FIELD

[0001] The embodiments herein generally relate to a rubber base mat with coir fibres and a method of manufacturing thereof. More particularly, the disclosure relates to a method of manufacturing rubber base mat with coir fibres.

BACKGROUND AND PRIOR ART

[0002] Coconut fibre is a natural fibre that is extracted from the outer husk of coconut. It is found between the hard, internal shell and the outer coat of a coconut. Popularly known as coir, coconut fibre is widely used in many products and articles including floor mats, doormats, brushes and mattresses.

[0003] Currently, coir is used in manufacturing of various products, wherein coir yarns of length greater than 15mm are utilized. However, such yarns do not provide feasibility in manufacturing and designing products of smaller dimensions. These products including long coir yarns are prone to shedding after a short duration of usage. Also, such products increase the cost of transportation due to larger size. Furthermore, products such as PVC tufted coir mats utilizing both coir yarns and liquid compounded PVC are not environmental friendly, and do not impart anti-skid properties.

[0004] Therefore, there is a need for an environmental-friendly rubber base mat with coir fibres. Moreover, there is a need for an economical method of manufacturing a rubber base mat with coir fibres with reduced shedding of coir fibres.

[0005] Some of the objects of the present disclosure are described herein below:

[0006] The main objective of the present disclosure is to provide a rubber base mat with coir fibres.

[0007] Another objective of the present disclosure is to provide a method of manufacturing a rubber base mat with coir fibres with thickness lesser than 10mm.

[0008] Still another objective of the present disclosure is to provide an environmental friendly rubber base mat with coir fibres and a method of manufacturing the rubber base mat with coir fibres.

[0009] Yet another objective of the present disclosure is to provide a rubber base mat with coir fibres with reduced fibre shedding.

[00010] The other objectives and advantages of the present disclosure 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 disclosure and are not intended to limit the scope thereof.

SUMMARY

[00011] In view of the foregoing, an embodiment herein provides a method of manufacturing coir fiber and a rubber base mat with coir fibres.

[00012] In accordance with an embodiment, the method includes the following steps. First, providing a rubber base having a predetermined width and length, wherein the rubber base includes an outer periphery and an inner surface area. Then, separating individual coir fibres from bundled coir fibres, by a willowing machine and cutting the individual coir fibres to obtain a first range of predetermined length of cut coir fibres, by a sheering machine. Next, vibrating and screening the cut coir fibres for obtaining short coir fibres having a second range of predetermined length, by a vibrating sorter machine. Then, coating a layer of adhesive on the inner surface area of the rubber base and spreading a selected length of the short coir fibres on the adhesive coated area of the rubber base. Finally, heating the rubber base with coir fibres to a predetermined temperature for obtaining a rubber base mat with coir fibres thereby preventing shedding of fibres.

[00013] In an embodiment, the first range of predetermined length can be in between 2 mm and 15 mm. In an embodiment, the second range of predetermined length can be in between 2 mm and 10 mm and the selected length can be picked from the range of 2 mm to 10 mm.

[00014] In an embodiment, the predetermined temperature can include a range of 100°C to 130°C.

[00015] In accordance with an embodiment, a height of the outer periphery can be greater than a height of the inner surface area of the rubber base. In an embodiment, the height of the outer periphery can be made based on the selected length of the short coir fibres, wherein a width of the outer periphery can be made from a range of 4 mm to 20 mm.

