FIELD OF INVENTION
This invention relates to compact PVC tufting machaine to produce small mats. The
mats are particularly PVC backed non woven mats of any size.
PRIOR ART
PVC tufting machinery is as such known in the art. Mr. Aboobacker Koya of M/s.
Wheels Free, Kozhikode, Kerala was the person to introduce coir tufting in India, and
the first machine manufactured by M/s. Wheels Free started production in Alleppey in
1991. Thereafter, only a few exporters had imported PVC Tufting Machinery costing
about Rs. 30 million per unit.
Prof. Goplalan Balachandran, presently Chairman, Coir Board since 15th February,
2012, residing at Convent Square, Alappuzha, Kerala - 688 012, has carried out in-
depth study to invent a mini tufting machine and entrusted with Mr. Koya to
manufacture a mini coir tufting machine with suitable modifications in the design of
the known art considering the difficulties faced by micro, small and medium
entrepreneurs for setting up such units.
Now, reference may be made to fig. 1 indicating conventional PVC tufting machine,
which can be used for production of 2 meter width mat only.
Major part of the production constitutes cut mats of maximum width of 50 cm,
wherein 2 meter width mat is slitted followed by cutting to get door mats of small size.
The available tufting machine is quite expensive and also very big and heavy.
Therefore, it requires more space for accommodating the machine. Again, it requires
more raw materials and involves more wastage of the material. Hence, it is not
affordable for small production units.
Hence, the present invention proposes a mini PVC tufting machine, which is quite cost
effective as compared to the prior art and also efficient.
OBJECTS OF THE INVENTION
Primary object of the present invention is to provide compact PVC tufting machine to
produce small mats which overcomes disadvantages associated with the prior art.

Another object of the present invention is to provide compact PVC tufting
machine to produce small sized mats which is simple in construction.
Yet another object of the present invention is to reduce the wastage
significantly associated with the prior art.
Further object of the present invention is to provide compact PVC tufting
machine to produce small sized mats which is efficient and reliable.
SUMMARY OF THE INVENTION
According to the present invention, the compact PVC tufting machine functions
with automatic shearing blades moving up and down operated with least power
consumption. The two ply yarn/single ply yarn is wound on a bobbing/creel
arrangement stand. The mini tufting machine draws yarn with the help of a
pair of rolls running at uniform speed, and feeds into a pair of rolls which
intermittently feeds required length of coir yarn depending on the pile height.
At the end of each feeding movement, the top knife cuts the yarn and pushed
into a curved chute to feed the piles over the conveyor running, at required
speed below the chute. PVC mix is spread onto the conveyor, at the starting
point and spread over the conveyor at required uniform thickness by a doctor
blade.
The yarns coming out of the chute are pressed into the PVC coating, and these
piles embedded in the PVC coating slowly moves with the belt like a mat, which
is heated by the heating panels below the conveyor. After traveling for required
length with a speed, the PVC gets cured followed by cooling of mat by
circulation of water at room temperature. Then this mat is rolled in a rolling
machine, which is cut to required size into door mats.
A specially designed thermic fluid wood fired heater circulates the hot thermic
fluid into the heating panels.

An electrically operated belt aligner controls the belt.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Further objects and advantages of this invention will be more apparent from
the ensuing description when read in conjunction with the accompanying
drawings of exemplary embodiments of invention and wherein:
Fig. 1 shows: Conventional PVC tufting machine.
Fig. 2 shows: Compact PVC tufting machine according to the present
invention.
DETAIL DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE
ACCOMPANYING DRAWINGS
The present invention discloses a compact PVC tufting machine to produce
mats particularly of small size. The mats are PVC backed nonwoven mats of
different length according to the customer's choice.
In this regard, reference may be made to fig. 2. A plurality of coir spools (10)
are loaded in a creel stand (6). Multitude of yarn draw rolls of cutting head (8)
rotating at uniform speed draw the coir yarn through a distribution plate (9)
into the cutting head and feed the same into the yarn feeding rolls.
Multiple yarn feeding rolls of the cutting head (8) rotate intermittently to feed
yarn of required length over the cutting head chute. The length of yarn depends
on pile height.
The tufting unit of invention comprises a conveyor frame (1) with a control
valve (13): A yarn feed gear box (12) is also provided with the tufting unit.

