DEVELOPMENT OF DURABLE PANELS FROM RECYCLED TEXTILE AND GARMENT CUT WASTE

Abstract

ABSTRACT The present invention relates to a process for developing durable composite panels from recycled textile waste. The process involves shredding textile waste, blending it with a natural bonding agent, and compressing the mixture under high pressure. The compressed panels are then cured in a thermal chamber to ensure durability and moisture resistance. The panels exhibit high tensile and compressive strengths, low water absorption, and good thermal and UV stability, making them suitable for applications in furniture, construction, and flooring. This eco-friendly recycling process provides a sustainable solution for textile waste management. Figure 1.

Specification

Description:DEVELOPMENT OF DURABLE PANELS FROM RECYCLED TEXTILE AND GARMENT CUT WASTE

FIELD OF THE INVENTION
The present invention relates to the field of recycling and repurposing textile waste. Specifically, the present invention relates to the development of durable composite panels made from post-consumer clothing and pre-consumed garment cut waste. These panels are intended for use in furniture, construction, and insulation applications and are manufactured through an environmentally friendly process that utilizes natural bonding agents.

BACKGROUND OF THE INVENTION
Recycling used textile clothing and garment industry cut waste plays a crucial role in sustainable waste management and the promotion of a circular economy. The fashion industry is known for its significant environmental impact, as it relies heavily on natural and synthetic fibers that require extensive resources to produce. Textile recycling directly addresses these concerns by reducing the demand for new raw materials such as cotton and synthetic fibers, which in turn conserves natural resources and decreases the environmental impact associated with resource extraction.
A major environmental concern is the volume of textile waste that accumulates in landfills. By recycling used clothing, we can divert these materials from landfills, thereby mitigating the environmental impact of landfill disposal and alleviating the space constraints of waste management sites. Additionally, the production of textiles, especially those made from synthetic fibers, contributes to greenhouse gas emissions. Recycling textiles reduces the need for new textile production, thus helping to lower the overall emissions generated by the industry.
Moreover, textile recycling supports the principles of a circular economy, where products and materials are designed to be reused, repurposed, and recycled rather than discarded after a single use. This approach extends the life cycle of textiles, minimizing waste and promoting a sustainable economy that values resource conservation. By incorporating recycled textiles into new products-such as durable composite panels for construction, furniture, and insulation applications-this invention aligns with the goals of reducing waste, conserving resources, and creating a more sustainable future.

SUMMARY OF THE INVENTION
The present invention relates to a process for developing durable composite panels using recycled textile waste and a natural bonding agent. The process involves shredding textile waste into small fibers, blending it with an eco-friendly bonding agent, and compressing the mixture under high pressure to form solid composite panels. The panels are then cured in a thermal chamber, which ensures the bonding agent solidifies, resulting in a structurally sound and durable product.
In one embodiment, the present invention relates to a process for developing durable composite panels using recycled textile waste and a natural bonding agent, wherein the bonding agent is formulated from tamarind kernel seed powder, carboxymethyl cellulose (CMC), and lime adhesive. These natural components not only improve the durability of the panel but also enhance its environmental sustainability. The invention includes methods for preparing the bonding agent and mixing it with shredded textile waste to create a stable composite that, once compressed and cured, can be cut, shaped, and used in furniture, construction, and other applications.

BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 depicts a process and equipment involved in the development of durable textile panels; Textile waste (TW) (1), Shredder machine (MC) (2), Bonding Agent (BB) (3), Blender machine (BL) (4),Hydraulic presser machine (HP) (5), Thermal chamber (TC) (6)and Durable panel (DP) (7), Tamarind kernel seed powder (TKS) (8), Carboxymethyl cellulose (CMC) (9), Lime adhesive (LA) (10), Shredded textile waste (STW) (11), Stable solid composite (SSC) (12), and Wet panel (WP) (13).
Referring to the drawings, the embodiments of the present invention are further described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated or simplified for illustrative purposes only. One of ordinary skill in the art may appreciate the many possible applications and variations of the present invention based on the following examples of possible embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The following description outlines various embodiments of the invention for illustrative purposes, without limiting its scope. Skilled persons in the field will appreciate that other configurations may also fall within the scope of this disclosure. Terms used herein carry their standard meanings in the relevant field, and synonyms may be used interchangeably. Examples provided are illustrative and do not limit the scope of the invention.
The present invention relates to a sustainable and innovative approach to repurpose textile waste, particularly post-consumer clothing and garment cut waste, into durable composite panels. These panels are created through a process involving shredding, bonding, compression, and curing, which transforms textile scraps into structurally sound materials suitable for various applications. The primary objective of this invention is to provide a robust, eco-friendly solution for textile recycling by developing high-quality panels with broad utility in construction, furniture, and insulation applications.
In one embodiment, the present invention relates to a process for developing durable composite panels using recycled textile waste and a natural bonding agent formulated from tamarind kernel seed powder (TKS) (8), carboxymethyl cellulose (CMC) (9), and lime adhesive (LA) (10).
In another embodiment, the present invention relates to a process for developing durable composite panels using recycled textile waste. The process involves shredding textile waste into small fibers, blending it with tamarind kernel seed powder, carboxymethyl cellulose (CMC), and lime adhesive; and compressing the mixture under high pressure to form solid composite panels. The panels are then cured in a thermal chamber, which ensures the bonding agent solidifies, resulting in a structurally sound and durable product.

Process For Developing Durable Composite Panels
Textile Waste
Textile waste is collected from various sources, such as discarded clothing and garment manufacturing scraps. This waste is then sorted based on fabric type, color, and other characteristics to ensure consistency in the end product. Once sorted, the textile waste undergoes shredding to break down the fabric into smaller fibers or chunks called as Shredded textile waste (STW) (11), facilitating easier blending and uniform distribution within the bonding agent. The shredding process is accomplished using a textile shredder with rotary cutters, producing fibers that can range from coarse chunks to fine fibers depending on the desired panel properties.
Bonding Agent
Tamarind kernel seed (TKS) (8) is an organic raw material powder derived from the endosperm of tamarind seeds by removing the outer shell and is used with Carboxyl methyl cellulose (CMC) (9) as a suspension agent that encourage the suspension of one liquid raw material with other. The cleaned tamarind seeds are spread out and dried under the sun or in a drying chamber until they become hard and brittle. This drying process helps reduce moisture content and ensures better stability. Once dried, the outer husks or shells of the tamarind seeds are removed. The de-husked tamarind seeds are then ground into a coarse powder using a grinder mill. This grinding process breaks down the seeds into smaller particles, making it easier to extract the glue raw material. The CMC (9) is used 30% along with TKS (8) 50% and blended using the lime adhesive 20% (LA) (10). The lime adhesive is prepared using fat lime, distilled water, powdered sand and fire ash. All the three raw materials are fed into the blending machine. They are mixed up well to form liquid bonding agent (BB) (3).
The bonding agent, essential to the panel's structural integrity, is composed of eco-friendly and sustainable materials. This agent includes tamarind kernel seed (TKS) powder (50%), carboxymethyl cellulose (CMC) (30%), and lime adhesive (LA) (20%). Each component contributes to the bonding agent's effectiveness and environmental sustainability. Tamarind kernel seed powder provides adhesive properties, carboxymethyl cellulose acts as a suspension agent to stabilize the mixture, and lime adhesive adds strength and moisture resistance. These components are blended with a precise water content (500 ml) to ensure an optimal consistency and adhesive quality in the bonding agent.
Mixing& Blending
The next step involves mixing the shredded textile waste with the bonding agent. The shredded textile waste (STW) (11) is thoroughly combined with the bonding agent (BB) (3) in a specialized mixing vessel or container of a blender machine. The precise ratio of shredded textile waste to bonding agent is adjustable, allowing for customization based on the desired properties of the final composite panel and its intended application. For applications requiring a strong, wood-like durable panel, a 50:50 ratio of shredded textile waste to bonding agent is ideal, yielding a highly compact and robust structure. For applications where moderate strength and flexibility are preferred, a 60:40 ratio of shredded textile waste to bonding agent is more suitable, creating a panel with enhanced flexibility and resilience.
Once the materials are loaded into the blender machine (BL) (4), they are kneaded to achieve the required stability and uniformity. The blending process is carefully controlled, utilizing both forward and reverse rotations of the machine to ensure a homogeneous mixture. This rotation strategy is crucial as it promotes the consistent dispersion of the bonding agent throughout the textile fibers, resulting in a stable solid composite (SSC) (12) blend. Upon completion of the mixing process, the SSC blend is collected from the blender machine, forming the basis for the durable panel. The uniform distribution of the bonding agent within the textile fibers guarantees that each section of the panel possesses consistent structural integrity and adhesive strength, which is essential for creating a high-quality, reliable product.
Compression& Curing
The stable solid composite (SSC) (12) blend is carefully placed into the mold of a hydraulic presser machine (HP) (5). Here, compression pressure is applied, which varies based on the desired thickness of the panel and its intended use. The pressure can range from 5 to 10 tonnes, allowing the blended mixture to be compacted into a specific shape and form. This compression process results in the formation of a wet panel (WP) (13), which retains some moisture due to the bonding agent and textile fibers.
Following the compression step, the WP undergoes a curing process to strengthen the bond between the fibers and bonding agent. This curing step is crucial as it enables the bonding agent to set and form a strong, cohesive structure. The curing process can involve both evaporation of residual moisture and potential chemical reactions within the bonding agent, which further solidify the panel. Curing time varies significantly based on the ratio of bonding agent to textile waste, environmental factors like temperature and humidity, and the thickness of the panel itself. Depending on these factors, curing might require several hours to several days to achieve optimal results.
For accelerated curing, a thermal chamber (TC) (6) was developed to ensure consistent drying of WP panels. The panels are placed horizontally on racks within the chamber, and forced hot air is circulated from all directions to facilitate even drying. The temperature of the forced air is controlled within a range of 40°C to 80°C, which helps remove moisture efficiently. After approximately five hours of controlled curing within this thermal chamber, a moisture-free durable panel (MDP) is produced, achieving around 92% dryness.
Once removed from the thermal chamber, the MDP is placed in racks with air circulation for further natural drying, which enhances the panel's durability by allowing it to reach a 100% dry state over time. At this point, the durable textile panel is fully developed and can be processed for various applications. The panel can be cut into different shapes and sizes, painted, or surface finished as required. Its versatility allows it to be used in multiple utility products, making it a practical and sustainable solution for repurposing textile waste into high-quality materials.

