EP1219231A2 - Bürstenmatte und ihre Herstellung - Google Patents

Bürstenmatte und ihre Herstellung Download PDF

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Publication number
EP1219231A2
EP1219231A2 EP20010304315 EP01304315A EP1219231A2 EP 1219231 A2 EP1219231 A2 EP 1219231A2 EP 20010304315 EP20010304315 EP 20010304315 EP 01304315 A EP01304315 A EP 01304315A EP 1219231 A2 EP1219231 A2 EP 1219231A2
Authority
EP
European Patent Office
Prior art keywords
plastic
layer
lengths
mesh fabric
assembly station
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20010304315
Other languages
English (en)
French (fr)
Inventor
Velayudhan Santhosh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Travancore Mats and Matting Co
Original Assignee
Travancore Mats and Matting Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Travancore Mats and Matting Co filed Critical Travancore Mats and Matting Co
Publication of EP1219231A2 publication Critical patent/EP1219231A2/de
Withdrawn legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L23/00—Cleaning footwear
    • A47L23/22—Devices or implements resting on the floor for removing mud, dirt, or dust from footwear
    • A47L23/26—Mats or gratings combined with brushes ; Mats
    • A47L23/266—Mats
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]

Definitions

  • This invention relates to the formation of a brush-type mat with lengths of fibrous materials embedded and extending up from a base layer of plastic, in which that base layer is essentially formed of a biodegradable plastic, the mat having superior physical and chemical characteristics.
  • Brush-type mats are well known, and are often used as doormats. They consist of a base layer of plastic into which are embedded the ends of tufts of fibrous material, portions of these tufts extending up from the base layer. Since such mats are generally used in applications where they are subjected to extremely rigorous conditions, they therefore must be capable of withstanding these conditions. Accordingly, in the past the base layer has usually been constituted of a cured plastic having appropriate physical and chemical characteristics, usually polyvinyl chloride or comparable material, into which the lengths of the fabric material forming the tufted portion of the mat are embedded. Those plastic materials, while generally satisfactory in terms of use, have a significant drawback which has recently become relatively critical, to wit, they are not biodegradable.
  • Non-biodegradable curable plastics are, of course, known, but their use in mats of the type under discussion has been contra-indicated because they have not in the past produced mats of adequate physical characteristics, in particular being deficient in the strength with which the tufted lengths of fibrous materials are reliably retained within the plastic layer and the resistance of the mats to tearing or the like.
  • the layer which forms the base of the mat is constituted by a layer of biodegradable plastic material such as rubber, preferably to a large degree natural rubber, which is reinforced by a mesh cloth embedded therein prior to the insertion of the lengths of fibrous material thereinto, that mesh cloth preferably being coated with the plastic, as by being dipped thereinto, before reaching and becoming embedded in that plastic layer.
  • the thus assembled combination of plastic backing layer, mesh cloth and upstanding lengths of fibrous material is then subjected to plastic curing in order to produce the desired mat material.
  • the lengths of fibrous material preferably are formed of coir yarn, as has long been the case.
  • the mesh cloth is preferably formed of jute or cotton.
  • the fibrous material generally designated 2 which will form the tufts of the mat are preferably constituted by coir yarn, the fibers being extracted from the husks of coconuts, cleaned and then spun by hand or machine to form yarn. That yarn is provided in a plurality of rolls 4. Many lengths of yarn 2 are unwound from the equally numerous rolls 4 and fed over roller 6 to an assembly station 8 of known construction and operation, the continuous yarn lengths 2 at this assembly station 8 being cut into short lengths which eventually become the tufts of the mat.
  • a mesh cloth is provided on a roller 12. That cloth is in mesh form so as to facilitate its incorporation into the end product and to better receive the inserted fibrous tufts. It has a width generally the same as the width of the mat to be produced. It passes from the roller 12 over a roller 14, into a bath 16 of appropriate uncured and soft plastic material and then through rollers 18 which serve to feed the cloth 10 under roller 20 and to the leading end of a driven Teflon conveyor belt 22 forming a part of the assembly station 8.
  • the plastic feeding mechanism generally designated 24, schematically shown in Fig. 4. It comprises a head 26 slidable back and forth on rod 28 and driven back and forth by rotated screw 30.
  • the head 26 has a nozzle 32 directed downwardly towards the upper reach of the Teflon belt 22 and is connected by conduit 34 and pump (not shown) to a suitable source of uncured plastic.
  • the head 26, when moved back and forth over the Teflon belt 22 while uncured plastic is being pumped out therefrom, forms on the Teflon belt 22 a layer of uncured plastic material having an appreciable thickness such as 4-8 mm, depending on the desired pulling strength and pile height of the end product, into which layer the mesh cloth 10 is embedded.
  • an appreciable thickness such as 4-8 mm
  • the vertical portion 8A of the assembly station 8 which is adapted to receive the fibrous material 2 and cut that fibrous material, as it is fed therethrough into short lengths the size of which is determined by the desired thickness of the mat to be produced.
