GB1563204A

GB1563204A - Animal stall provided with a multi-layer bedding material

Info

Publication number: GB1563204A
Application number: GB49979/75A
Authority: GB
Original assignee: Individual
Current assignee: Individual
Priority date: 1975-12-05
Filing date: 1975-12-05
Publication date: 1980-03-19

Description

(54) AN ANIMAL STALL PROVIDED WITH A MULTI-LAYER BEDDING MATERIAL (71) I, WILFRED JOHN CALLOW, a British Subject of Netherclay Farm, Thurlbear, Taunton, Somerset, do hereby declare the invention for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: The present invention relates to a stall or cubicle for animals provided with a bedding element which is soft enough to provide comfort for the animal, while being sufficiently tough to resist damage over an extended period of time, and is also cleanable to facilitate extended use.

Bedding for animals is usually provided at present by layers of straw which is merely distributed loosely over the floor of an enclosure for the animals. However, straw rapidly becomes soiled with urine and faeces and must then be discarded and replaced with fresh bedding straw. Recently straw has been in very short supply and therefore the price has increased considerably, underlining the waste inherent in this system; various alternative bedding materials have been considered such as recycled wood chippings and shredded paper, but these all utilise the same principle of disposal when soiled.

When animals are kept in enclosed surroundings it is essential to provide bedding materials, both for the comfort of the animal and, more importantly, for maintaining thermal insulation between the animal and the ground.

The present invention seeks to provide a stall or cubicle including a bedding element which is sufficiently strong and scuff resistant to withstand rupture when walked on by relatively heavy animals such as cattle, and which can be cleaned and re-used for extended periods. One of the most difficult problems to overcome in designing a bedding element suitable for cattle is the provision of a sufficiently tough surface to withstand rupture by the hooves of heavy animals whilst nevertheless being sufficiently resilient to provide the required degree of comfort.

According to the present invention, there is provided a stall or cubicle for animals, such as cattle, comprising a base, two upright sides and a bedding element located on the base and comprising a sheet of resilient foam plastics material having a resistant, flexible, waterproof surface layer on an upper, major face thereof, the resistant, flexible waterproof surface layer being of substantially the same foam material as the said sheet but foamed to a higher density.

By using waterproof resilient foam material for the surface layer of the bedding element, the requisite degree of resilience for comfort of the animal is achieved while avoiding the difficulties of saturation by urine and consequent problems in cleaning the element for subsequent use. Particularly for dairy cattle, absolute cleanliness is essential, and it would be totally unacceptable to use bedding elements which could not be thoroughly cleaned as can embodiments of the present invention, and possibly even sterilised if this were deemed desirable.

The two upright side walls of cattle stalls are usually spaced about 3 feet apart, and may have a manger or other feeding arrangement at one end (hereinafter termed the front end), and cubicles usually comprise separators of steel or other tubing with a low ridge or heel block at the entrance or rear end. The cows are directed to walk into the stall or cubicle, stepping over the heel block, and are able to eat from the manger or feeding apparatus at the front end if such is provided.

The length of the stalls or cubicles is such that the rear feed of the cow can fit just inside the heel block so that the rump of the cow projects slightly out from the stall. A gutter running along the entrances of a row of stalls or cubicles collects the majority of the urine and dung, and consequently only a small proportion falls within the stall or cubicle itself.

The surface layer of resistant waterproof material of the bedding element used in the stall or cubicle of the present invention provides the resistance against rupture when the cow moves about within the stall; preferably there is a layer of the waterproof material on each major face of the said sheet so that the element can be fitted into a stall either way up and be expected to have a longer life.

Bedding elements used in the invention may be made as a continuous strip or roll, for subsequent trimming to size to fit in the appropriate stalls or cubicles or other enclosures in which they are to be used, or they may be made individually. In the latter case the surface layer of resistant waterproof material may entirely surround the foam material of the said sheet aiding the cleaning of this.

In stalls or cubicles provided with a heel block the bedding element is conveniently positioned abutting this so that the heel block acts to retain the bedding element in the stall or cubicle against any displacements which may be caused by scuffing of the animal's feet.

The surface layer or layers of denser foam material may be formed integrally with the said sheet, although preferably it or they are formed separately from the said sheet and subsequently bonded thereto either by adhesive or by heat welding.

Suitable materials for use in the manufacture of embodiments of the present invention are foamed polymeric materials, particularly polyolefines which can be formed with a closed cell structure.

One suitable material for the bedding element is a polyethylene closed cell foam. The term "closed cell" is used herein to define a foam material in which the majority of the cells are not intercommunicating. The said sheet may be constituted by a single layer of polymeric foam material or may be constituted by a plurality of layers of foam material.

