Title of Invention

RUBBERIZED COIR MATTRESSES AND A PROCESS FOR THEIR PREPARATION

Abstract The present invention discloses a newer, low cost and easy to operate mechanism to prevent mattress sagging by developing rubberized coir mattress with improved strength and durability. The rubberized coir mattress construction disclosed herein comprises (a) at least two rubberized coir sheets, each of said sheets having at least one non-planner surface having one or more formations such that at least one formation is complementary to at least one formation on another sheet and (b) walling provided to hold the sheets in their mated configuration.
Full Text FORM-2 THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
PROVISIONAL
Specification
(See section 10 and rule 13)
COIR MATTRESSES
(a) KANKARIA KUNDAN ZUMERLAL
an Indian National of Jnandhara, Manik Nagar, Burudgaon Road, Ahmednagar 414001,
Maharashtra, India; and
(b) MRS. KANKARIA SMITA KUNDAN
an Indian National
Of Jnandhara, Manik Nagar, Burudgaon Road, Ahmednagar 414001,
Maharashtra, India
THE FOLLOWING SPECIFICATION DESCRIBES THE INVENTION.

This invention relates to Coir mattresses.
Particularly, this invention relates to rubberized coir mattresses.
Rubberized Coir Mattress is an agro based product manufactured from coconut fiber & natural rubber. Natural Rubber comes in liquid form with 52/60% Dry Rubber Content. Coconut Coir/fibre is received in rope form which after untwisting are found as small tiny springs. The length of coconut fiber varies from 1/2" to 2". The combination of the both - Coir Fibre & liquid latex alongwith the chemicals, forms the Rubberised Coir Blocks. There are few chemicals used for better curing & Antioxidants like:-
• Zinc Oxide
• Sulphur
• Zinc Salt of 2 -Marcapto-Benzothiazle -ZMBT
• Zinc Diethyl of dithoicarbamate -ZDC
• Polymerised 2,2 4-Trimethyl -12 Dihydroquinoline -TDQ
• China Clay
• Dispersal - F
• Ginasul (used as an emulsifying agent)
The process of manufacturing Rubberised Coir Mattress in short is -
1. Coir fibres are internally locked at required width above which liquid rubber is sprayed on it. Due to rubbers' own property it gives resilance to Coir.
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2. This coir fibre with latex is then passed in different stages like Chambering, Hydraulic Pressing (to maintain thickness of the final product), Vulcanising, Cutting the Blocks at required dimensions. The process includes Hot Air at average temperature of 80 to 110 degree centigrade. One the precuts is cured in vulcanizing it is then inspected & used for further manufacturing of final Mattresses/ Cushions.
3. The above procedure is done for manufacturing of Rubberised Coir Bare Blocks. After production of these Rubberised Bare Blocks they are covered with the relevant tapestries.
This invention envisages a Coir Mattress & process of making the same with embossing which will avoid the sagging problems a limitation in the existing mattresses & which will increase the life of the product by 3 to 4 times.
Mehtod for preparation of Embossed Mattress:
For 3" Mattress :
1. Two Rubberised Coir sheets of equal thickness and size are prepared separately. For preparation of these sheets required length and width is cut on the Rotary Cutter.
2. Then these pieces are mounted on table called 'Stacking Table' which is mounted on Electronic Weighing Scales. Here the gross weight of the required product is maintained in such a way that each and every sheet is uniformly stacked.
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3. The required weight of the required size depending upon the grade of quality is pushed on to a Mat Press Machine where the total product whose size gets much more expanded then the required thickness. To get the semi size this mat press is used on which the block is pressed.
4. After that the semi product / block is sent on a manual spray booth where the top and bottom of the block is manually spread to get a good surface finishing and resilience for the coir blocks.
Procedure of Embossing:
1. First we mount one bottom Rubberised Coir sheet (which has already completed the operation upto manual spraying). On this the designed die as per required length and width is mounted. Again the die is covered with the second top Rubberised Coir Sheet. The total assembly is now again sent to Mat Press for pressing.
2. Now the same assembly is loaded on a Hydraulic Press Machine. Here the assembly is pressed for the final required thickness at 105 to 115 degree. The product is semi cured i.e. the moisture content from the coir blocks gets evaporated. The Assembly is kept in Hydraulic Press for a prescribed time depending upon the quality of the block manufactured. Then the Assembly is unloaded & dismantled to remove the inserted die.
3. Now the same embossed two Coir Sheets are loaded on Hydraulic Press machine again for 10 minutes. Once these coir blocks are removed
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from Hydraulic Press machine again form 10 minutes. Once these coir blocks are removed from Hydraulic Press, these bare blocks are kept at one side where moisture of the product gets removed.
4. Then these 2 Coir sheets are matched with each other & sent to the Bandsaw Section where the required length and width is cut. The matched 2 Coir Sheets are sent to Walling Section for side walling with Hessian Cloth. The side walling with Hessian Cloth is done to avoid the separation of 2 coir sheets.
5. After this the same is loaded on the trolleys to the Vulcanizing Chamber for final curing at 100 to 110 degree. Here the coir blocks are 100% finally cured. Once the coir blocks are vulcanized properly -they are send to finishing process.
Same procedure is following for any size and thickness of Mattress with a dividation by 2 sheets.
Types of Embossing:
Various types of dies are designed for embossing on the coir Sheets. The embossing is done for -
a) The variable Density to occur at different locations of the R.C. Blocks.
b) Increasing the stiffness
c) Increasing the Resilience
d) Increasing the Hardness with uniformity
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e) Increasing the life of Mattress by 3 to 4 time as compared to the regular Rubberised Coir Mattress.
The main aim of embossing the sheets is to avoid the sagging problem, increase Stiffness, Resilience & important increase life by 3 to 4 times then conventional process. The design of die may vary as per our technical innovation.
Distinct features of Embossed Mattresses:
1. The Mattresses in accordance with this invention are prepared by dividing the Sheet in 2 pes and by spraying latex extra on 2 sides where the specified die is designed due to which extra bonding is there. This increase the life of Mattress by 3 to 4 times than the Routine Mattress.
2. Where the embossing is done on 2 sheets & where the sheet is compact - the Density of that compact area is increased by 30% as compared to the Density maintained in the Mattress.
3. As per IS Std: 8391-1987- Resistance to Flexing Test should be carried out giving 250000 strokes, whereas for this new Embossed Mattress -we had carried out extra test by giving 12 Lacs strokes - 4 times more -the following are the results observed
Results of Trials conducted: Sample Size: No: 1-100 mm x 100 mm x 116 mm Sample Size: No: 2-100 mm x 100 mm x 117 mm Grade: Firm
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Flexing Test Report after 50,000 strokes
Sample 1st: Initial Thickness - 117 mm. After flexing thickness - 116 mm
Sample 2nd .-.Initial Thickness - 116 mm. After flexing thickness - 115 mm
Flexing Test Report after 1,00,000 storkes
Sample 1st: Initial Thickness - 117 mm. After flexing thickness - 114 mm
Sample 2nd : Initial Thickness - 116 mm. After flexing thickness - 113 mm
Flexing Test Report after 4,00,000 storkes
Sample 1st: Initial Thickness - 117 mm. After flexing thickness - 108 mm
Sample 2nd : Initial Thickness - 116 mm. After flexing thickness - 105 mm
After 12 Lac Strokes
Sample 1st: Initial Hardness-12.430 Kg. After flexing thickness - 10.249 Kg Initial Thickness :117 mm. After flexing thickness - 96 mm
Sample 2nd : Initial Hardness - 12.830 Kg. After flexing thickness - 10.139
Kg
Initial Thickness : 116 mm. After flexing thickness - 98 mm
Result:
Percentage of flexing (by hardness) = 19.28%
Percentage of flexing by thickness = 16.72%
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Lab Results:
Medium Grade: Results

