DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
As amended by the Patents (Amendment) Act, 2005
&
The Patents Rules, 2003
As amended by the Patents (Amendment) Rules, 2016

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
TITLE
“A METHOD OF MANUFACTURING RECYCLED COMPOSITE MATERIAL FROM INDUSTRIAL WASTE”
APPLICANT
(a) Name : GREENSOLE FOOTWEAR PRIVATE LIMITED
(b) Nationality : Indian
(c) Address : A-460 Ram Fashion Exports, TTC Industrial Area, MIDC,
Mahape, Navi Mumbai- 400710, Maharashtra, India

The following specification particularly describes the nature of the invention and the manner in which it is to be performed.
CROSS-REFERENCE
This application claims the benefit of priority to Indian Provisional Application No. 202321015171, filed on March 07, 2023, and subsequently post-dated to September 07, 2023, which is incorporated herein by reference.

TECHNICAL FIELD OF INVENTION
The present invention described herein, relates to a method of manufacturing a recycled composite material. More particularly, it pertains to a sustainable method of producing composite materials using waste materials discarded from the textiles, sports and other footwear industry, thereby solving environmental challenges of today's Globalized world.

BACKGROUND OF INVENTION
The number of products being produced for different applications every day is almost beyond measurement. Though each product serves a different purpose, all begin with the extraction of raw materials and move through subsequent phases such as production, transport to the point of sale, consumption and, finally, disposal. This series of phases makes up the life cycle of any product and each phase can harm our environment.
There is a wide range of footwear products currently available, which use an array of natural and synthetic raw materials and manufacturing processes. The extraction of these materials, as well as the emissions caused by manufacturing processes, are responsible for the environmental impact of footwear.
Single-use products have a high environmental impact due to their short use life, although as a product with a finite life span, more durable footwear also poses a problem in this regard.
At present, all these materials used in apparel, footwear, sports and lifestyle industry are landfilled towards end of their life, and there is no process currently to segregate and utilize them in footwear, apparel, accessory, automobile, and other industries.
In today's day and age we cannot go for unlimited production of material nor depend on our natural resources to constantly replenish, we must adapt a life which has circularity, if we observe the cycle of nature we see water evaporating, becoming clouds where it aids in weather and then comes to land as rain only to evaporate again and the cycle repeats, we also require a similar structure in our materials where we use fresh material to make something after use the waste is reused for a new purpose, after end of life a third purpose, in this way our consumption and waste to landfill will reduce by 60% overtime.
Therefore, considering the drawbacks and several other ongoing issues and challenges being faced on improper recycling of waste, dumping in landfills, incineration and non- conservation of resources, there is a need for innovation which uses all the dumped materials and puts them to a new use in form of a recycled and sustainable material used for making sustainable footwear and other uses for a greener planet.

The Present invention offers an effective solution by utilizing the waste materials for making sheets, that can be reused in footwear, apparel, accessory, automobile, and other industries.

OBJECT OF THE INVENTION
The primary object of the invention is to provide a method of manufacturing a recycled composite material.
Another object of the invention is to provide a sustainable composite material of a specific thickness using waste materials discarded from textile, sports and other footwear industry in a particular proportion.

SUMMARY OF THE INVENTION
The present invention discloses a method of manufacturing a recycled composite material from industrial waste, specifically targeting waste materials from the textile, sports, and footwear industries. This composite material is created by grinding waste materials into a fine powder, mixing them with a binding agent, aerating the mixture, and forming sheets of specific thickness. The resulting composite material can be used in various industries, including footwear, apparel, automotive, and accessories, thereby contributing to a sustainable and circular economy.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The nature and scope of the present invention will be better understood from the accompanying drawings, which are by way of illustration of a preferred embodiment and not by way of any sort of limitation. In the accompanying drawings:
Fig 1 illustrates grinded tennis balls, eva, sole, and other waste besides the final material in powdered form for use in the manufacturing of the composite material in accordance with an embodiment of the present invention;
Fig 2 illustrates of pair of slippers being made from the recycled composite material in accordance with an embodiment of the present invention;

DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a method of using waste materials from textiles, footwear, sports industry in a particular ratio to make a green composite material of various thickness which can be molded into a shoe, slippers, sliders and various other sustainable products with multiple applications.
The present invention utilizes various waste materials, including but not limited to EVA (Ethylene-Vinyl Acetate), Grinded sole material, Coffee powder, Tennis ball, Rubber along with other textile and footwear industry waste.
The manufacturing process of the recycled composite material involves following steps:
1. Material Preparation -
a) Sorting: Waste materials are sorted based on their type and composition.
b) Grinding: The sorted materials are ground into a fine powder with a particle size of approximately 100 microns. This consistent size is crucial for achieving a uniform final product

