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Patent Searching and Data


Title:
BRUSH MATS
Document Type and Number:
WIPO Patent Application WO/2005/103364
Kind Code:
A1
Abstract:
Brush mats with non-skid base comprising encasing a brush mat with flat base and bristled top surface within two vulcanisable rubber sheets made from rubber composition such as herein described, having a viscosity range of 40 to 70 at 100°C, the said encased brush mat within a mould being provided with sleeve cutting edges around its periphery.

Inventors:
VELIYIL VELAYUDHAN PAVITHRAN (IN)
Application Number:
PCT/IN2004/000114
Publication Date:
November 03, 2005
Filing Date:
April 23, 2004
Export Citation:
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Assignee:
VELIYIL VELAYUDHAN PAVITHRAN (IN)
International Classes:
A47L23/26; B32B25/10; D03D25/00; D06N3/00; (IPC1-7): D06N3/00; D03D25/00
Foreign References:
EP1293160A22003-03-19
GB761730A1956-11-21
Attorney, Agent or Firm:
Harikrishnan R. (80 ft Main Road 6th Bloc, Koramangala Bangalore 5, IN)
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Description:
BRUSH MATS Field of Invention: This invention generally relates to brush mats with non-skid backings. The mats manufactured according to this invention will have various utilities such as mats, panels, carpets and the like, and may be made from natural fibers like coir, jute and hemp. This invention also relates to a method of manufacturing Brush Mats. Prior Art : It is well known in the art that there are two types of mats and they are categorized as brush mats and brushless mats. As floor coverings, the conventional P mats have been found inadequate, One disadvantage is that dust, dirt and water seep through the loosely held fibres, and accumulate on the floor below. This also enhances their tendency to slip which is considerably more when used on modern day polished flooring. It is further known in the art that mats with non-skid backings have been 5, developed to overcome disadvantages of the conventional mats described above. Mats with non-skid backings are. found to be sturdy, durable and do not allow dirt, dust and moisture to seep through and reach the flooring below. According to the hither to known art non- woven, non-skid mats are prepared by positioning a plurality of yarns, ropes and braids of natural/synthetic fibre in a side-by- Q side relationship within a housing. A Vulcanisable rubber composition is prepared by mixing components like natural/synthetic rubber, carbon black, zinc acid, antioxidants, accelerators, fillers and the like, in a conventional mixing mill. This rubber composition is converted into sheets of desired shape and size with the help of a calendaring mill. A sheet thus prepared is positioned over the braids or yarns in the 5 housing. This assembly is then vulcanized in a known manner thereby firmly embedding the braids, yarns, ropes and the like on the surface of the rubber layer. Further according to the hitherto known art, brush mats with non-skid backings are prepared by a rather cumber some method. A Vulcanisable sheet is prepared by any conventionally known method and cut to the desired shape and size. A plurality of core members, preferably metal rods of the desired length and thickness are selected. Natural or synthetic yarn is then wound around these core members and a plurality of such core members, having the yarn wound thereon are then placed on the prepared rubber sheet in side-by-side relationship. The assembly is then vulcanized and cooled. Thereafter the yarn wound around the core members is cut at the top surface of the core members which are subsequently removed. The bristles or brushes embedded in the rubber sheet may then be sheared to provide a uniform file length. Non-skid brush mats.prepared by the method described above are costly and labour intensive. Accordingly, it is the primary object of this invention is to develop a method of making brush mats with non-skid backing which is simple in operation and is cost effective. Brush mats are woven by techniques known in the art. These mats have a uniform woven backing from which bristles project to give a tufted brush effect. Brush mats of different sizes, shapes, colours and designs are available in the market and one of the advantages of this invention is readily available brush mats can be made use of. Preferred Embodiment of Invention : Rubber sheets are prepared by admixing natural or synthetic rubbers with accelerators, ' plasticisers like pine tar, tyre crumbs, china clay, stearic acid, mercaptobenzo- thiazodisulphide, sulphur and other conventional rubber moulding components. A preferred rubber moulding composition has the following components: Rubber(RMA4) 8 Kg Mercaptobenzothiazel-disulphide 150 gm Stearic acid 300 gm Antioxidants 100 gm Tyre crumbs 40 kg , China clay 7 Kg Plasticisers like Pine tar 4 Kg Sulphur 150 gm The above ingredients are mixed thoroughly in a conventional mixing mill. The compound should have a viscosity ranging from 40 to 100 in ML4 at 1000C. The viscosity of the moulding composition can be controlled by the addition of softeners while the strength of the composition may be increased by using synthetic rubbers like 5, styrene butadiene rubbers. The moulding composition is then cost into sheets with the help of a calendaring machine and the cast sheets are cut to the desired size and shape. The mould for making the non-skid brush type mats are provided with a flat base plate and a suitably designed cover plate. The design or monogram of the cover plate should correspond with the top surface design of the final product. The mould should also 10 have sleeve cutting edges on all the four sides to effect clear cutting of the moulded product. According to this invention, the method of making non-skid brush mats consist of the following: An appropriate brush mat with a flat bottom surface is selected. Calendared vulcanisable rubber sheets prepared from the moulding composition 15 described above are positioned on either side of the selected brush mat to completely overlap .the flat bottom surfaces and the tufted top surface. This assembly is then positioned within the mould so that the plain base rests on the plain back plate of the mould and the brushes rest on the designed top plate. The mould with the assembly within it is then passed through a hydraulic press in a horizontal position to vulcanize »20 the rubber sheets. The mould may be heated to a temperature above 1000C to 18O0C and the pressure may vary from 300 psi to 1500 psi. The vulcanization may be continued for a period of 5 mts to 30 mts. These are the steps involved in moulding and vulcanizing rubber composition. Pressure, temperature and time of vulcanization may vary depending on the nature of the rubber composition used and are not critical. »25 Both . the rubber sheets encasing the brush mat in between will melt and the liquid composition from the top rubber sheet will seep down to fill the grooves and voids in between the bristles of the brush mats. Further, the pressure of the bristles act on the designed upper plate of the mould while the plain base plate provides a uniform bottom layer. This technique of moulding provides adequate support to the bristles/brushes which get uniformly embedded in the rubber melt. The mould is then cooled and the brush mat with non-skid rubber backing taken out. The bristles may then be sheared to produce a uniform tuft all over the surface. The sleeve cutting edges on the mould facilitates easy removal of the article from the mould and ensures clearly cut edges. % The brush mats used may be dyed and designed and may have a desired monogram embossed or designed on its upper surface. The -mould may have channels or grooves around it so as to provide an outwardly extending non-skid border around the periphery of the brush mats. The size, shape and design of the mould may vary to provide mats of the desired choice. For |.0 instance, the mould may be oval, square, round or rectangular in shape. The method according to this invention of making brush mats with non-skid backings comprises encasing a brush mat with a flat base and bristled top surface within two vulcanisable rubber sheets made from rubber composition such as herein described having a viscosity range of 40 to 70 at 1000C, positioning the said encased •15 brush mat within a mould having a base plate and a cover plate, said mould being provided with sleeve cutting edges around its periphery, pressing the said assembly in a horizontal position, cooling and removing the brush mat with non-skid backings therefrom. This invention also includes brush mats with non-skid backings made according 20 to the above process. It should be understood that various obvious equivalents are within the scope of this invention. For instance, the assembly of brush mat with rubber sheet encasing may be pressed mechanically, manually or hydraulically to effect the complete melting and vulcanization of the rubber compound. Similarly the cover plate may be provided with 25 suitable designs to be embossed on the top surface of the brush mat of this invention.