[00016] In an embodiment, the adhesive can include any adhesive materials, preferably can include an aqueous polymer dispersion of vinyl acetate-ethylene copolymer. In an embodiment, the vibrating sorter machine includes a plurality of filters for screening the cut coir fibres to the length in the range of 2 mm and 10mm. In an embodiment, thickness of the rubber base can be in a range from 2 mm to 10 mm, preferably 2 mm to 5mm, thereby the short coir fibres facilitating manufacturing rubber base mat with coir fibres of reduced weight and dimensions. [00017] In accordance with an embodiment, a method of manufacturing the rubber base can include the steps of mixing a plurality of components including natural rubber, synthetic rubber, reclaimed rubber, rubber chemicals including zinc oxide, stearic acid, accelerators, anti-oxidants, sulphur, booster, fillers including rubber waste powder and china-clay, plasticisers, rubber process oil for obtaining a flexible rubber compound, rolling the flexible rubber compound for obtaining sheets of required thickness and width, by a calendaring machine and cutting the sheets to required shapes and dimensions for obtaining the rubber base. [00018] In an embodiment, one of a rubber mixing mill machine and a kneader machine performing mixing of the components for obtaining the flexible rubber compound.

[00019] In accordance with an embodiment, a rubber base mat with coir fibres, comprises a rubber base including an inner surface area and an outer periphery, a layer of an adhesive can be coated on the inner surface area of the rubber base, a plurality of coir fibres having a selected length can be picked from a second range of predetermined length and the selected coir fibres are spread on the adhesive and integrated with the rubber base, thereby preventing shedding.

[00020] In an embodiment, the second range of predetermined length can be from 2mm to 10 mm. In an embodiment, a height of the outer periphery can be greater than a height of the inner surface area. In an embodiment, a height of the outer periphery can be made based on the selected length of the short coir fibres, wherein a width of the outer periphery can be selected from a range of 4 mm to 20 mm. In an embodiment, a thickness of the rubber base can be provided in a range of 2mm to 5mm.

[00021] 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 embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS

[00022] 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.

[00023] Fig.l illustrates a method of manufacturing coir fibre and a rubber base mat with coir fibres, according to an embodiment herein;

[00024] Fig. 2a illustrates a perspective view of a rubber base mat with coir fibres, according to an embodiment herein;

[00025] Fig. 2b illustrates a side view of a rubber base mat with coir fibres, according to an embodiment herein; and

[00026] Fig. 3 illustrates a top view of a rubber base mat with coir fibres, according to an embodiment herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[00027] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and detailed in the following description. Descriptions of well- known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[00028] As mentioned above, there is a need for an environmental-friendly rubber base mat with coir fibres. In particular, there is a need for an economical method of manufacturing a rubber base mat with coir fibres with reduced shedding of coir fibres. The embodiments herein achieve this by providing “A rubber base mat with coir fibres and a method of manufacturing thereof’. Referring now to the drawings and more particularly to Fig.l and Fig.3, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.

[00029] Fig.l illustrates a method of manufacturing a rubber base mat with coir fibres. The method includes the following steps. A rubber base is provided having a predetermined width and length is provided 101. The rubber base can include an outer periphery and an inner surface area. Then, individual coir fibres can be separated 102 from a plurality of bundled coir fibres, using a willowing machine. The willowing machine can include a hollow circular shaft with a plurality of metal spikes provided circumferentially on an inner surface, wherein the bundled coir fibres are fed in the hollow circular shaft and individual coir fibres are separated during rotation of the circular shaft.

[00030] The separated individual coir fibres are fed into a sheering machine for cutting 103 the individual coir fibres to obtain a first range of predetermined length of cut coir fibres. In an embodiment, a first range of predetermined length of the cut fibres can be provided in between 2mm and 15 mm. The cut coir fibres are fed in a vibrating sorter machine, wherein the cut coir fibres are vibrated 104 in a feeding chamber and screened 104 through a plurality of filters to obtain short coir fibres of length having a second range of predetermined length. In an embodiment, the second range of predetermined length can be provided in a range between 2mm and 10mm. In the vibrating sorter machine, the cut coir fibres are fed in the feeding chamber, wherein the feeding chamber vibrates for transferring the coir fibres through the plurality of filters attached below the feeding chamber. The plurality of filters includes mesh of different sizes ranging lesser than 10mm. In an embodiment, selected length of the short coir fibres can be picked from the range between 2mm and 10mm. The short coir fibres facilitate manufacturing products of varied dimensions with reduced weight of coir fibres.

