TITLE OF THE INVENTION
COIR SHOE INSOLE

BACK GROUND OF THE INVENTION

Present in invention relates to coir shoe insole, completely an eco friendly product with specific feature of pedicure and acupressure action, It will massage the user's feet when walking or running ,and also reduce the pressure of the user's feet.

In walking feet must bear a burden of 0.8.about. 1.2 times of the body. Since the reaction force of the foot from the ground is applied on the palm or arch of the foot sole, knee or backbone, it is generally advisable to insert insoles within a pair of shoes to absorb the shock of the foot, thereby avoiding the sole problem caused due to long term impact of the foot against the ground during walking. Furthermore or in other words, it can be say that, due the effect of walking , 100 % of the body weight will move down on the heel and continues to the outer border, crosses the ball of the foot to the big toe joint and moves forward to spring off the toes. While stand still, 50% of body weight is on the heel, 25% weight concentrated at the base of the big toe joint and 25% spread across the ball of the foot. In long term, the weight pressure on to the foot will cause the risk of damage to our body joints and spinal column. Hence suitable type of insoles within a pair of shoes cannot be discarded.

Recently public are much concern about the health benefits from their daily wearing apparels due to the skin allergies and other health issues were being common, shoe in particular, is one of the necessary and primary wearing apparel, Hence, necessity for a healthy shoe insoles Most of the shoe insoles available on market are made of materials such as TPR (Thermoplastic-Rubber), PU (Polyurethane), and MCR (microcellular rubber) etc but such material shoe insoles have lots of demerits, longer use of those materials may cause skin problem or other health issues. A conventional plane leather-made insole for shoes only provides cushioning characteristics, which does not have sufficient performance on shock and impact absorbing. U.S.Pat. No. 7,140,126 disclosed a plastic insole, which improves the disadvantages of the conventional plane insoles and can be just placed into a shoe. The conventional insole takes advantages of elastic property and softness of plastic material (e.g. silicon) for absorbing shocks and impacts during walking, so as to achieve foot protection and comfort. The reason why the soft plastic insoles are so popular is that they can be fabricated thin enough to be placed inside the shoes.

However, the shock absorbing property of the soft plastic insole has a disadvantage. Because the soft plastic insole has a damping effect, a user requires a more strenuous effort to walk, and thereby he/she easily got muscle fatigue. Moreover, die soft plastic insole is too soft to provide a

sufficient elasticity, and thus the impact resistance is relatively low.

All Shoe insoles initially have functioned to protect user's feet from body weight or to function as foot supporting surface or to give flexible action to the feet ,but none of these soles were concern concern about the material of manufacture. Most of the manufacturing materials are highly chemically processed therefore long course of use such material is not safe for the health. Hence the probabilities of side effects are lot.

The leather manufacture is one of the oldest, traditional based process continually adopted in our country to enable develop the materials acceptable to meet the standards and specification for its application in the leather products industries. In the past, the leather was being considered as the only option as a material for its versatile applications in the fabrication of leather based products. It is a known fact that the shortage of leather and its costing factor would not any more meet the real need and demand of the emerging industries involving in the production of leather product for domestic as well as international markets. The present situation reveals that the composition of leather in the products is minimal and there are alternate materials such as polymers, rubbers and green materials becoming dominant as well as prominent for applications in footwear and leather goods/garment industries.

Keeping in view of this situation, the material coir being natural in its characteristics has been identified as the material of potential usage in footwear industry. The coir is a by-product from coconut industry and is considered to be a major renewable resource for better utility. In this study, the exploring of coir as a composite material is being proposed. The ingredients for the composition of coir for the development of usable product would be identified in the Research and Development applications. It has been planned to carry out the experimental methods within the facilities available at CLRI and also prefer to seek the guidance and support from the industries mainly engaging in the development of coir based composite materials for versatile applications. Once, the composite materials developed would be evaluated in the testing laboratory and the materials meeting the physical parameters for footwear would be suggested for applications as a component in the assembly of footwear. The advantages expected are the abundance of materials resources, affordable at low price, value addition and as a new material for footwear industry.

Accordingly it is an object of the present invention to overcome or ameliorate the disadvantages of the prior art. It is also an object of the present invention to provide alternative structures which are less cumbersome in assembly and operation and which moreover can be made relatively inexpensively. Alternatively it is an object of the invention to at least provide die public with a useful choice.