Experimental Details and Properties of Textile Waste Panels
The following sections provide a comprehensive overview of the physical, mechanical, and durability properties of panels manufactured according to the methods described above. Each panel underwent rigorous testing to determine its suitability for various applications. The experimental details are summarized in the tables below for clarity and reference.
Table 1: Panel Specifications and Curing Conditions
Panel Size Textile Waste(g) Bonding Agent Composition(g) Thickness (mm) Compression Load (T) Curing Temp. (°C) Curing Time (hr)
1.5 ft x 1.5 ft (152 mm x 152 mm) 500 TKS (1000 g), CMC (600 g), LA (400 g) 15 5 - 10 40 - 80 5
2 ft x 2 ft (600 mm x 600 mm) 500 TKS (1000 g), CMC (600 g), LA (400 g) 10 5 - 10 40 - 80 5
1 ft x 1 ft (300 mm x 300 mm) 500 TKS (1000 g), CMC (600 g), LA (400 g) 20 5 - 10 40 - 80 5

Table 2: Physical Properties of Panels
Parameter Value (1.5 ft x 1.5 ft) Value (2 ft x 2 ft) Value (1 ft x 1 ft) Test Method
Density (g/cm³) 1.25 1.28 1.32 ASTM D792
Thickness (mm) 15 10 20 Caliper Measurement
Moisture Content (%) 7 8 9 Oven Dry Method
Surface Roughness (µm) 2.3 2.5 2.7 Surface Profilometer

The physical properties, including density, moisture content, and surface roughness, indicate that these panels are consistent in composition and well-suited for a range of applications. The higher density in the 1-foot panels signifies their suitability for applications requiring increased structural strength.

Table 3: Mechanical Properties of Panels
Property Value (1.5 ft x 1.5 ft) Value (2 ft x 2 ft) Value (1 ft x 1 ft) Test Method
Tensile Strength (MPa) 28 25 32 Mechanical Load Test
Flexural Strength (MPa) 42 44 48 Mechanical Load Test
Impact Resistance (kJ/m²) 4.8 4.5 5.2 Drop Test
Hardness (Shore D) 68 65 70 Rockwell Hardness Test
Compressive Strength (MPa) 95 90 105 Compression Test

The mechanical properties demonstrate that the panels possess high tensile, flexural, and compressive strengths. The 1-foot panel with a thickness of 20 mm exhibited the highest mechanical strength, which makes it ideal for applications like flooring and load-bearing furniture.