In such an embodiment adjacent layers may be of different densities or of the same density, the layers being bonded together by adhesive or heat welding. The latter is preferred, however, since the heat welding produces an interface of high density having a very low thermal conductivity which improves the thermal in sul.ting properties of the bedding. The resistant flexible waterproof surface layer may for example be constituted by a foamed polyurethane elastomer or by a foamed polyethyl- ene, the inner sheet being constituted by the same material as the surface layer, but of lower density, as will be more particularly described below.

'hatever polvmeric material is used for its composition it is preferred that the sheet material has a thickness of at least 5 mm and a density within the range 30 kg/m3 to 70 kg/m3. It is preferred that the surface layer thickness lies within the range 1.5 to 10 mm, the limits depending on the nature of the polqmeric material, and has a density within the range 100 to 170 kg/m3.

Embodiments of the present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a cross section of a bedding element for use in a stall or cubicle of the present invention; Figures 2A and 2B are cross sections through alternative bedding elements for use in the present invention; Figure 3 is a perspective view of a row of cubicles of the invention, each incorporating a bedding element; Figure 4 is a cross sectional view of a further alternative bedding element having a multi-layer centre sheet.

Referring now to Figure 1, there is shown a bedding element generally indicated 11 and comprising a single centre layer 12 of polyethylene closed cell foam material about 10 mm thick and having a density in the region of 50 kg/m3 to each major face of which is bonded a surface layer 13, 14 of polyethylene closed cell foam material, about 5 mm thick and having a density in the region of 120 kg/m3. The bonding is effected by flame laminating adjacent layers of preformed foam material. The centre layer is exposed at the edges of the element but this is not disadvantageous since, being a closed cell foam it is not permeable.

Figure 2 illustrates two alternative embodiments which differ from that of Figure 1 in that the surface layer completely encloses the said sheet. In Figure 2A a sheet 15 of relatively less dense foam material is bonded by heat welding or by adhesive to two surface layers 15a, 15b of relatively more dense foam material, and also to an edging strip 15c of the relatively more dense foam material which, although a complete element is not shown, extends all around the edge of the element. Because it is completely surrounded the said sheet 15 need not be an impermeable foam and an open cell structure may be used.

In the embodiment of Figure 2B a sheet 16 which again, may be an open cell porous foam if desired (although a closed cell structure is preferred so that the element remains waterproof even if surface layer is ruptured) is surrounded by two waterproof closed cell foam layers 16a, 16b, which are bonded to the inner sheet and sealed together along the edge 16c so as completely to surround the inner foam sheet. Such a construction may be made suitably in a mould, or alternatively two individual layers 16c, 16b may be bonded one to either side of the central foam sheet 16 and subsequently the two surface layers 16a, 16b may be pressed together through the foam 16 and joined by some suitable adhesive or by heat welding.

Referring now to Figure 3 there is shown a cubicle generally indicated 25 defined by sides comprising a plurality of parallel bars 17, 18, 19 embedded at the front end of the cubicle 25 into a wall 26. The bars 17, 18, 19 are supported by an upright bar 20, and a curved bar 21 defines the entrance. At the entrance to the cubicle 25 there is a heel block 18 over which a cow or other animal must step in order to enter the cubicle 25.

The floor 23 of the building may be of concrete or other suitable material and over this, within the cubicle 25, is a layer of sand, limestone or other suitable filling. On the filling layer there is provided a bedding element 11 such as that illustrated in Figures 1, 2A, 2B or 4. The heel block 18 serves to retain the bedding element 11 in position against displacement by rhe scuffing of the animals hooves. The bedding element 11, being waterproof, can be cleaned by hosing down when necessary, and provides adequate resilience and warmth for the animals when they are in the cubicles during the winter.

In Figure 4 there is shown an element 11 in which the centre sheet comprises three layers 27a, 27b, 27c of closed cell polyethylene foam 5 mm thick and each of a density of 50 kg/m3. The three layers 27a, 27b, 27c are heat welded together by flame lamination, this producing two interface regions of very dense polyethylene which has a very low coefficient of thermal conductivity and therefore gives the element very efficient thermal insulating properties. The surface layers 13, 14 are the same as in the embodiment of Figure 1.

As a further alternative the layer 27b could be of a different density (higher or lower) from that of the layers 27a, 27c, or, in fact, could even be of a different foamed material having different physical properties.

It will be appreciated that in all of the embodiments the higher density foam surface layer has a substantial thickness and contributes materially to the resilience of the bedding element. In the embodiment of Figure 1 the dense foam surface layers 13, 14 are, together, approximately as thick as the filling layer 12, and in the embodiment of Figure 4 the dense foam surface layers 13, 14 are as thick or thicker than each of the less dense foam filling layers 27a, 27b, 27c. In general it can be stated that the relative thickness of the dense foam surface layers may vary from one quarter of the thickness of the filling layer to substantially the thickness of the filling layer.

