Process of manufacture of woven doormat

Abstract

 A Doormat/Floormat for indoor and outdoor use made out of a stiff wire frame (1) covered with Coconut fibre and having twisted in circular brush fibre rods (3) weaved in a cadjan pattern with in this frame (1) and the said twisted fibre rods (3) being bound by suitable diameter binding wire (4) to the frame (1) characterized by identical appearance and features on both top and the bottom side of the mat.

Description

PRIOR ART

[0001] Conventional Door mats hereto manufactured with fibre and steel rods have been in use at the entrances exits of doorways and opening of all types of buildings and the designs and techniques, used so far have served the purpose only partly, creating certain disadvantages as listed below.

[0002] The dirt mud or any other substance such as snow are not completely removed from the feet, boot or shoe as the wiped dirt accumulates on the fibre since these are placed and fixed on a flat horizontal plane generally parallel to the floor on which the doormat is placed. Therefore, the doormat with such profiles are not efficient and requires periodical cleaning such as lifting and shaking off the dirt with vigorous vibrations. These actions are not only tedious, also reduces the life time of the mat drastically.

[0003] The doormats with steel wires exposed have the distinct disadvantage of the steel rods getting corroded due exposure to the atmosphere and due to constant presence of moisture from the users of the floormat.

[0004] These conventional type doormats made of coconut fibre or coconut fibre products such as the twine and yarn etc., have the fibre material in a tight configuration on a flat surface thereby preventing drying by rapid evaporation of any moisture acquired along with dirt during rains or snow.

[0005] Also some of the conventional doormats are made to certain designs to give a cosmetic effect using dyed yarn. For example the shape of the Elephant or a Fish will be the shape of the doormat. A distinct disadvantage of this type of mat is the absence of a stiff frame to hold the mat together. The loose floormats of this type whether rectangular or a design shape tend to extend with the transverse forces resulting due to the weight of the persons walking over and with time they get deformed and distorted. Some of these prior art mats are made with coconut fibre twisted in the form of yarn with different colours. Some of these mats made with coconut fibre twisted yarn have a steel rod frame or a support. Since these mats are made with yarn of uneven diameters they tend to have an uneven surface thereby leaving spaces to accumulate the dirt without falling through the mat to the underside. This problem warrant these mats to be periodically cleaned with vigorous shaking. Regular cleaning process make the yarn in the mats get loose and thereby leaving room for the mats to get easily damaged.

INTRODUCTION

[0006] The object of the present invention is aimed at overcoming most of the disadvantages of the prior art doormats and floormats listed above, and using as far as possible ecologically friendly natural fibres.

[0007] The present invention provides a doormat/floormat as set out in claim 1 or 9.

[0008] the present invention also provides introduction of various cosmetic effects, designs and even 3 dimensional patterns to the doormat by using different colours and types available in the said materials. This doormat is so designed with provision of circular fibre rods made out by twisting the galvanized wire with the inserted fibre. These fibre rods are set in a weaved pattern similar to the pattern used in weaving coconut leaves to make cadjans. This pattern eliminates the usual flat surface of the floormat/doormat and makes it more efficient and durable. The gaps created by the weaves allows the dirt and dust to fall under the said mat and also provides air circulation for rapid evaporation of the frequently present moisture.

[0009] The said twisted in fiber rods are made as per description given in this applicationt's granted patent No.11028 dated 11/7/97. These are made by twisting metal wire with brush fibre entangled in the twisting wire using a specially designed machine. These can be made to required lengths and densities of fibre using this machine to obtain cylindrical fibre rods of required diameters & lengths. Different types of fibre and various coloured fibres can be used. Generally the said twisted in fibre rods are placed perpendicular to each other in the weaving pattern and hence the brushing action is more effective compared to the fibre with optimum density and enables quick evaporation of any moisture and thereby drying the present invention mat in a short time.

[0010] Due to the nature of the raw materials used in making this mat in the present invention it could be made in a variety of colours, patterns, designs and shapes to give a matching effect to the place of its use and to suit any individual user's taste or requirement. Since it is possible to make the said novel mat with identical features and properties on both top and bottom sides, both these said sides can be used in turns and this feature enhances the durability and the lifetime of these types of novel mats.

[0011] Some of the conventional door mats are made to certain designs as mentioned earlier with a stiff outer frame as required by the specific design The said mat with the "Twisted in fibre rod" frame around it increases the strength and the compactness of the mat what ever the design may be, and thereby making it more durable.

DESCRIPTION

[0012] Due to the nature of the coconut fibre materials used in making these mats as per the present invention it is possible to produce these in a verity of colour patterns, shapes, sizes and possibility to get a matching affect to the place of its use and to suit any individual user's requirements or tasts. Since the mat may be made with identical shape and designs on both top and bottom sides, it becomes a reversible mat and both these sides may be used in turns and this feature enhances the durability of the product.

