetic materials are used in the fashion industry, then the industry can meet production demands, but it contributes to 10% of annual global carbon emissions and 20% of wastewater
Solution Approach 1:
The patent enables the fashion industry to serve its own environmental needs by producing synthetic leather materials that inherently reduce carbon emissions and water pollution. The bio-based formulation system uses renewable agricultural waste and biodegradable components, allowing the industry to maintain productivity while self-correcting its environmental impact through sustainable material selection
Data Source
AI summary
The present invention relates to a synthetic material coated with a bio-based formulation comprising residual wastes, an eco-friendly process for preparing the formulation from residual wastes to obtain a synthetic material which is a high value-added material