WO2005055770A1 - Coir fibre tufting machine - Google Patents

Abstract

This invention relates to a process of manufacturing coir fibre tufted mat and a machine for manufacturing the said mat. The method comprises the following steps. a. Production of non woven coir brush mat by inserting cut lengths of coir fibre into a viscous PVC based compound or a rubber based compound. b. Impregnating the coir fibre onto the base compound. c. Curing in a heating (14) cooling chamber (15) to produce continuous lengths of a c Coir brush mat. d. Cutting the mat into smaller door mats of any size and shape (16). Further a unique machine if fabricated to manufacture tufted mat.

Description

COIR FIBRE TUFTING MACHINE FIELD OF INVENTION

This invention pertains to agricultural industries. Particularly this invention is concerned with agricultural, processing machinery. More particularly this invention is concerned with coir fibre tufting machine.

SUMMARY OF INVENTION The inventor has made a great effort to provide a method and a machine which meet the requirement of the industry and overcome the problem associated in the prior art. To achieve the above object according to first aspect and feature of the present invention there is provided a method to improve, efficiency, . According to second aspect and feature of the invention in addition to the first feature the invention comprises a coir tuft machine, which is unique, rugged efficient, economical. At the outset of the description which follows it is to be understood that ensuring description only illustrate a particular form of this invention.

However, such particular form is only an exemplary embodiment without intending to imply any limitation on the scope of this invention.

Accordingly, the description is to be understood as an exemplary embodiment and reading of the invention is not intended to be taken restrictively. The above and other objects features and disadvantages will be clear from the following description of preferred embodiment taken in conjunction with accompanying drawings. The foregoing description is outlined rather broadly preferred and alternative feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing and modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should realize such equalent conception do not depart from the spirit and scope of the invention in its broadest form.

BRIEF DESCRIPTION OF DRAWINGS The accompanying drawings are intended to provide further understanding of invention and is incorporated in and constitute a part of invention. The drawings illustrate an embodiment of invention and together with the description illustrate principle of invention. The drawings should not be taken as implying any necessary limitation on the essential scope of invention. The drawings are given by way of non-limitative example to explain the nature of the invention. For a more complete understanding of the instant invention reference is now made to the following description taken in conjunction with accompanying drawings. The various feature of novelty which characterise the invention are pointed out specifically in the claims which a part of description. For a better understanding of the invention, its operating advantage, specific objects obtained by its use, reference should be made to the drawings and descriptive matter is which there are illustrated and described preferred embodiments of invention. Referring now to drawings, where like numerals designate identical or corresponding parts throughout the referred views. Now the invention will be described in detail with reference to the drawings that accompany the complete specification. The nature of invention and the manner the invention is to be performed is clearly described in the complete specification. Figure ϊ of the drawings shows the conventional process and the machinery known in the art. Figure 2 of the drawing shows the novel process and the machinery involved in manufacturing coir fibre tufted mat.

DETAILED DESCRIPTION OF AN EMBODIMENT OF INVENTION It is a non-woven Coir (coconut husk fibre) brush mat/matting, produced by inserting cut lengths of Coir FIBRE into a viscous PVC based compound (or Rubber based compound). The Coir FIBRE that is impregnated onto the base compound is cured in a heating / cooling chamber to produce continuous lengths of coir brush mat or matting. This mat can be cut into smaller doormats of any size and shape. Accordingly the process consists of following steps a. Production of non woven coir brush mat by inserting cut lengths of coir fibre into a viscous PVC based compound or a rubber based comound. b. Impregnating the coir fibre onto the base compound. c. Curing in a heating / cooling chamber to produce continuous lengths of c Coir brush mat. d. Cutting the mat into smaller door mats of any size and shape. The Conventional Tufting machine is based on using coir yarn onto a PVC based the yarn creel stand which is shown by figure 1 (a). The coir fibre tufting machine using coir fibre tufted mat is shown in figure 2 of the drawing.

MANUFACTURING EQUIPMENT AND PROCESS: For the purpose of convenience the entire system of equipment for coir fibre tufting machine is divided into two parts: first part and second part. The machinery involved in the first part is as follows. Conveyor (1): A belt conveyor is used to feed the coir fibre into the Willowing Machine.

Willowing Machine (2): The pressed bundles of Coir / Kokos fibres (i.e., Coconut Husk Fibre) are opened up and these fibres are separated using the Willowing Machine. This machine is a fast rotating circular shaft with long metal spikes (approximately 3 inches height) along the surface of the shaft.