Table 4: Durability and Environmental Resistance Tests
Test Condition Result
(1.5 ft x 1.5 ft) Result
(2 ft x 2 ft) Result
(1 ft x 1 ft) Test Method
Water Absorption (%) 24 hours immersion 4.8% increase in weight 4.8% increase in weight 5% increase in weight Immersion Test
Thermal Stability 80°C for 5 hours No significant change No significant change No significant change Chamber Test
UV Resistance 240 hours exposure Slight discoloration Slight discoloration No discoloration Chamber Test
Fungal Resistance 24 days exposure No growth observed No growth observed No growth observed Spectral Analysis

The durability tests confirm that these panels are water-resistant and can withstand high temperatures and prolonged UV exposure. Additionally, their fungal resistance indicates that they are suitable for use in humid environments, making them a reliable option for indoor and some outdoor applications.

Table 5: Application-Specific Tests
Application Test Condition Result
(1.5 ft x 1.5 ft) Result
(2 ft x 2 ft) Result
(1 ft x 1 ft)
Furniture Panels Load-bearing capacity 290 kg without failure 260 kg without failure 320 kg without failure
Wall Panels Sound insulation 29 dB reduction 29 dB reduction 32 dB reduction
Flooring Panels Abrasion resistance 0.075 g loss per 1000 cycles 0.075 g loss per 1000 cycles 0.065 g loss per 1000 cycles

Application of the Panels
The panels developed through this process can be moulded into any shape and structure for making variety of products such as storage containers, vessels, pots, utility plates and decorative items. The panels have versatile applications in various fields including:
Furniture Manufacturing: Due to their load-bearing capacity, these panels are well-suited for use in creating tables, cabinets, and shelving. Experiments demonstrated that the panels could support weights up to 320 kg, proving their suitability for furniture.
Construction and Insulation: The panels exhibit sound insulation properties, reducing noise transmission by up to 32 dB. This makes them ideal for use as wall cladding or partitioning in residential and commercial buildings.
Flooring Applications: The panels' abrasion resistance, tested at a weight loss of only 0.065 g per 1000 cycles, confirms their durability for flooring.

It may be appreciated by those skilled in the art that the drawings, examples and detailed description herein are to be regarded in an illustrative rather than a restrictive manner. , Claims:We Claim:

1. A process for developing durable composite panels from textile waste, comprising:
a. Shredding textile waste (11) to obtain shredded textile fibers;
b. Mixing the shredded textile fibers with a bonding agent comprising tamarind kernel seed powder (8), carboxymethyl cellulose (9), and lime adhesive (10) to form a compacted homogenous composite;
c. Compressing the composite mixture under a pressure of 5 to 10 tonnes to form a wet composite panel (13);
d. Curing the wet composite panel (13) in a thermal chamber (6) at a temperature of 40°C to 80°C for 5 hours to obtain a moisture-free, durable panel (7); and
e. Placing the moisture-free durable panel (7) in racks with air circulation for further natural drying, enhancing the panel's durability by allowing it to reach a 100% dry state over time;
characterized in that the developed durable composite panel exhibits a tensile strength above 28 MPa, flexural strength above 42 MPa, and compressive strength above 95 MPa, while maintaining water absorption below 5% after 24 hours of immersion.
2. The process as claimed in claim 1, wherein the bonding agent composition comprises 50% tamarind kernel seed powder, 30% carboxymethyl cellulose, and 20% lime adhesive by weight.
3. The process as claimed in claim 1, wherein the curing process removes excess moisture and solidifies the bonding agent, resulting in a moisture-dry panel.
4. The process as claimed in claim 1, wherein a 1-foot panel with a thickness of 20 mm exhibits a tensile strength of 32 MPa, flexural strength of 48 MPa, and compressive strength of 105 MPa.
5. The process as claimed in claim 1, wherein the panel reduces noise transmission by 32 dB.
6. The process as claimed in claim 1, wherein the panel has an abrasion resistance of 0.065 g per 1000 cycles.
7. The process as claimed in claim 1, wherein the panel supports weights up to 320 kg.

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