WO2006059339A1

WO2006059339A1 - Mats with woven boot scrapper

Info

Publication number: WO2006059339A1
Application number: PCT/IN2004/000371
Authority: WO
Inventors: Suseelan Sanjeev Koncherry
Original assignee: Suseelan Sanjeev Koncherry
Priority date: 2004-12-01
Filing date: 2004-12-01
Publication date: 2006-06-08
Also published as: US20080000038A1

Abstract

A combination of coir and polypropylene in the doormats as product is unique. The construction of mats with coir and polypropylene, done on traditional handlooms make it a unique product in its segment.

Description

Mats with woven boot scrapper

Field of Invention

This invention generally relates to manufacturing of doormats. More particularly the invention relates to doormats with or without latex backing. In particular this invention relates to doormats made of coir and polypropylene. This invention relates to a manufacturing process of doormats and rugs having coir and polypropylene.

Prior Art

This is for the very first time a product being developed having coir and polypropylene. When a doormat is made using coir and polypropylene and conventional weaving, the product becomes a versatile and affordable one.

It offers high utility and convenience of usage. It is an innovative product and a revolutionary concept in the category of hand woven doormats.

Summary of Invention The inventor has made a great effort to provide a method to meet the requirements of the industry and to overcome the problem associated in the prior art.

According to one object of invention a method is provided to improve the product so that it is unique, rugged and economical. Another object of the invention is to employ traditional and conventional method of weaving in order to manufacture doormats.

Another object of the invention is to employ rubber being natural product as raw material for manufacture of doormats..

Another object of invention is to invent a novel method of manufacturing doormats, which provide increased softness.

To achieve the above object according to first feature of the invention there is a method provided to improve the quality of the product.

At the outset of the description which follows it is to be understood that ensuing description only illustrate a particular form of this invention. However, such particular form is only an exemplary embodiment without intending to imply any limitation on the scope of this invention. Accordingly, the description is to be understood as any exemplary embodiment and reading of the invention is not intended to be taken restrictively.

The above and other objects, features and disadvantages will be clear from the following description of preferred embodiment taken in conjunction with accompanying drawings.

The foregoing description is outlined rather broadly preferred and alternative feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that forms the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing and modifying other structures for carrying out the same purposes of the invention. Those skilled in the art should realize such equivalent conception do not depart from the spirit and scope of the invention in its broadest form. Brief description of drawings The accompanying drawings are intended to provide further understanding of invention and is incorporated in and constitute a part of invention. The drawings illustrate an embodiment of invention and together with the description illustrate principle of invention. The drawings should not be taken as implying any necessary limitation on the essential scope of invention.

The drawings are given by way of non-limitative example to explain the nature of the invention.

For a more complete understanding of the invention instant reference is now made to the following description taken in conjunction with accompanying drawings.

The various feature of novelty which characterizes the invention are pointed out specifically in the claims which form a part of description. For a better understanding of the invention, its operating advantage, specific objects obtained by its use, reference should be made to the drawings and the descriptive matter in which there are illustrated and described preferred embodiments of the invention. Now the invention will be described in detail with reference to the drawings that accompany the complete specification. The nature of invention and the manner the invention is to be performed is clearly described in the complete specification.

Fig. 1 of the drawing shows in elevation the mat of the specification (1600xl200x24b)

Fig. 2 of the drawing shows in elevation the mat of the specification

(1600xl200x24b)

Fig. 3 of the drawing shows in elevation the mat of the specification

(1600xl200x24b) DETAILED DESCRIPTION OF AN EMBODIMENT OF

INVENTION

The construction of mats with coir and polypropylene, done on traditional handlooms make it a unique product in its segment.

Now the invention will be described in detail with reference to the following description bearing the sequence of manufacturing process in order to obtain carpets and rugs having wool loop on jute base is described in detail.