The cutting head has one fixed blade fitted to the bottom knife holder and a --
moving blade fitted to reciprocating top knife holder of rotating assembly. When
the feed rolls complete the feeding, the top knife moves against the bottom
knife, and yarns are cut into piles and fed into the chute. Further movement of
top knife pushes the cut piles into the chute. The cut piles coming out of the
chute, enter the conveyor belt (11), over the PVC coating, in the form of a mat.
They are then pressed into the PVC film spread over the conveyor by a pressing
bar operated by the rotating assembly.
The PVC mix is spread onto the conveyor from the mixing vats by gravity, and
passes below a doctor blade, adjusted to get the required thickness for the PVC
film. When the PVC film passes below the chute, the yarn is pressed into the
PVC film by the pressing bar as explained. The cut piles in the form of a mat
embedded in PVC mix move over a plurality of heating panels (2) mounted
under the conveyor belt.
The conveyor belt is for example: Teflon coated synthetic belt, which is suitable
for the working temperature of 170 to 200°C. After moving for a length over
heating panels, the PVC mix is fully plasticized, and then cooled, by passing
over a length of cooling panels cooled by water circulation.
At other end, there is a head drum (3) together with head drum support (4) and
head drum adjust (5).
The mat produced is rolled in a rolling machine (7). The rolls are removed from
the rolling machine when it reaches required length.
This mat is cut into different length and width to obtain door mats. This mat
can be finished by shearing followed by stenciling/flocking.

A wood fired thermic fluid heater speeially destgned to snit the fufting unit ot
invention, which circulates the thermic fluid of temperature of about 200°C
into the heating panels. Thermic fluid of temperature of about 170°C returns to
the thermic fluid heater for re-circulation.
As indicated in the figure, an electro mechanical belt aligner (14) is provided so
as to control the belt.
PVC Mixer:- PVC mix is prepared in portable vats, using PVC mixer. A number
of vats are required for running one shift of 8 hours. Electrical motor driven
agitator is fitted on a frame vertically. The vat is kept below the agitator. The
agitator can move up and down with the help of a handle for thorough mixing.
The PVC mix comprises of PVC (Poly Vinyl Chloride), DOP (Diociylpthalate),
Stabilizer, Filler (Dolomite or Lime Stone) and Dye in the required ratio.
To prepare PVC mix, DOP is mixed with dye. This is followed by addition of PVC
resin slowly. Thereafter, filler is added slowly to mix while mixing temperature
should not exceed 40°C.
Advantageous features
- Compact
- Cost effective
- Involves much less wastage as compared to prior art.
- Requires fewer raw materials.
- Faster processing.
It is to be noted that the present invention is susceptible to modifications,
adaptations and changes by those skilled in the art. Such variant embodiments
employing the concepts and features of this invention are intended to be within
the scope of the present invention, which is further set forth under the
following claims:-

We Claim;
1. A compact PVC tufting unit to produce mats particularly of small size
comprising a cutting head to feed yarn into chute, cut plies of yarn from
which enter a conveyor belt with PVC film.
2. A compact PVC tufting unit to produce mats particularly of small size as
claimed in claim 1 wherein the cutting head, multiple yarn draw rolls of
which draw coir yarn through a distribution plate into the cutting head
and feed the same into a plurality of yarn feeding rolls of said cutting
head.
3. A compact PVC tufting unit to produce mats particularly of small size as
claimed in claim 1 or 2 wherein said yarn feeding rolls rotating
intermittently to feed yarn of required length over the cutting head chute.
4. A compact PVC tufting unit to produce mats particularly of small size as
claimed in any of the preceding claims wherein the cutting head
comprises a fixed blade Fitted to bottom knife holder and a moving blade
fitted to reciprocating top knife holder of rotating assembly in which the
top knife moves against the bottom knife to cut the yarns into piles,
which are fed into the chute.
5. A compact PVC tufting unit to produce mats particularly of small size as
claimed in any of the preceding claims wherein the cut piles in the form
of a mat are pressed into the PVC film over the conveyor by means of a
pressing bar operated by the rotating assembly.

6. A compact PVC tufting unit to produce mats particularly of small size as
claimed in any of the preceding claims wherein the PVC mix onto the
conveyor passes below a doctor blade for required thickness of the PVC
film.
7. A compact PVC tufting unit to produce mats particularly of small size as
claimed in any of the preceding claims wherein multitude of heating
panels are placed under the conveyor belt for heating the cut piles
embedded in PVC mix, wherein the PVC coated cut piles pass over a
plurality of cooling panels cooled by water circulation and a rolling
machine is provided at one end for rolling the cooled mat.
8. A compact PVC tufting unit to produce mats particularly of small size as
claimed in any of the preceding claims comprising a thermic fluid heater
to circulate the thermic fluid to the heating panels, and a belt aligner to
control the belt.
9. A compact PVC tufting unit to produce mats particularly of small size as
claimed in any of the preceding claims wherein the PVC mix comprising
of PVC (Poly Vinyl Chloride), DOP (Diociylpthalate), Stabilizer, Filler
(Dolomite or Lime Stone) and dye in the required ratio.
10. A compact PVC tufting unit to produce mats particularly of small
size as claimed in any of the preceding claims is associated with the
advantageous features such as herein described.