Textiles and process for making textiles and dyes from tobacco plants

Abstract

A textile and a dye manufactured from fibers that are derived from tobacco plants and a process for making the textile and dye from the tobacco plants. In a preferred embodiment, the tobacco is organically grown and the entire tobacco plant, including stem and leaves, is utilized to produce the tobacco plant fiber used for making a textile and a natural dye utilized to color the textile or other textiles. One or more secondary material fibers can be mixed with the tobacco plant fiber to produce the textile. The process percolates a hot liquid solution onto tobacco plant material to cause a chemical reaction with the tobacco plant material to produce the tobacco plant fiber. Preferably, the process is a closed-loop system that minimizes the impact on the environment and utilizes less material, fuel and other resources. The dye does not require a mordant to bind with the textile.

Claims

1. A textile, comprising a tobacco plant fiber derived from a tobacco plant, wherein said textile comprises said tobacco plant fiber mixed with one or more secondary material fibers, said secondary fibers comprising at least one of a natural fiber and a synthetic fiber.

2. The textile of claim 1, wherein said tobacco plant is at least substantially organically grown.

3. The textile of claim 1, wherein said tobacco plant fiber is manufactured to form a fabric.

4. A textile, comprising a tobacco plant fiber derived from a tobacco plant, wherein said tobacco plant fiber is derived from said tobacco plant by treating a tobacco plant material with a liquid solution.

5. The textile of claim 4, wherein said tobacco plant fiber is colored with a dye produced from said tobacco plant while producing said tobacco plant fiber.

6. A fabric, comprising a textile consisting essentially of a tobacco plant fiber derived from a tobacco plant, wherein said textile comprises said tobacco plant fiber mixed with one or more secondary material fibers, said secondary fibers comprising at least one of a natural fiber and a synthetic fiber.

7. The fabric of claim 6, wherein said tobacco plant is at least substantially organically grown.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings which illustrate the preferred embodiments and the best modes presently contemplated for carrying out the present invention:

(2) FIG. 1 is a chart summarizing the overall process of deriving a textile and dye from tobacco plants configured according to a preferred embodiment of the present invention; and

(3) FIG. 2 is a chart summarizing the hot liquid solution utilized in the process summarized in FIG. 1 to produce tobacco plant fibers and a natural dye from tobacco plants.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(4) With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, the preferred embodiments of the present invention are set forth below. The enclosed text and drawings are merely illustrative of one or more preferred embodiments and, as such, disclose one or more different ways of configuring the present invention. Although specific components, materials, configurations and uses are illustrated, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein. For instance, although the figures and description provided herein show certain steps and compounds for the process of producing fiber and dye from tobacco plants, those skilled in the art will readily understand that this is merely for purposes of simplifying this disclosure and that the present invention is not so limited.

(5) A process for producing textile and dye from tobacco plants that is configured pursuant to a preferred embodiment of the present invention is shown generally as 10 in the figures. As set forth in more detail below and summarized in FIG. 1, the process 10 of the present invention preferably utilizes organically grown tobacco plants 12 to provide the tobacco plant material 14 which is treated to produce tobacco plant fibers 16 that are utilized to form a textile 18 which is processed to form a fabric 20 that can be used to make clothing, handbags, bags, rope, covers, bedding and a wide variety of other materials that are commonly made from textiles that have natural and/or synthetic fibers. In the preferred embodiment, the process 10 of the present invention also produces a natural dye 22 and other useful by-products from the tobacco plants 12. Although tobacco plants 12 grown according to currently available, non-organic methods can be utilized in the process 10 of the present invention, organically grown tobacco plants 12 are preferred due to the fact that such tobacco plants 12 do not require the use of chemicals which are typically considered to be potentially harmful to the environment. As shown in FIGS. 1 and 2, the preferred process 10 of treating the tobacco plants 12 does not introduce any harmful chemical wastes into the environment and is configured as a closed-loop system that substantially reuses all of the materials produced by the process 10 that is not selected as an end product (e.g., the textile 18 and dye 22). The process 10 of the present invention preserves the beneficial features of the tobacco plants 12 to produce tobacco plant fibers 16 that are utilized in a unique textile 18 which can produce fabrics 20 of exceptional value.