Manufacturing Process

Materials Used 1. Coir

2. Polypropylene

3. Conventional Loom General Construction Reed Count - 70 s Weft - 16/10 cm Warp- 12/10 cm The weaving operations are done in the conventional looms. Two separate beams are required for manufacturing the doormat. One beam is required for coir yarns and the other is required for polypropylene yarns. The coir warp threads and polypropylene threads are drawn through the respective mail eyes of the heald and then through the read spaces. These are tied on the cloth roller. The ends are drawn through the fifth reed (three coir ends and one polypropylene). This will be repeated throughout the full width of the doormat. These are then connected to the corresponding treadle according to the tie up and treadling plan. Treadles operate according to the treadling plan. The base weave of the doormat is 2/2 panama weave. For warp and weft coir yarn is used and for locking purpose of coir brush polypropylene yarn is used. The diameter of coir yarn is changed according to the treadling plan. This is a three shaft design. Two Shafts are used for 2/2 weave and one is for polypropylene. To begin with two series boucle weave product is formed and then by pressing of third shaft, polypropylene yarns are raised as a loop and the coir brush is inserted. It is locked by polypropylene yarns. When the first shaft is pulled down corresponding series of warp threads are raised. Weft is inserted by passing of shuttles and then by beating of sley these are fixed in a well manner. The second shaft is then pulled down. Next series of warp is raised and weft is inserted and sley is beaten. By pressing the third shaft polypropylene yarns are raised, coir brush is inserted below the polypropylene threads and it is locked. Again the first and second shafts are operated and two series of weft is inserted and thus a groove is formed in between the coir brushes. The polypropylene yarn is visible only in the portion of coir brushes. The first shaft and the second shaft are operated again and the weft is inserted. Then by pressing of third shaft polypropylene yarns are raised and coir brush is placed. Thus the operation is repeated and the doormat is manufactured. Preparation of Coir brush Materials used

Metal wires (galvanized) - 14- 16mm

14 - 16 mm galvanized metal wires are used for preparation of coir brush. One end of this wire is attached by a hook on a machine (wire twister) and the other end is connected to a hand-rotating device. The fibres are arranged in a tray as per the height of the brush required. This tray is placed just beneath the wire and in between the hook and the rotating device. The twisted wires capture the fibre brazils during the rotation of the rotating device. Thus the coir brush is formed.

Claims

1. A method of manufacturing doormat having woven boot scrapper which comprises of following steps: a. Two separate beams are required for manufacturing the doormat. One beam is required for coir yarns and the other is required for polypropylene yarns. The coir warp threads and polypropylene threads are drawn through the respective mail eyes of the heald and then through the read spaces. These are tied on the cloth roller. The ends are drawn through the fifth reed (three coir ends and one polypropylene). This will be repeated throughout the full width of the doormat. These are then connected to the corresponding treadle according to the tie up and treadling plan. Treadles operate according to the treadling plan. b. The base weave of the doormat is 2/2 panama weave. For warp and weft coir yarn is used and for locking purpose of coir brush polypropylene yarn is used. The diameter of coir yarn is changed according to the treadling plan. This is a three-shaft design. Two Shafts are used for 2/2 weave and one is for polypropylene. To begin with two series boucle weave product is formed and then by pressing of third shaft, polypropylene yarns are raised as a loop and the coir brush is inserted. It is locked by polypropylene yarns. c. When the first shaft is pulled down corresponding series of warp threads are raised. Weft is inserted by passing of shuttles and then by beating of sley these are fixed in a well manner. The second shaft is then pulled down. Next series of warp is raised and weft is inserted and sley is beaten. Expressing the third shaft polypropylene yarns are raised, coir brush is inserted below the polypropylene threads and it is locked. Again the first and second shafts are operated and two series of weft is inserted and thus a groove is formed in between the coir brushes. The polypropylene yarn is visible only in the portion of coir brushes. d. The first shaft and the second shaft are operated again and the weft is inserted. Then by pressing of third shaft polypropylene yarns are raised and coir brush is placed. Thus the operation is repeated and the doormat is manufactured. e. 14 - 16 mm galvanized metal wires are used for preparation of coir brush.

One end of this wire is attached by a hook on a machine (wire twister) and the other end is connected to a hand-rotating device. The fibres are arranged in a tray as per the height of the brush required. This tray is placed just beneath the wire and in between the hook and the rotating device. The twisted wires capture the fibre brazils during the rotation of the rotating device. Thus the coir brush is formed.

2. A method of manufacturing doormat having woven boot scrapper as claimed in claim 1 wherein the ply and diameter of coir yarn and polypropylene yarn being changed according to the requirement of square metre weight of the product.