  • Those short lengths of fibrous material are, at the assembly station 8, oriented vertically and pushed down so that their lower ends become embedded in the plastic layer formed by the head 26 into which the mesh fabric 10 is embedded.
  • the mesh cloth 10 is applied to the Teflon belt 22 before it reaches the plastic feeding mechanism 24, so that the plastic is poured evenly onto the mesh cloth 10 to form the plastic base layer with the mesh cloth 10 embedded therein. The thickness of that plastic layer is maintained relatively constant by means of a doctor blade included in the assembly station 8.
  • a continuous embryonic mat is produced consisting of a continuous layer of uncured plastic stabilized and strengthened by the mesh fabric 10 with a substantially continuous series of tufts of fibrous material extending up therefrom. That embryonic mat is then subjected to a treatment such as a heating treatment in order to cure the plastic and thus produce the finished product. As here disclosed, that cure is accomplished in two stages.
  • the Teflon belt 22 extends for an appreciable distance from the vertical portion 8A of the assembly station 8, is provided with an internal heat source (not shown) and may be provided with a cover 36 to define at least a preliminary heat treatment or vulcanizing chamber through which the continuous embryonic mat, when it leaves the assembly station, slowly passes. That may, for example, involve travel of 10 meters at a temperature of about 160° C. This will usually not completely cure the resin but will sufficiently cure it so that it will readily release from the Teflon belt 22.
  • This semi-cured matting is fed onto a second conveyor belt 36 which may be formed of stainless steel. It too is provided with heating means (not shown), and as the mat moves along with the belt 36 its curing is completed.
  • the belt 36 may be approximately 30 meters in length, the temperature to which the matting is subjected may be about 160° C. and the matting may move along with the belt 36 for approximately 45 minutes.
  • the finally cured matting thus produced, generally designated 38, is wound up on a reel 40, ready for cutting and shearing, as is conventional.
  • the plastic material in the bath 16 and the plastic material fed onto the Teflon belt 22 and the mesh cloth 10 are preferably the same. As indicated above, it is important that the composition of the plastic material be biodegradable.
  • a preferred biodegradable material is rubber latex and in particular, but not exclusively, natural rubber latex, combined with the usual and known compounding agents such as accelerators, vulcanizing agents, activators, and coloring agents.
  • One particular formulation which has produced good results is as follows, the wet weights being set forth in the proportions to produce 100 kilograms of material: Wet Wt. 1. Styrene Butadiene Rubber latex (SBR) (50% dry rubber compound) 10.00 kg 2. Natural rubber latex (50% dry rubber compound) 40.00 kg 3.
  • An alternative and particularly preferred formulation is as follows: Wet Wt. 1. SBR or Styrene Butadiene Rubber latex (50% dry rubber) plus or minus 10% 3.00 kg 2. Natural rubber latex (53% dry rubber content) 60.00 kg 3. Emulsion MC140 strength 35% (poly Vinyl acetate emulsion)(VA) 20.00 kg 4. 10% Ammoniated oleate (stabilizer) or an alternate stabilizer 4.00 kg 5. Fungicide (Phenolic based anti fungal) 0.06 kg 6. Sulphur (Vulcanizing agent) (Rubber grade 50% dispersion) 2.00 kg 7. ZDC (Zinc Diethyl Dithiocarbonate) (50% dispersion) (Accelerator to increase speed of vulcanization) 2.00 kg 8. Zinc Oxide (40% dispersion) (Activator) 0.80 kg 9. Saturated ammonium chloride solution 30% 0.20 kg 10. Ammoniated water (5%) 10.00 kg 11. Pigment as required for color
  • the proportions of all of the elements may be varied, and in particular the proportions of the first four elements may be varied by plus or minus 10%.
  • Other biodegradable plastics may be substituted, in particular in place of the polyvinyl acetate.
  • the disclosed specific formulation is primarily natural rubber to which a minor amount of synthetic rubber has been added to improve the physical characteristics of the end product, which is also the case with respect to the polyvinyl acetate and stabilizer, but those elements and may be omitted or provided in somewhat different proportions, and other biodegradable plastics may be substituted for them.
  • the sulphur, ZDC and zinc oxide are ball milled and set aside.
  • the polyvinyl acetate emulsion is mixed with the ammoniate water, after which the stabilizer, fungicide and pigment are added and mixing continues. After those materials are thoroughly mixed the rubber latex and the previously mixed sulphur, ZDC and zinc oxide are added, mixing continues, and finally the other compounds are mixed into the overall composition, after which that composition is ready for feeding through the feeding mechanism 24.
  • the thus constituted mats, after curing the plastic, are particularly well suited for strenuous use, for example, as a door mat, because the tough fibrous tufts which extend up from the plastic base are retained in that base with a reliability (pulling strength) exceeding that characteristic of prior art mats using a conventional polyvinyl chloride plastic, while the plastic backing itself exhibits improved stability and tearing strength when compared with the prior art.
  • This is due to a large degree to the reinforcement of that plastic layer by the cloth 10, the mesh nature of which not only facilitates its embedment in the plastic layer but also facilitates lengthwise insertion of ends of the tufting material 2 into the plastic layer for retention therein.
  • the mats of the present invention are biodegradable.