[00031] Then, in an embodiment, a layer of an adhesive is coated 105 on the inner surface area of the rubber base. The selected length of the short coir fibres are spread 106 on the adhesive coated area on the rubber base. The rubber base with the coir fibres is heated in a heating chamber to a predetermined temperature for obtaining a rubber base mat with coir fibres. The predetermined temperature can be provided in a range between 100°C and 130°C.

[00032] In an embodiment, a method of manufacturing the rubber base includes the following steps. First, mixing a plurality of components including but not limited to natural rubber, synthetic rubber, reclaimed rubber, rubber chemicals, booster, fillers, plasticisers, rubber process oil in a rubber mixing mill machine for a predetermined duration of time to produce a flexible rubber compound. In an embodiment, the rubber chemicals include but not limited to like zinc oxide, stearic acid, accelerators, anti oxidants, sulphur. In an embodiment, the fillers include but not limited one or a combination of rubber waste powder, china-clay. In an embodiment, the predetermined duration of time ranges from 20 minutes to 50 minutes.

[00033] In another embodiment, a method of manufacturing the rubber base includes adding the components in a kneader machine to a predetermined duration of time. The predetermined duration of time ranges from 6 minutes to 15 minutes. Then rubber latex, hardener and the rubber chemicals are added in agitators having planetary motion to produce the flexible rubber compound.

[00034] In an embodiment, the produced flexible rubber compound is fed in a calendaring machine for rolling the flexible rubber compound to obtain rubber sheets. The rubber sheets can be obtained in required shape, thickness and width for manufacturing the rubber base. In an embodiment, the thickness of the rubber base is in a range between 2mm and 5mm.

[00035] Fig. 2a illustrates a perspective view of a rubber base mat with coir fibres, manufactured using the method described above. The rubber base mat 201 includes the inner surface area 201a and the outer periphery 201b. In an embodiment, a height of the outer periphery 201b is greater than a height of the inner surface area 201a. The height of the outer periphery 201b is made based on the second predetermined length of the short coir fibres. A width of the outer periphery 201b is made from a range of 4mm to 20 mm The short coir fibres include a selected length picked from 2mm to 10mm. In an embodiment, the short coir fibres 201 of selected length are spread unevenly on the adhesive coated area in the inner surface area 201a on the rubber base 201, wherein the coir fibres 201 are oriented in plurality of directions.

[00036] Fig. 2b illustrates a side view of a rubber base mat with coir fibres, manufactured using the method described above.

[00037] Fig. 3 illustrates a top view of a coir with rubber base doormat, manufactured using the method described above.

[00038] A main advantage of the present disclosure is that the method provides manufacturing a rubber base mat with coir fibres.

[00039] Another advantage of the present disclosure is that the rubber base mat with coir fibres prevents shedding of coir fibres. [00040] Still another advantage of the present disclosure is that the method of manufacturing a rubber base mat with coir fibres is environmental friendly and economical.

[00041] Yet another advantage of the present disclosure is that the method of manufacturing rubber base mat with coir fibres can facilitate production in varied dimensions and shapes including thickness lesser than 10mm.

[00042] Still another advantage of the present disclosure is that the method of manufacturing a rubber base mat with coir fibres includes coir fibres of length lesser than 10mm.

[00043] Yet another advantage of the present disclosure is that the method of manufacturing rubber base mat with coir fibres imparts anti-skid properties.

[00044] Still another advantage of the present disclosure is that the method of manufacturing rubber base mat with coir fibres reduces the quantity of coir required, thereby reducing cost of raw material and weight of the product.

[00045] Yet another advantage of the present disclosure is that the method of manufacturing rubber base mat with coir fibres imparts brushing effect, compactness and evenness on surface.

[00046] Still another advantage of the present disclosure is that the method of manufacturing coir facilitates manufacturing products of varied dimensions and imparts dimensional stability, thereby enabling packing in straight form or roll form.

[00047] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.