Blower (3): The fibres are blown up a chute. The reason why it is blown up a chute is to separate any heavy debris like stones etc. from the fibre. The chute (4) has a Swiveling motion attachment at the top end, so that the fibres are spread evenly width-wise, and not get accumulated in one place.

Hopper / Trough (6): At the bottom of the Hopper is a continuous belt conveyor, onto which the moistened fibre gets deposited. The amount of fibre on the conveyor can be controlled by adjusting the conveyor speed, or by adjusting the gap between the conveyor and the trough, and also by means of 'Compactor' (8) on the conveyor, adjacent to the Trough. A compactor is a simple device that will control the amount of fibre on the conveyor belt.

Multi-stage Combs (9): The comb is a circular tube (of the same width as that of the conveyor belt) with spikes set on the outer surface of the tube. The sheet of fibre flowing on the conveyor belt passes through several such combs, arranged one after the other, starting with a coarse toothed comb (with the comb bristle set wide apart) to finer toothed combs (with the comb bristles set closer to each other). Each comb is set slightly above the conveyor belt, without touching it. The combs rotate in the same direction as that of the conveyor belt, at a slightly higher speed than the speed of the conveyor, thereby straightening the fibres on the conveyor belt. The machinery involved in the second part is as follows. PVC-based compound (or Rubber-based compound) feeding device (10) : This is a device to spread the base compound onto a continuous Teflon conveyor belt. It is nothing but a pump delivering the liquid compound through a flexible pipe with 'limit-switch' controlled traverse motion. The compound is spread evenly onto the Teflon belt (13) and the belt transports the compound to the cutting machine. Teflon belt is used for easy release of the cured compound.

Cutting / Tufting Head (ID: This is a precision, cam-controlled cutting machine, which cuts the straightened coir fibres (that are fed into it by a belt conveyor) at pre-set lengths. The cut fibres are then implanted vertically onto the PVC-based (or Rubber-based) compound, on the Teflon belt, through. a precision hopper / trough (12).

Heating chamber (14): The Teflon belt conveyor now passes through a Heating Chamber where the base compound of the Tufted Coir brush mat is cured. * The temperature and length of the heating chamber depends on the composition of the base compound and also on the speed of the Teflon conveyor.

Cooling Chamber (15): After the base of the tufted mat is cured in the heating chamber, the Teflon conveyor passes through a Cooling Chamber. The cooling chamber assists in the easy release of the tufted mat from the Teflon conveyor, and also enhances the appearance of the backside of the mat.

Side-cutting and Rolling device (16): The continuous tufted coir mat that comes out the cooling chamber is cut evently along the two edges and is then rolled and cut.

RAW MATERIALS: 1. Coir Fibre 2. PVC based compound, or Rubber based compound Upto now Tufted Coir Brush mat is made using Coir Yarn, which is fed into the Cutting / Tufting Head. The coir yarn is then cut into pre-set lengths and then impregnated into the base compound and then cured to produce the mat. With the development of the new technique, it is possible to make Tufted Coir Brush Mat using coir fibre, instead of Coir Yam, thereby eliminating one very important raw material in the manufacturing process (i.e. replacing the usage of spun Coir yam with coir fibre). It may be noted that the 2 part of the "Manufacturing Equipment and Process" is exactly identical for both the Coir yam and Coir fibre Tufting process. It is the 1^st Part of the "Manufacturing Equipment Process" that is unique to the Coir fibre Tufting Process, and Coir yam is directly fed from the Creel Stands onto the Cutting / Tufting Machine). The following are the major advantages of coir fibre Tufted Mat over Coir yam tufted Mat: 1. Substantial reduction in the cost of Raw Materials: The current market price for Coir Yam is about Indian Rupees Twenty per kilogram, whereas the cost of good quality Coir fibre is only about Indian Rupees Eight per kilogram. 2. Improved Brush Surface: The yam that is currently available in market is hand spun, which makes it highly uneven. This unevenness of the thickness and twist of yam is reflected on the surface of the tufted mat by way of holes in the mat, etc. when fibre is used for tufting there is better compactness and evenness of the tufted surface. 3. Reduction in Shedding of Fibres:- One of the major problem with tufted mats produced using yam is the shedding of fibres. The reason for this is that not all the fibres in the yam get impregnated onto the base compound. However, this problem is minimized when fibres re impregnated onto the base compound. 4. Streak free mat surface: Since fibres are used instead of yam, there is minimal chance of streaks on the mat surface (which are caused by colour variation of yarn). 5. Greater Design Possibility etc: Newer varieties of mats can be produced by blending different coloured fibes to produce "mottled" effect doormat surface. Also fibre dyed or fibre bleached mat will have a more even and better finish. The invention has been explained in relation to specific embodiment. It is inferred that the foregoing description is only illustrative of the present invention and it is not intended that the invention be limited 'or restrictive thereto. Many other specific embodiments of the present invention will be apparent to one skilled in the art from the foregoing disclosure. All substitution, alterations and modification of the present invention which come within the scope of the following claims are to which the present invention is readily susceptible without departing from the spirit of the invention. The scope of the invention should therefore be determined not with reference to the above description but should be determined with reference to appended claims along with full scope of equivalents to which such claims are entitled.

