[0011] In the drawings, reference numeral 1 generally designates a door-mat according to
the invention, constituted by a base support 2 and a pile layer 3, of a usual height.
The base support 2 is formed by a weave cloth 4, normally made of T.N.T. polyester
or polypropylene, joined to a synthetic jute wound underlay 5 by a particular rubber
latex compounds on the underlining surface of which an embossed pattern is impressed
for anti-slip purposes.
[0012] The door-mat 1 is further provided with an outer finish comprised of a perimetral
skirt made of a continuous ribbon 6, having the same colouring as the door-mat yarn
and also made of T.N.T. polyester, thermally fixed at the end of its perimeter.
The pile layer 3 is formed by a yarn, woven onto the cloth 4 of the base support 2,
which according to the invention comprises a polypropylene thread coupled with a stiffening
core formed by a nylon filament.
More particularly, the yarn is constituted by two ends of continuous, bulked and ingrained
BCF polypropylene thread 7, and by two ends of a single nylon 66 filament 8. Normally
the amount of the polypropylene thread 7 is around 78% by weight, and that of the
single nylon filament 8 is around 22% by weight of the yarn.
Production of the yarn disclosed in the above is performed as follows.
Firstly, initial coupling of each end of the polypropylene thread 7 with the single
nylon filament 8 is carried out. Then kinking of the polypropylene thread 7 over the
single nylon filament 8 is performed, by means of a double-twisting machine, i.e.
in opposite twist directions as diagrammatically depicted in figure 3, so as to obtain
a balanced twisting of the single ends of the thread 7. Lastly fixing between the
thread 7 and the filament 8 is performed by thermal action, normally through a continuous
tunnel heat-set treatment.
Weaving of the yarn thus constituted by the polypropylene thread 7 and the nylon filament
8 is then carried out on a particular tufting loom, of the type conventionally known
as "full wide repeat scroll tufting machine", capable to obtain multiple colour patterns,
as well as to produce, if desired, an uneven eight surface of the pile 3. By differentiating
the weaving height with terry and pile it is in practice possible to "engrave" the
trampling surface of the door-mat 1, so as to create for instance channels intended
to facilitate shoe cleaning and discharge of powder, loam etc.
Due to this weaving technique, a refinement appearance is achieved thus completing
and enriching the function of the door-mat according to the invention, which is not
only confined to cleaning but also provides a fitting-up complementary effect.
The further manufacturing and finishing steps of the door-mat 1 are substantially
conventional.
Due to the provision of the single nylon filament 8, the door-mat according to the
invention is provided with remarkable resilience and wear resistance characteristics,
along with an immediate lift up performance of the trampling areas thereof back to
the indeformed condition.
Moreover the door-mat according to the invention has permanent anti-static and
anti-slipping characteristics, and is adapted to be easily cleaned even by means of
a washing machine.
Naturally, the details of construction and the embodiments may be widely varied
with respect to what has been disclosed and illustrated, without thereby departing
from the scope of the present invention, such as defined in the appended claims.