SUMMARY OF THE INVENTION

This present invention relates to coir shoe insole, and process there, the novel advantages of the said coir insole are namely complete eco friendly, skin friendly ,non allergic ^providing pedicure action, comfortable feeling while walking , high breathing capacity, 100% water desorption, perspiration absorbing, salt water resistance, Anti fungal and Anti bacterial, thermo regulatory, long lasting and bio degradable capacity ;the process of the said coir insole consist of rope untwisting, then untwisted rope sent to rubberized coir machine, where latex sprayed during the process .after that sheet collect from the machine and keep under a hot pressing machine at 1.7kg for 10 minutes and dried at open atmosphere for 30 minutes finally sheet cut as required shape for foot wear

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Coir is a natural fibre extracted from the husk of coconut, the products generally made out of coir fiber are floor mats, doormats, brushes, mattresses, etc. Coir is the fibrous material found between the hard, internal shell and the outer coat of a coconut. Other uses of brown coir (made from ripe coconut) are in upholstery padding, sacking and horticulture.

Coir fibers are categorized in two ways. One distinction is based on whether they are recovered from ripe or immature coconut husks. The husks of fully ripened coconuts yield brown coir. Strong and highly resistant to abrasion, its method of processing also protects it from the damaging ultraviolet component of sunlight. Dark brown in color, it is used primarily in bmshes, floor mats, and upholstery padding. On the other hand, white coir comes from the husks of coconuts harvested shortly before they ripen. Actually light brown or white in color, this fiber is softer and less strong than brown coir. It is usually spun into yarn, which may be woven into mats or twisted into twine or rope.

Coir fibres are found between the hard, internal shell and the outer coat of a coconut. The individual fibre cells are narrow and hollow, with thick walls made of cellulose. They are pale when immature, but later become hardened and yellowed as a layer of lignin is deposited on their walls. Each cell is about 1 mm (0.04 in) long and 10 to 20 jam (0.0004 to 0.0008 in) in diameter.Fibres are typically 10 to 30 centimetres (4 to 12 in) long. Brown coir harvested from fully ripened coconuts is thick, strong and has high abrasion resistance. Mature brown coir fibres contain more lignin and less cellulose than fibres such as flax and cotton, so are stronger but less flexible. The coir fibre is relatively waterproof, and is one of the few natural fibres resistant to damage by saltwater. Fresh water is used to process brown coir.

Processing:Green coconuts, harvested after about six to 12 months on the palm, contain pliable white fibres. Brown fibre is obtained by harvesting fully mature coconuts when the nutritious layer surrounding the seed is ready to be processed into copra and desiccated coconut. The fibrous layer of the fruit is then separated from the hard shell (manually) by driving the fruit down onto a spike to split it (dehusking).

Brown Fibre: the fibrous husks are soaked in pits or in nets in a slow-moving body of water to swell and soften the fibres. The long bristle fibres are separated from the shorter mattress fibres underneath the skin of the nut, a process known as wet-milling. The mattress fibres are sifted to remove dirt and other rubbish, dried in the sun and packed into bales. Some mattress fibre is allowed to retain more moisture so it retains its elasticity for twisted fibre production. The coir fibre is elastic enough to twist without breaking and it holds a curl as though permanently waved. Twisting is done by simply making a rope of the hank of fibre and twisting it using a machine or by hand. The longer bristle fibre is washed in clean water and then dried before being tied into bundles or hanks. It may then be cleaned and 'hackled' by steel combs to straighten the fibres and remove any shorter fibre pieces

Coir is a versatile hard fiber obtained from the husks of coconut. The coir fiber is one of the hardest natural fibers because of its high content of lignin; coir is must more advantageous in different application for erosion control, reinforcement and stabilization of soil and is preferred to any other natural fibres. The fibre is a hygroscope, with moisture content of 10% to 12% at 65% humidity and 22% to 55% at 95% relative humidity. Of all natural fibers coir processes the greatest tearing strength, retained as such even in very wet conditions. The physical appearance and quality of the fibres varies widely. The color of the fibre is not only influenced by the species of the nut from which it is derived but also its maturity, time lapse between dehusking and retting ect. However under identical conditions of these variables, the fiber extracted from infant nuts exhibit a pale yellow color. The intensity of color and thickness increase with age and the fibres are remarkably stiff and posses good extensibility.