Claims

1. A method of manufacturing coir fibre tufted mat comprises the following steps: e. Production of non woven coir bmsh mat by inserting cut lengths of coir fibre into a viscous PVC based compound or a rubber based comound, f. Impregnating the coir fibre onto the base compound, g. Curing in a heating / cooling chamber to produce continuous lengths of c Coir bmsh mat, h. Cutting the mat into smaller door mats of any size and shape.

2. Coir fibre tufting machine for manufacturing coir fibre tufted mat as claimed in Claim 1 comprising the following features. a. A .belt conveyor is used to feed the coir fibre into the Willowing Machine, b. Willowing Machine wherein the pressed bundles of Coir / Kokos fibres (i.e. Coconut Husk Fibre) are opened up and these fibres are separated using the Willowing Machine, this machine is a fast rotating circular shaft with long metal spikes (approx. 3 inches height) along the surface of the shaft, c. Blower whereby the fibres are blown up a chute, the reason why it is blown up a chute is to separate any heavy debris like stones from the fibre, the chute has as Swiveling motion attachment at the top end, so that the fibres are spread evenly width-wise, and not get accumulated in one place, d. Hopper / Trough wherein at the bottom of the Hopper is a continuous belt conveyor, onto which the moistened fibre gets deposited, the amount of fibre on the conveyor can be controlled by adjusting the conveyor speed, or by adjusting the gap between the conveyor and the trough, and also by means of 'Compactor' on the conveyor, adjacent to the Trough, wherein the compactor is a simple device that will control the amount of fibre on the conveyor belt, e. Multi-stage Combs wherein the comb is a nothing but a circular tube (of the same width as that of the conveyor belt) with spikes set on the outer surface of the tube, the sheet of fibre flowing on the conveyor belt passes through several such combs, arranged one after the other, starting with a coarse toothed comb (with the comb bristle set wide apart) to finer toothed combs (with the comb bristles set closer to each other), f. Each comb is set slightly above the conveyor belt, without touching it, the combs rotate in the same direction as that of the conveyor belt, at a slightly higher speed than the speed of the conveyor, thereby straightening the fibres on the conveyor belt, g. PVC - based compound (or Rubber-based compound) feeding device wherein the said device to spread the base compound onto a continuous Teflon conveyor belt which is nothing but a pump delivering the liquid compound through a flexible pipe with 'limit-switch' controlled traverse motion, the compound is spread evenly onto the Teflon belt and the belt transports the compound to the cutting machine, h. Cutting / Tufting Head which is a precision, cam-controlled cutting machine, which cuts the straightened coir fibres (that are fed into it by a belt conveyor) at pre-set lengths, the cut fibres are then implanted vertically onto the PVC-based (or Rubber-based) compound, on the Teflon belt, through a precision hopper / trough, i. Heating chamber wherein the Teflon belt conveyor now passes through a Heating Chamber where the base compound of the Tufted Coir bmsh mat is cured, the temperature and length of the heating chamber depends on the composition of the base compound and also on the speed of the Teflon conveyor, j. Cooling Chamber wherein after the base of the tufted mat is cured in the heating chamber, the Teflon conveyor passes through a Cooling Chamber, the cooling chamber assists in the easy release of the tufted mat from the Teflon conveyor, and also enhances the appearance of the back side of the mat and k. Side-cutting and Rolling device wherein the continuous tufted coir mat that comes out the cooling chamber cut evenly along the two edges and is then rolled and cut.

3. A process of manufacturing coir fibre tufted mat as described in the complete specification and as illustrated by way of drawings.

4. A machine of manufacturing coir fibre tufted mat as described in the complete specification and as illustrated by way of drawings