(6) The process 10 of the present invention utilizes a procedure the inventor refers to as bio-degumming which takes advantage of the unique properties of the various varieties of tobacco plants 12 to breakdown the fibers 16 thereof in an environmentally non-impact manner that results in little damage to the fibers 16 produced by the process 10. The bio-degumming of the present process 10 does not utilize or result in the harmful chemicals and other waste products that are typically used or associated with breaking down the pectin during the standard decortification procedure used to separate the bast fibers from the woody core of plants. In addition, the process 10 of the present invention includes a method of bio-digestion that uses the whole plant, including the stem and leaves, in an anaerobe environment to breakdown all elements of the fiber, stem and leaf into the desired useful fibers 12 and dye 22. When the bio-digestion is stopped at the correct time, which is likely to vary with different varieties of tobacco plants 12, the tobacco leaves, stems and waste fiber are in the desired condition, without loss of strength and feeling brittle (which can occur with other processes and/or plants). In addition to not requiring any additional chemicals, enzymes or other auxiliary materials, the process 10 of the present invention does not compromise the natural color, aroma and fragrance of the tobacco plants 12, which are then beneficially utilized in the textiles 18 and fabrics 20 produced by process 10. The natural liquor produced by the non-invasive process 10 of the present invention allows the tobacco plant fiber 16 and dye 22 to be unique for processing into the desired textile 18.

(7) As stated above, in the preferred embodiment the process 10 of the present invention utilizes organically grown tobacco plants 12 as the source of the plant materials 14 that is converted to the textile 18, dye 22 and any other products. Organically grown tobacco plants 12 for use with the process 10 can produce abundant crops, including leaf and stem fiber, with no pesticides, herbicides or defoliants due to the fact that the tobacco plants 12 will be grown for the dedicated purpose of being utilized by the process 10 to produce textiles 18 and dyes 22 instead of being grown for the normal smoking, chewing and like tobacco products. One benefit of utilizing tobacco plants 12 for fiber instead of wood chips is that the stem, leaves and other plant material of the tobacco plant 12 has twice as much cellulose and fiber per unit weight. One benefit of utilizing organically grown tobacco plants 12 is that the use of tobacco plant fibers 16 would be an environmentally-friendly alternative to synthetic petroleum-based fibers and wood pulp. Overall, the process 10 would benefit human health and the environment and lower the usage of water and energy.

(8) Although a wide variety of tobacco plant varieties may be utilized for the process 10 of the present invention, the Burley, Va., Oriental and Basma varieties are believed to be most suited for being grown organically, e.g. with no herbicides, pesticides or other chemicals, for the process 10. Preferably, only natural insects would be used to control pests. Because the process 10 of the present invention utilizes the entire tobacco plant 12, including stems and leaves, the process 10 effectively allows the entire tobacco plant 12 to be biodegradable. Other benefits of the process 10, particularly with regard to facilitating the use of organically grown tobacco plants, is that it will result in higher overall yield, lower production costs, lower capital costs and far less pollution, energy consumption and water usage. Because the tobacco is not cured for the process 10 of the present invention, there will be a further reduction in energy usage and much less need for wood, thereby reducing the impact on the environment, particularly the soil and air. Presently, it is believed there is very little, if any, tobacco plants 12 that are grown in an organic, environmentally-friendly manner.

(9) As stated above, preferably the process 10 of the present invention is configured to be a closed-loop system, as best shown in FIG. 1. Because the tobacco plants 12 are more plant-like than tree fiber, toxic chemicals are not required to break down the tobacco plant 12 into a pulp or fiber-like pulp that can be utilized to form the tobacco plant fibers 16 for the textile 18 of the present invention. Instead, the process 10 of the present invention utilizes the natural chemicals in the tobacco plant 12 to break down the tobacco plant material 14 to obtain the desired fibers 16. Basically, as set forth below, the tobacco plant materials 14 stew in their own juice for a sufficient amount of time, which is likely to depend on the variety of tobacco plant 12, to produce the tobacco plant fibers 16. Although individual components of the tobacco plant 12 can be utilized in the process 10 of the present invention, the preferred configuration of the process 10 utilizes the entire tobacco plant 12 to increase fiber product, improve efficiency and reduce waste. As also stated above, the process 10 of the present invention is believed to be applicable to all varieties of tobacco plants 12. In addition to providing tobacco plant fiber 16 that is used for textiles 18, which can be made into a variety of fabrics 20, the process 10 of the present invention also produces a natural dye 22, as shown in FIG. 1, that can be utilized with the tobacco plant-derived textile 18 (or the textile 18 can be the natural color of the tobacco plant fiber 16) and with other textiles. As set forth in more detail below, the dye 22 produced by the process 10 is permanent, is more resistant to fading and does not require a mordant to stabilize the dye and bond it to the textile 18 or any other textile.