TEST REPORT FOR RUBBERISED COIR BLOCK
PRODUCTION DATE: 15.01.2006 BATCH NO.:-060115 NORMAL SIZE:-72" x 36" x 3" - Wt: 8.3 GRADE :-MEDIUM kg REF STD :-IS : 8391 -SAMPLE WEIGHT :- 0.052 kgs, 1987 LAB TESTING DATE: 19.01.2006 REAFFIRMED 1999AMDTN0..1
Sr Name of test Clause no. Specified value Routine Mattress New patent
1) DIMENSION 5.2
a) Length 94/106 mm 100 mm 100 mm
b) Width 94/106 mm 100 mm 100 mm
c) Thickness 70/82mm 82 mm 76 mm
2) Indentation hardness 6.1 6.00 to 8.99 kg. 7.2 kg *9.8 kg(FirmGrade
3) Ageing test 6.2 ± 20% + 17.30 + 12.50
4) Flexing test 6.3 ± 20% + 18.20 + 16.85
5) Compression test 6.4 25% max 20.40% 16.75 %
6) Compression test 6.4 15% max 12.32% 10.84 %
7) PH 6.5 5.0 TO 8.5 7.4 7.4
8) Chloride test 6.6 0.3% 0.228% 0.228 %
9) Sulphate test 6.7 0.2% 0.138% 0.138 %
10) Density 7.1 60 TO 69 D 65 D 75 D
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Observations:
1. We have prepared both the Mattress - Routine as well as new Embossed Mattress in Medium Grade. In Routine Mattress the Density is observed as specified of Medium Grade only, whereas in new Embossed Mattress the Density is increased & is observed in Firm Grade.
2. The Hardness required for Medium Grade is 6 to 8.99 kg. In Routine Mattress it is observed 7.2 legs whereas in this invention the Hardness has gone upto 9.8 kg. This means it has gone in Firm Grade.