Landscapes

  • Laminated Bodies (AREA)
EP20010304315 2000-12-27 2001-05-15 Bürstenmatte und ihre Herstellung Withdrawn EP1219231A2 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US748460 2000-12-27
US09/748,460 US20020119716A1 (en) 2000-12-27 2000-12-27 Method of making a brush-type mat and the mat produced thereby

Publications (1)

Publication Number Publication Date
EP1219231A2 true EP1219231A2 (de) 2002-07-03

Family

ID=25009538

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20010304315 Withdrawn EP1219231A2 (de) 2000-12-27 2001-05-15 Bürstenmatte und ihre Herstellung

Country Status (2)

Country Link
US (1) US20020119716A1 (de)
EP (1) EP1219231A2 (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1293160A2 (de) 2002-09-25 2003-03-19 Travancore Mats & Matting Co. Bürstenmatte und ihre Herstellung
WO2005055770A1 (en) * 2003-12-12 2005-06-23 Prasad Arun Coir fibre tufting machine

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004031501A1 (en) 2002-10-01 2004-04-15 Dodge-Regupol, Incorporated Noise and vibration mitigating mat
US20060244187A1 (en) 2005-05-02 2006-11-02 Downey Paul C Vibration damper
CN100534262C (zh) * 2005-09-16 2009-08-26 富葵精密组件(深圳)有限公司 膜孔形成装置及方法
WO2013136341A1 (en) 2012-03-16 2013-09-19 Prasad Arun A coir mat, a method for making the coir and an apparatus for making the coir mat
JP6386791B2 (ja) * 2014-05-21 2018-09-05 クリーンテックス・ジャパン株式会社 マット及びマットの製造方法
US20180202150A1 (en) 2015-06-25 2018-07-19 Pliteq Inc. Impact damping mat, equipment accessory and flooring system
CA3005384C (en) 2015-06-25 2020-09-22 Pliteq Inc. Impact damping mat, equipment accessory and flooring system
EP3935932A1 (de) * 2020-07-07 2022-01-12 Andreas Stihl AG & Co. KG Schneidmesser für einen schneidkopf und schneidkopf für eine motorsense
US20260033701A1 (en) * 2022-08-29 2026-02-05 Sharun Padinjareveettil VARGHESE A rubber base mat with coir fibres and a method of manufacturing thereof

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1293160A2 (de) 2002-09-25 2003-03-19 Travancore Mats & Matting Co. Bürstenmatte und ihre Herstellung
EP1293160A3 (de) * 2002-09-25 2004-07-07 Travancore Mats & Matting Co. Bürstenmatte und ihre Herstellung
WO2005055770A1 (en) * 2003-12-12 2005-06-23 Prasad Arun Coir fibre tufting machine

Also Published As

Publication number Publication date
US20020119716A1 (en) 2002-08-29

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