(10) The process 10 of the present invention, best summarized in FIG. 1, preferably comprises a treating system 24 that applies a heated liquid solution 26 to the tobacco plant material 14 to interact with the plant materials 14 so they will stew in their own juices and break down the plant materials 14 into the tobacco plant fiber 16 and dye 22. Preferably, the treating system 24 is a closed-loop system. Water in the closed-loop treating system 24 will be reused to treat the plant material 14 or used to produce the dye 22. The tobacco plants 12, which are preferably organically grown, are harvested to obtain the tobacco plant materials 14 that will be utilized in the process 10 of the present invention. In contrast to normal tobacco harvesting, the entire tobacco plant 12 is harvested from the field, significantly simplifying the harvesting process. In fact, under certain circumstances, it may be beneficial to harvest the tobacco plants 12 by hand instead of utilizing machinery to reduce fuel consumption and the pollution that is associated with mechanical harvesting. Once harvested, the tobacco plant materials 14 are placed inside the closed-loop treating system 24 and a hot liquid solution 26 is applied to these tobacco plant materials 14. In one embodiment, the ratio of hot liquid solution 26 to tobacco plant materials 14 is approximately 4.5% by weight, with the hot liquid solution 26 at a temperature of approximately 170 F. and applied for approximately 180 minutes, as necessary to sufficiently soften the tobacco plant materials 14. Some varieties of tobacco plants 12, may require a higher or lower liquid temperature and/or a shorter or longer exposure time period. Typically, the hot liquid solution 26 will break down the tobacco plant materials 14 and result in a breakdown of approximately 55% of the weight of the tobacco plant materials 14, which is approximately 12.8% to 17% higher material remaining than wood pulp or linen.

(11) The application of the hot liquid solution 26 to the tobacco plant material 14 produces steam that significantly aids in the necessary breakdown of the tobacco plant material 14. The steam also sets the dye liquor of dye 22 as a permanent solution that does not require the use of heavy metals or salts. In the preferred embodiment, the hot liquid solution 26 is achieved by heating water in an environmentally-friendly manner, such as using a geothermal source 28 (as shown in FIG. 2), solar energy or other such sources. As also shown in FIG. 2, in a preferred embodiment, the hot liquid solution 26 comprises heated water, ammonia-dioxide and sulphur-dioxide, which are mixed into solution and applied to the tobacco plant material 14 in the treating system 24. Experimentation by the inventor has found that this combination creates a chemical reaction with the tobacco plant material 14 that beneficially breaks down the tobacco plant material 14 into the desired pulp material 30, which is then used to make tobacco plant fiber 16, and produces a high quality, useful dye 22 without creating the various environmental issues associated with other fiber processes. The water used in the hot liquid solution 26 should be clean and not contain any chemicals, such as chlorine or the like.

(12) In the preferred embodiment, the hot liquid solution 26 is applied to the tobacco plant material 14 utilizing a drip percolation process, which has been found to sufficiently soften the tobacco plant material 14, including the leaves, into the desired tobacco plant fiber 16. The application of the percolating hot liquid solution 26 onto the tobacco plant material 14 that converts the material 14 to fiber 16 produces steam. For use as a textile 18, the pulp material 30 is removed while still in a fibrous stage. In contrast, for use to make paper, the pulp is as soft (e.g., near-liquid form) as possible to produce the desired thin fiber. In the present invention, the pulp material is then washed and dewatered to produce the tobacco plant fiber 16 that is used to form the textile 18. The textile is then processed into the desired fabric 20 by spinning, weaving, knitting, crocheting, bonding, pressing or by other known processes or combinations thereof as applicable for the fabric 20. Among other products, the textile 18 can be utilized to form yarn, thread, fleece or the like. As shown in FIG. 1, the steam that is produced in treating system 24 is condensed back into liquid and directed back into the hot liquid solution 26 and any non-condensable gases are dissipated. By recycling and reusing materials and utilizing the entire tobacco plant, the closed, integrated environment of the treating system 24 reduces or substantially eliminates any pollution from the process 10 of the present invention.