TEST REPORT FORRUBBERISED COIRBLOCK
PRODUCTION DATE: 20.01.2006 LOT NO.: 060120 NORMAL SIZE:-72" x 72" x 4" - Wt: GRADE :-FIRM 25.50 kgs REF STD :-IS : 8391 -SAMPLE WEIGHT :- 0.078 kgs, 1987 LAB TESTING DATE: 25.01.2006 REAFFIRMED 1999AMDTNO.:l
Sr Name of test Clause no. Specified value RoutineMattress NewPatentMattress
1) DIMENSION 5.2
a) Length 94/106 mm 100 mm 100 mm
b) Width 94/106 mm 100 mm 100 mm
c) Thickness 94/115 mm 104 mm 98 mm
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2) Indentation hardness 6.1 9.00 to 11.99 Kg- 10.20 kg. * 12.328 kg (Extra Firm Grade)
3) Ageing test 6.2 ± 20% + 15.30% + 13.77%
4) Flexing test 6.3 ± 20% + 12.18% + 08.20%
5) Compression test 6.4 ± 25% +21.68% + 17.65%
6) Compressiontest 6.4 ±15% + 11.58% + 09.20%
7) PH 6.5 5.0 TO 8.5 7.9 7.9
8) Chloride test 6.6 0.3% 0.229% 0.229%
9) Sulphate test 6.7 0.2% 0.144% 0.144%
10) Density 7.1 70 TO 79 D 75 D 85 D
*Observations:
1. We have prepared both the Mattress - Routine as well as new Embossed Mattress in Firm Grade. In Routine Mattress the Density is observed as specified of Firm Grade only, whereas in new Embossed Mattress the Density is increased & is observed in Extra Firm Grade.
2. The Hardness required for Firm Grade is 9 to 11.99 kg. In Routine Mattress it is observed 10.20 kgs whereas in this invention the Hardness has gone upto 12.328 kg. This means it has gone in Extra Firm Grade.
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TEST REPORT FORRUBBERISED COIRBLOCK
PRODUCTION DATE: 20.01.2006 BATCH NO. .-060120 NORMAL SIZE:-72" x 48" x 5" - Wt: GRADE .-EXTRA 28.5 kgs FIRM WEIGHT :- 0.131 kgs REF STD :-IS : 8391 -LAB TESTING DATE: 27.01.2006 1987 N0..1 REAFFIRMED 1999AMDT
Sr Name of test Clause no. Specified value Routine Mattress NewPatentMattress
1) DIMENSION 5.2
a) Length 94/106mm 100 mm 100 mm
b) Width 94/106mm 100mm 100mm
c) Thickness 121/142mm 130mm 124 mm
2) Indentation hardness 6.1 12.00 to 15.00 Kg. 12.848 kg 16.852 kg
3) Ageing test 6.2 ± 20% + 17.89% + 13.55%
4) Flexing test 6.3 + 20% + 13.28% +8.65%
5) Compression test 6.4 ± 25% + 21.0% + 16.95%
6) Compression test 6.4 ±15% + 10.25% +8.50%
7) PH 6.5 5.0 TO 8.5 6.8 6.8
8) Chloride test 6.6 0.3% 0.252% 0.252%
9) Sulphate test 6.7 0.2% 0.129% 0.129%
10) Density 7.1 80 TO 100 D 100 D HOD
Observations: 1. We have prepared both the Mattress - Routine as well as new patent Mattress in Extra Firm Grade. In routine Mattress the Density Is observed as specified of Extra Firm Grade only, whereas in new Embossed Mattress the Density is increased & is observed more than Extra Firm Grade.
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2. The Hardness required for Extra Firm Grade is 12 to 15 kg. In Routine Mattress it is observed 12.848 kgs whereas in this invention the Hardness has gone upto 16.852 kg. This means it has gone more than Extra Firm Grade.
The invention will be described with reference to the accompanying drawings, in which
Figures, 1 2 and 3 illustrate the process flow for making embossed coir mattress in accordance with this invention. The drawings are self explanatory.
The embossing may be in the form of corrugations and may be uniform throughout the body of the mattress elements or may be in a portion or may be irregular as shown in the drawings.
Dated this 25th day of May 2006