2. Mixing
a) The ground materials are mixed in specific proportions. For example:
• Coffee: 25 grams
• Rubber: 25 grams
• EVA: 25 grams
• Tennis ball outer material: 25 grams
b) This mixture is then combined with a bonding agent, such as Dunlop, in a 2:1 ratio (2 parts waste material to 1 part bonding agent).
c) The materials are thoroughly mixed using a rotator to ensure consistent distribution.

3. Aeration - Sufficient aeration is provided to the mixture using an aerator. This step helps in achieving the desired consistency and properties of the final material.

4. Spreading and Drying
a) Once the mixture achieves the desired consistency, it is evenly spread on a lining material. The lining can be made of hemp, textile, or cloth, depending on the intended application.
b) The spread mixture is left to dry for approximately 12-24 hours.

5. Bonding - The materials are bonded together at a temperature of approximately 220-260 degrees Celsius. This temperature range allows for proper melting and bonding of the various components.

The present invention allows for various combinations of waste materials, providing flexibility in the manufacturing process and the properties of the final product. Some possible combinations include:
1. EVA, coffee, tennis balls, rubber
2. Tennis ball outer material, EVA
3. Crushed sole, EVA, new waste material, t-shirt waste
4. Coffee, TPR (Thermoplastic Rubber)
5. Sugarcane molasses, EVA

In accordance to an aspect of the present invention, it important to note that the nature of the materials being mixed affects the final recycled composite material. Coffee powder with particles smaller than 100 microns cannot be made into a sheet on its own. It must be mixed with materials of heavier consistency, such as EVA with particles larger than 100 microns or tennis ball material.
Further, in accordance to an aspect of the present invention, For large-scale manufacturing, the invention employs specialized machinery for Sorting waste materials, Grinding materials to the required particle size, Rotating and mixing components, rolling the material to achieve various thicknesses, drying the final product

Applications
The recycled composite material produced by this method can be used in various applications, including but not limited to Footwear (shoes, slippers, sliders), Apparel, Accessories, Automobile industry components and other sustainable products
This invention addresses several environmental concerns namely reduction of waste sent to landfills, conservation of natural resources by reusing existing materials, decrease in the environmental impact of the footwear and textile industries and promotion of a circular economy model in manufacturing.
Further, the present invention utilizes waste materials that would otherwise be discarded, creates a sustainable, eco-friendly material, reduces dependency on virgin raw materials, offers versatility in material combinations, provides a solution for industries to manage their waste responsibly
The present invention has been designed as per Indian conditions as it is easily workable using the materials in a particular proportion and in any of the said combinations to achieve the desired output.
,CLAIMS:CLAIMS:
We claim:
1. A method of manufacturing a recycled composite material, comprising the steps of:
a. Sorting and grinding industrial waste materials, including EVA, ground soles, coffee powder, and tennis balls, into a fine powder with a particle size of approximately 100 microns;
b. Mixing the ground materials with a binding agent in a predetermined ratio using a rotating device to ensure uniform mixing;
c. Providing aeration to the mixture to facilitate proper bonding;
d. Spreading the mixed material onto a lining material and allowing it to dry for a specified duration;
e. Heating the dried composite material to a temperature range of 220 to 260 degrees Celsius to achieve bonding and form a composite sheet of desired thickness.
2. A method of manufacturing a recycled composite material as claimed in claim 1, wherein the predetermined ratio of waste materials to bonding agent is 2:1.
3. A method of manufacturing a recycled composite material as claimed in claim 1, wherein the bonding agent is Dunlop
4. A method of manufacturing a recycled composite material as claimed in claim 1, wherein the lining material is selected from the group consisting of hemp, textile, and cloth.
5. A method of manufacturing a recycled composite material as claimed in claim 1, wherein the material comprises a combination of EVA, coffee powder, rubber, and tennis balls, mixed with a binding agent.
6. A method of manufacturing a recycled composite material as claimed in claim 1, wherein the material is formed at a bonding temperature is between 220-260 degrees Celsius.
7. A method of manufacturing a recycled composite material as claimed in claim 1, wherein the composite material can be molded into footwear, apparel, accessories, and automotive components