Morphologically, coir is a multi cellular fibre with 12 to 24 microns in diameter and the ratio of length to Thickness is observed to be 35. Cells of the fibre surface are occasionally covered with the silicised stigmata. The chemical constituents have found to be cellulose, lignin, hemi cellulose and pectin. The percentage of the ingredients in the fibre is largely governed by the age of the nut from which it is derived. Cellulose and lignin are the major constituents and higher lignin content makes the fiber stiffer and tougher.

Chemical Compound Description of coir shoe insole boards Natural latex

Natural latex is the most important product obtained from latex; more than 12,000 plant species yield latex containing rubber, though in the vast majority of those species the rubber is not suitable for commercial use.

TQ

• Tq means (Rubber Antioxident TMQ (Tq)

• Its toxicity is light, pollution is low, fine solution with rubber.

• Rubberized coir industry used in fire proof and dampproof chemical

• Tq particular excellent kinds of general purpose ammonia anti-ageing agent Apperance:

• Amber to browns flake or granular initial M.P (Min) 80-100

• Loss on drying (Max ) % 0.30

• Rubberized coir is a versatile products used largely as a expensive substitute cushioning material for foam rubber in furniture, upholstery, mattresses.

ZINC OXIDE

• Zinc Oxide is an in organic compound with the formula ZnO,

• Zinc Oxide is a white powder that is in soluble in water,

• Rubber manufacture between 50% and 60 % of ZnO use it's the rubber industry

• Mainly vulcanization of rubber ZnO additive also protect rubber from fungi.

• It is good transparency and strong room temperature.

ZDC

• ZDC off white powder

• ZDC ( Zinc diethyl dithiocarbamate

• This product is insoluble in water

• It has a rapid vulcanization rate, used with accelerant TMTD, DM Prevulcanization in inbitor or anti ager mb. Can improve the storage performances of rubber materials.

• It is a general super speed accelerant for natural rubber, synthetic rubber and latex.

SULFAR

• Lemon yellow ( Sulphur or sulfur)

• Sulphur elemental Sulphur is the most widely used vulcanization agent in the rubber industry.

• Vulcanization is a natural durable materials via the addition of sulfur.

• Fiber cross linking introduced by vulcanization prevents the polymer chains from moving independently.

• Cross links with higher number of sulpur atoms give the rubber good dynamic properties but less heat resistances.

• Dynamic properties are important for flexing movements of the rubber.

R.OIL

• R.oil means rubber oil latex manufacturing process

• The useful properties of the rubber seed oil make it similar to well - known linseed and soybean oil.

• Specially developed for providing properties of facilitate mixing operation, reducing compounding time and improving processibility of rubber.

• Latex mixing very important r.oil.

CHINA CLAY

• China clay (Kaolinite)

• Color white and power form

• Kaolinite has a low shrink - swell capacity and a low cation- ex change capacity.

• It is a soft, earthy usually white mineral

• For modifying the properties of rubber upon vulcanization, in adhesives to modify rhedlogy.

• China clay is incorporated into both natural and synthetic rubber compounds and is the rubber industry most widely used non-black filler with reinforcing propertices, cable insu!ations,generalmoulding,latex.

• The basic and conventional ingredients for latex compound are Sulphur.Zinc, Oxide and ZDC a part from these material we may require stabilizers,antioxidants,Plasticizers, extenders,fillers, modifiers etc....

M.OH

• M.Oil is latex mixing compound chemical.

MATERIALS AND METHOD

Preparation of Composite

Coir rope untwisted by untwisted machine, the untwisted coir fibre directly sent to a rubberized coir machine, after that composite sheet will collect from the machine and keep sheet under a hot pressing machine at 1.7kg for 10 minutes then dried at open atmosphere for 30 minutes. Finally the sheet cut as required shape for foot wear.

