A rubber base mat with coir fibres and a method of manufacturing thereof

Abstract

The present disclosure explains a rubber base mat with coir fibres and method of manufacturing thereof. The method includes the following steps. First, providing (101) a rubber base having a predetermined width and length, wherein the rubber base includes an outer periphery and an inner surface area. Then, separating (102) individual coir fibres from bundled coir fibres and cutting (103) the individual coir fibres to obtain a first range of predetermined length of cut coir fibres. Then, vibrating and screening (104) the cut coir fibres for obtaining short coir fibres having a second range of predetermined length. Next, coating (105) a layer of adhesive on the inner surface area and spreading (106) a selected length of the short coir fibres on the adhesive coated area. Finally, heating (107) the rubber base with coir fibres to a predetermined temperature for obtaining rubber base mat with coir fibres thereby preventing fibre shedding.

I claim: 
     
         1 . A method of manufacturing a rubber base mat with coir fibres, comprising the steps of:
 providing ( 101 ) a rubber base having a predetermined width and length;   characterized in that   wherein the rubber base includes an outer periphery and an inner surface area;   separating ( 102 ) individual coir fibres from bundled coir fibres, by a willowing machine;   cutting ( 103 ) the individual coir fibres to obtain a first range of predetermined length of cut coir fibres, by a sheering machine;   vibrating and screening ( 104 ) the cut coir fibres for obtaining short coir fibres having a second range of predetermined length, by a vibrating sorter machine;   coating ( 105 ) a layer of adhesive on the inner surface area of the rubber base;   spreading ( 106 ) a selected length of the short coir fibres on the adhesive coated area of the rubber base; and   heating ( 107 ) the rubber base with coir fibres to a predetermined temperature for obtaining a rubber base mat with coir fibres thereby preventing shedding of fibres.   
     
     
         2 . The method as claimed in  claim 1 , wherein the first range of predetermined length provided between 2 mm and 15 mm. 
     
     
         3 . The method as claimed in  claim 1 , wherein the second range of predetermined length provided between 2 mm and 10 mm; and
 wherein the selected length picked from the range of 2 mm to 10 mm.   
     
     
         4 . The method as claimed in  claim 1 , wherein the predetermined temperature includes a range of 100° C. to 130° C. 
     
     
         5 . The method as claimed in  claim 1 , wherein a height of the outer periphery ( 201   a ) is greater than a height of the inner surface area ( 201   b ) of the rubber base. 
     
     
         6 . The method as claimed in  claim 1 , wherein the height of the outer periphery ( 201   a ) is made based on the second range of predetermined length of the short coir fibres, wherein a width of the outer periphery ( 201   a ) is made from a range of 4 mm to 20 mm. 
     
     
         7 . The method as claimed in  claim 1 , wherein the adhesive including an aqueous polymer dispersion of vinyl acetate-ethylene copolymer. 
     
     
         8 . The method as claimed in  claim 1 , wherein the vibrating sorter machine including a plurality of filters for screening the cut coir fibres to the length in the range of 2 mm and 10 mm. 
     
     
         9 . The method as claimed in  claim 1 , wherein thickness of the rubber base is in a range from 2 mm to 5 mm, thereby the short coir fibres facilitating manufacturing rubber base mat with coir fibres of reduced weight and dimensions. 
     
     
         10 . The method as claimed in  claim 1 , wherein manufacturing the rubber base including 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.   
     
     
         11 . The method as claimed in  claim 10 , wherein one of a rubber mixing mill machine and a kneader machine performing mixing of the components for obtaining the flexible rubber compound. 
     
     
         12 . A rubber base mat with coir fibres manufactured based on the method as claimed in  claim 1 , comprising:
 a rubber base ( 201 ) including an inner surface area ( 201   a ) and an outer periphery ( 201   b );   a layer of an adhesive coated on the inner surface area ( 201   a ) of the rubber base ( 201 );   a plurality of coir fibres ( 202 ) having a selected length picked from a second range of predetermined length; and   wherein the coir fibres ( 202 ) spread on the adhesive and integrated with the rubber base ( 201 ), thereby preventing shedding.   
     
     
         13 . The rubber base mat with coir fibres as claimed in  claim 12 , wherein the second range of predetermined length is from 2 mm to 10 mm. 
     
     
         14 . The rubber base mat with coir fibres as claimed in  claim 12 , wherein a height of the outer periphery ( 201   b ) is greater than a height of the inner surface area ( 201   a ). 
     
     
         15 . The rubber base mat with coir fibres as claimed in  claim 12 , wherein a height of the outer periphery ( 201   b ) is made based on the second predetermined length of the short coir fibres, wherein a width of the outer periphery ( 201   b ) is made from a range of 4 mm to 20 mm. 
     
     
         16 . The rubber base mat with coir fibres as claimed in  claim 12 , wherein a thickness of the rubber base ( 201 ) provided in a range of 2 mm to 5 mm.