WHAT I CLAIM IS: 1. A stall or cubicle for animals, such as cattle, comprising a base, two upright sides and a bedding element located on the base and comprising a sheet of resilient foam plastics material having a resistant, flexible waterproof surface layer on an upper, major face thereof, the resistant, flexible water-proof surface layer being of substantially the same foam material as the said sheet but foamed to a higher density.

2. An animal stall or cubicle as claimed in Claim 1, in which the bedding element has a waterproof surface layer on each major face of the said sheet.

3. An animal stall or cubicle as claimed in Claim 1 or Claim 2, in which the or each surface layer of the bedding element is formed integrally with the said sheet.

4. An animal stall or cubicle as claimed in Claim 1 or Claim 2 in which the or each surface layer of the bedding element is formed separately from the said sheet and subsequently bonded thereto.

5. An animal stall or cubicle as claimed in any preceding claim, in which the said sheet of the bedding element has a closed cell structure.

6. An animal stall or cubicle as claimed in Claim 5, in which the material of the said sheet is a closed cell polyethylene foam.

7. An animal stall or cubicle as claimed in any of Claims 1 to 6, in which the foam plastics material of the said sheet has a density within the range 30 Kg/m3 to 70 Kg/mg and a thickness of at least 5 mm.

8. An animal stall or cubicle as claimed in any of Claims 1 to 7, in which the foam plastics material of the surface layer has a density within the range 100 to 170 Kg/mX and a thickness within the range 2 to 10 mm.

9. An animal stall or cubicle as claimed in any of Claims 1, 2, 4 or 5, in which the said sheet and the surface layer are constituted by a foamed polyurethane elastomer.

10. An animal stall or cubicle as claimed in Claim 9, in which the foamed polyurethane elastomer skin has a thickness in the range from 1.5 mm to 5 mm.

11. An animal stall or cubicle as claimed in any preceding claim, in which the said sheet of resilient foam plastics material is constituted by a plurality of layers of foam material.

12. An animal stall or cubicle as claimed in Claim 11, in which adjacent layers of the foam material of the said sheet have different densities.

13. An animal stall or cubicle as claimed in Claim 11, in which adjacent layers of foam material of the said sheet have the same density, the layers being bonded together.

14. An animal stall or cubicle as claimed in Claim 13, in which the layers of foam of the said sheet are bonded together by heat welding.

15. An animal stall or cubicle as claimed in any of Claims 1 to 14, in which the edges of the element are also covered by the material of the said surface layer.

16. An animal stall or cubicle as claimed in any of Claims 2 to 14, in which the surface layers covering the major faces of the element are bonded together at or adjacent the edges of the elements.

17. An animal stall or cubicle comprising a base, two upright sides and a bedding element substantially as hereinbefore described with reference to, and as shown in, Figures 1, 2

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. entrance to the cubicle 25 there is a heel block 18 over which a cow or other animal must step in order to enter the cubicle 25. The floor 23 of the building may be of concrete or other suitable material and over this, within the cubicle 25, is a layer of sand, limestone or other suitable filling. On the filling layer there is provided a bedding element 11 such as that illustrated in Figures 1, 2A, 2B or 4. The heel block 18 serves to retain the bedding element 11 in position against displacement by rhe scuffing of the animals hooves. The bedding element 11, being waterproof, can be cleaned by hosing down when necessary, and provides adequate resilience and warmth for the animals when they are in the cubicles during the winter. In Figure 4 there is shown an element 11 in which the centre sheet comprises three layers 27a, 27b, 27c of closed cell polyethylene foam 5 mm thick and each of a density of 50 kg/m3. The three layers 27a, 27b, 27c are heat welded together by flame lamination, this producing two interface regions of very dense polyethylene which has a very low coefficient of thermal conductivity and therefore gives the element very efficient thermal insulating properties. The surface layers 13, 14 are the same as in the embodiment of Figure 1. As a further alternative the layer 27b could be of a different density (higher or lower) from that of the layers 27a, 27c, or, in fact, could even be of a different foamed material having different physical properties. It will be appreciated that in all of the embodiments the higher density foam surface layer has a substantial thickness and contributes materially to the resilience of the bedding element. In the embodiment of Figure

1 the dense foam surface layers 13, 14 are, together, approximately as thick as the filling layer 12, and in the embodiment of Figure 4 the dense foam surface layers 13, 14 are as thick or thicker than each of the less dense foam filling layers 27a, 27b, 27c. In general it can be stated that the relative thickness of the dense foam surface layers may vary from one quarter of the thickness of the filling layer to substantially the thickness of the filling layer.

or 4 of the accompanying drawings, located on the base.

18. An animal stall or cubicle as claimed in any preceding claim, in which the bedding element is held in place by a heel block forming an upstanding ridge across the entrance to the stall.

19. An animal stall or cubicle as claimed in any preceding claim, in which the base comprises a layer of sand or limestone laid on a concrete floor.

20. An animal stall or cubicle substantially as hereinbefore described, with reference to, and as shown in Figure 3 of the accompanying drawings.