SPECIFICATION OF SHEET FORMING UNIT

1. Set air pressure at latex for 1.5-2bar

2. Feed curled fibre in to the plant

3. Adjust vertical feeder according to the process size as per customer order like 40" 46" and 51"

4. Latex spray is done by automatic pneumatic control. If is adjusted as per customer size and quality requirement.

Coir shoe insole boards testing results

From the results obtained, the characteristics of the coir sheets have been studied in detailed manner and the pros & cons have been discussed in the report. The deliberations on the results obtained on the properties would help us to understand the potential usage of die coir composite material in footwear industry.

FLEXING INDEX

In the table, the flexing index value for the coir and texon are furnished. The flexing index is improved in the case of coir that of texon.

TENSILE STRENGTH AND ELONGATION %

Tensile strength is lesser for coir when compared with the texon. But the elongation percentage value shows higher value.

WATER ABSORPTION & DESORPTION %

Water absorption is very less which is very advantageous and the desorption percentage is high

SCUFF RESISTANCE

Scuff resistance is relatively lesser for coir when compared with texon.

COMPRESSION SET

Compression set is strong and good.

STITCH TEAR STRENGHT

For both coir and texon, stitch tear strength is relatively equal.

RESISTANCE TO PEELING

The resistance to peeling is equal for both coir and texon.

CLAIMS

I claim: .

1 A newfangled coir shoe insole , characterized complete eco friendly, skin friendly ,non allergic .providing pedicure action, high breathing capacity, 100% water desorption, perspiration absorbing, salt water resistance, Anti fungal and Anti bacterial, thermo regulatory, long lasting ,bio degradable capacity and comfortable feeling while walking

2 The shoe insole as clamed in claiml, characterized in that said pedicure action means, feet support portion of the insole or the upper surface of the insole form in coarse nature therefore the abrasive character of the heal supporting surface helps to getting rid of the flaky and dry dead skin cells from bottom of the feet, leaving them smoother and pristine condition, the exfoliation process also helps to rejuvenate the feet by opening up the pores of your skin to increase blood circulation.

3 The shoe insole as claimed in claim 1 wherein has good absorption of 54% desorption of 100%,this property is very important in maintaining food comfort by absorbing perspiration.

4 The shoe insole as clamed in claiml.characterized in that said thermo regulatory means ,it helps to regulate the temperature around the feet, the rugged portion of the said shoe insole gives gentile massage and light pressure to the feet while walking ,the acupressure or reflexology points directly correspond to different areas of the body, through light pressure and die friction of walking activate those nerve endings and send healing relief throughout the body including the temperature maintenance around the feet under different weather atmosphere ,the said insole ultimately provide an invigorate result.

5 The shoe insole as clamed in claiml, wherein has a very high natural breathing property as it is pours in nature.

6 The shoe insole as clamed in claiml, wherein made of palm fiber material which gives a natural feel while in worn, unlike other cushion material insoles its elasticity nature does not loses even after long term of use.

7 The shoe insole as clamed in claimlwherein 100% bio-degradable and can be composted even after extensive uses.

8 The shoe insole as clamed in claimlwherein have advantage anti bacterial and anti fungal, it helps to fight and heal foot type fungus such as athlete's foot, also shoes will stay odor free

9 The shoe insole as claimed in claim 1, wherein have the other characters like long lasting , salt water resistance and light weight, the coir fibre is relatively waterproof. and is one of the few natural fibres resistant to damage by saltwater.

10 The shoe insole as claimed in claim lwherein tensile strength is lesser compared with texon but the elongation period is higher value.

11 The shoe insole as claimed in claim 1, wherein include an Innovative process method which comprises following steps: a)rope untwisting) Rubberized coir m/c (Mixing of chemical latex two side spraying, Rubberized coir m/c (Mixing of chemical latex two side spraying, increasing in the composition latex softness is more),c) Wave scale,d) Hot pressing (10 min),e)half hrs cooling,f)Cutting (measurement of the coir sheet cut),g)platting,h)(80 c heat and pressure 200 in both side plating),the said process could be more clearly specify as ,Rope untwisted by untwisted machine, the untwisted coir fibre directly sent to a rubberized coir machine, after that composite sheet collect from the machine, weighed and calculates the gram square meter of Sheet, then the sheet keep under a hot pressing machine at 1.7kg for 10 minutes and dried at open atmosphere for 30 minutes, finally sheet cuts as required shapes for foot wear.