(13) The fiber 16 produced by the process 10 of the present invention has been found by the present inventor to have an innate aroma that impregnates the fiber 16 and a fragrance that fully penetrates the fiber 16, which is in contrast to other natural and synthetic fibers. The fragrance, which smells good, is subtle, yet somewhat complex. In addition, further contrasting with other fiber materials, the fragrance is retained by the fiber 16 of the present invention for a very long time and has been found to, in effect, regenerate itself with mild washing. The oils produced in the process 10 and imbedded in the fibers 16 naturally softens the fabric 20, significantly reducing the need for other chemical products to soften the clothes or other items made from fabric 20. The resulting fiber 16 is strong, yet soft and rather luxurious with a natural uncompromising sheen. The fiber 16 looks and feels like fine silk, yet it can be spun into bulky yarn for outerwear used with outdoor fabrics. The colors created of the fabric 20 resulting from fiber 16 produced by the process 10 is a natural, unique color that is saturated into the fiber 16 and lasts through many washings, making the fabric 20 highly valuable without compromising the fiber 16.

(14) As also summarized in FIG. 1, some of the excess liquid that is applied to the tobacco plant material 14 in the treating system 24 is returned in the process 10 to be reused in the hot liquid solution 26. The remaining portion of the liquid, particularly that which is removed during the de-watering of the pulp material 28 is utilized for the dye 22. In effect, the process 10 of the present invention creates its own dye 22 that can be utilized to dye the textile 18 which is produced from the tobacco plant fiber 16 and/or other textiles. One particular advantage of the dye 22 produced by process 10 is that it does not require a chemical mordant to saturate the textile 18 or other textiles. Instead, the dye 22 permanently attaches itself to a textile, including textile 18, to effectively become part of the textile 18, as opposed to other dyes that do not attach themselves to the fibers and, therefore, require a mordant to dye the textile 18. This feature, which is unique to tobacco plants 12, substantially allows full utilization of as much of the tobacco plant 12 as possible in a single process, namely the process 10 of the present invention. The elimination of the need for the mordant to set the dye reduces the requirement for additional chemicals and, as such, provides a number of environmental benefits.

(15) As stated above, the dye 22 that is produced by the process 10 of the present invention can be utilized to color the textile 18 produced from the tobacco plant fiber 16, other textiles and/or blends of the textile 18 and other textiles. For purposes of the present invention, the fibers that are utilized to produce other textiles are referred to as secondary material fibers 32, as shown in FIG. 1. Secondary material fibers 32 may be natural fibers, such as those obtained from animal, plant or mineral sources (including wool and cotton), and synthetic fibers, such as nylon, polyester, acrylic and the like, or a combination of natural and synthetic fibers. The availability, desirability and beneficial uses of the various secondary material fibers 32 are generally well known in the art. As shown in FIG. 1, the secondary material fibers 32 can be mixed with the tobacco plant fiber 16 to produce the desired textile 18 having properties of the combined fiber. The dye 22 produced by the process 10 has a wide range of available color hues, estimated to be 50 or more color hues, ranging from pale to intense colors. The color of the dye 22 is primarily affected by the variety of tobacco plant 12 and the stage of growth the tobacco plant 12 is at when it is harvested.

(16) The uses for the fiber 16, textile 18 and dye 22 made from tobacco plants 12 are virtually unlimited. The ability of the fiber 16 derived from the process 10 of the present invention to be utilized for a wide variety of different products will create a new market for tobacco plants 12 and encourage the tobacco plants 12 to be organically grown, providing a new, environmentally-friendly use for a plant that is now considered by many to be toxic and not beneficial to society. The process 10 of the present invention could be utilized to support a completely sustainable economy from the farm to the factory, which will be beneficial for local employment, while leaving a very small footprint on the region or regions where the tobacco plants 12 are growing and being processed into fiber 16. Unlike the presently available means of producing fiber, the process of the present invention produces fiber 16 by utilizing virtually the entire tobacco plant 12 without the use of toxic chemicals that are discharged to or disposed in the environment.

(17) While there are shown and described herein one or more specific embodiments of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to various modifications with regard to any dimensional relationships set forth herein, with regard to its assembly, size, shape and use and with regard to the materials used in its construction. For instance, there are a number of components described herein that can be replaced with equivalent functioning components to accomplish the objectives of the present invention.