[0013] This floormat/doormat may be combined with a bootscraper/bootwiper/bootmat and made as one article for dual purpose as well.

[0014] The present invention relate to a specially designed doormat/floormat which is made with a stiff metal wire frame consisting of brush fibre rods in a rectangular fashion or to a desired design to be used as a cleaning device near any entrance or exit of any household or industry to remove dust, dirt, mud, snow or any other form of dirt even in the hardened state which could generally be removed/brushed off with the conventional doormat hereto manufactured.

[0015] The frame is generally made out of a stiff steel wire having a diameter about 4 or 6mm to accommodate the ends of the twisted in fibre rods having the weave pattern which fills completely the area confined within the said frame.

[0016] The present invention essentially consists of two basic parts. The frame which holds the centre portion rigidly is one part and the other is the weaved pattern twisted in fibre rods which makes the centre portion.

PREFERRED EMBODIMENT

[0017] The following description of the preffered embodiment does not in any way limit the scope of this present invention to this embodiment only and the description of this said embodiment is an example of one of the many possible embodiments that are covered by the independent and the appended claims defined at the end part of this complete specification.

[0018] The main component, the twisted in brush fibre rods with the unique weave pattern of this novel floormat/doormat in the present invention are special and these said rods are
   Systematically made with special purpose tools and assembled with customer designed machines and apparatus that are already patented.

[0019] Galvanized Iron wire may be used to make the frame and this may be around 4mm in diameter confirming to ASTM A641 class 3 heavily galvanized. The zinc coating of this wire may be around 290 grm/sqmm and the tensile strength is in the range of 41-55kg/sqcm.

[0020] Generally the frame size is limited to substantially rectangular 550mm by 345mm with the possibility of manufacture of larger or smaller versions or specific designs as per the requirements.

[0021] Please refer to drawings 1-8 of the mat given in the attached sheet. They clearly describe the features of this present invention. The main feature being the unique design of the weave which has been traditionally used in making the Coconut leaf coverings for village house roofing called the cadjans. The frame (1) may be made to any shape or size and the space within the said frame (1) is filled up with the weaved twisted in Brush fibre rods (3) which are circular or cylindrical in shape. The frame is covered with coconut fibre. The stiff steel wire frame (1) may also be made out of twisted in circular brush fibre rods (2).

[0022] The ends of the said brush fibre rods (3) are connected to the frame (1) by binding wire (4) of a suitable diameter and strength to hold them in place rigidly.

Claims

1. A Doormat/Floormat for indoor and outdoor use made out of a stiff wire frame (1) covered with Coconut fibre and having twisted in circular brush fibre rods (3) weaved in a cadjan pattern with in this frame (1) and the said twisted fibre rods (3) being bound by suitable diameter binding wire (4) to the frame (1) characterized by identical appearance and features on both top and the bottom side of the mat.

2. A Doormat/floormat for indoor and outdoor use made out of a stiff steel wire frame (1) covered with coconut fibre and having twisted in circular brush fibre rods (3) weaved in a cadjan weaving pattern within the frame (1) and as claimed in claim 1 where the stiff steel wire frame (1) is also made out of twisted in circular brush fibre rods (2).

3. A doormat/floormat/Bootscraper as claim in claimed 1 or 2 where the component materials may be given colours or patterns of arrangements to give enhanced cosmetic effect to the end product.

4. A doormat/floormat as claimed in any of the above claims where the said mat may be of the shape of an animal or tree or any other desired 3dimentional/2 dimentional shape as well.

5. A doormat/floormat as claimed in any of the above claims where the cadjan weaving pattern twisted fibre rods (3) may be of different diameters or of the same diameters.

6. A doormat/floormat as claimed in any of the above claims where the mat could be reversibly used as the top and bottom surface are identical in appearance having the same features.

7. A doormat/floormat as claimed in any of the above claims where the said mat is combined with bootwiper or brush mat to enhance the cleaning properties of a shoe or a boot or it's sole.

8. A doormat/floormat as claimed in any of the above claims where the said mat frame (1) is incorporated with additional twisted in fibre rods (3) to substantially protrude the said frame (1) around and above the center weaved portion of the mat.

9. A doormat/floormat for indoor or outdoor use comprising a wire frame (1) substantially covered with natural fibre, and further comprising rods (3) comprising metal wire twisted with natural fibre, the rods (3) being woven into a pattern contained within the frame (1), the rods (3) being fixed to the frame (1) characterised in that the doormat/floormat has substantially identical appearance on the top and bottom sides thereof.

Drawing