Jewan of RVK- Dewan & Co Applicants' Patent Attorneys

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Documents:

805-MUM-2006-ABSTRACT(11-5-2009).pdf

805-MUM-2006-ABSTRACT(22-5-2007).pdf

805-MUM-2006-ABSTRACT(25-5-2006).pdf

805-mum-2006-abstract(complete)-(22-5-2007).pdf

805-mum-2006-abstract(granted)-(21-1-2011).pdf

805-mum-2006-abstract-1.jpg

805-MUM-2006-CANCELLED PAGES(11-5-2009).pdf

805-mum-2006-cancelled pages(19-8-2010).pdf

805-MUM-2006-CLAIMS(11-5-2009).pdf

805-MUM-2006-CLAIMS(AMENDED)-(10-06-2010).pdf

805-mum-2006-claims(amended)-(10-6-2010).pdf

805-MUM-2006-CLAIMS(AMENDED)-(19-8-2010).pdf

805-mum-2006-claims(complete)-(22-5-2007).pdf

805-mum-2006-claims(granted)-(21-1-2011).pdf

805-MUM-2006-CLAIMS(MARKED COPY)-(10-06-2010).pdf

805-MUM-2006-CORRESPONDENCE(11-5-2009).pdf

805-mum-2006-correspondence(2-7-2007).pdf

805-MUM-2006-CORRESPONDENCE(20-5-2010).pdf

805-MUM-2006-CORRESPONDENCE(25-2-2010).pdf

805-mum-2006-correspondence(ipo)-(21-1-2011).pdf

805-mum-2006-description (provisional).pdf

805-MUM-2006-DESCRIPTION(COMPLETE)-(11-5-2009).pdf

805-mum-2006-description(complete)-(22-5-2007).pdf

805-mum-2006-description(granted)-(21-1-2011).pdf

805-MUM-2006-DRAWING(22-5-2007).pdf

805-MUM-2006-DRAWING(25-5-2006).pdf

805-mum-2006-drawing(complete)-(22-5-2007).pdf

805-mum-2006-drawing(granted)-(21-1-2011).pdf

805-mum-2006-drawings.pdf

805-MUM-2006-FORM 1(19-8-2010).pdf

805-MUM-2006-FORM 1(25-5-2006).pdf

805-mum-2006-form 18(2-7-2007).pdf

805-mum-2006-form 2(11-5-2009).pdf

805-mum-2006-form 2(complete)-(22-5-2007).pdf

805-mum-2006-form 2(granted)-(21-1-2011).pdf

805-MUM-2006-FORM 2(TITLE PAGE)-(11-5-2009).pdf

805-mum-2006-form 2(title page)-(complete)-(22-5-2007).pdf

805-mum-2006-form 2(title page)-(granted)-(21-1-2011).pdf

805-mum-2006-form 2(title page)-(provisional)-(25-5-2006).pdf

805-MUM-2006-FORM 26(10-6-2010).pdf

805-mum-2006-form 5(22-5-2007).pdf

805-mum-2006-form-1.pdf

805-mum-2006-form-2.doc

805-mum-2006-form-2.pdf

805-mum-2006-form-26.pdf

805-mum-2006-form-3.pdf

805-mum-2006-marked copy(10-6-2010).pdf

805-MUM-2006-MARKED COPY(19-8-2010).pdf

805-MUM-2006-POWER OF ATTORNEY(19-8-2010).pdf

805-MUM-2006-REPLY TO EXAMINATION REPORT(10-06-2010).pdf

805-MUM-2006-REPLY TO HEARING(19-8-2010).pdf

805-MUM-2006-SPECIFICATION(AMENDED)-(19-8-2010).pdf


Patent Number 245497
Indian Patent Application Number 805/MUM/2006
PG Journal Number 04/2011
Publication Date 28-Jan-2011
Grant Date 21-Jan-2011
Date of Filing 25-May-2006
Name of Patentee KANKARIA KUNDAN ZUMERLAL
Applicant Address JNANDHARA, MANIK NAGAR, BURUDGAON ROAD, AHMEDNAGAR 414001,
Inventors:
# Inventor's Name Inventor's Address
1 KANKARIA KUNDAN ZUMERLAL JNANDHARA, MANIK NAGAR, BURUDGAON ROAD, AHMEDNAGAR 414001,
2 MRS. KANKARIA SMITA KUNDAN Jnandhara, Manik Nagar, Burudgaon Road, Ahmednagar 414 001, Maharashtra, India
PCT International Classification Number A47C27/14
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA