EP0273072A1 - Method of manufacturing mats for cleaning purposes, and a mat for cleaning purposes - Google Patents

Abstract

Mats for cleaning surfaces, in particular foot-mats, are composed of a basic, mainly plastic material with a fibrous layer and a support layer for the fibrous layer, and of fibres having a bristle-like structure applied on the basic material. The mats are economically produced by using the technical advantages of the fibres and bristles. Parts of the basic material (2) are melted by heating the fibres (8), if necessary the support layer (9) as well, and compressed up to or into the support layer forming recesses (10) in the fibrous layer (8). Bristles (12) are introduced parallel to each other in the recesses (10) and linked with the compressed basic material by melting their extremities (13).

Description

The invention relates to a process for the production of mats for the processing of surfaces or for cleaning purposes, in particular floor mats, which consists of a base material predominantly made of plastic with a fiber layer and a carrier layer fixing this and of bristle-like structure applied to the base material. The invention further relates to a mat produced in this way.

Mats in the sense of the invention are understood to mean any flat material in sheet form or in the form of blanks of any size. In terms of application technology, this means in particular doormats, floor mats, rugs, carpet tiles or webs, band brushes or also smaller cuts in the form of pads or the like. Mat material of this type is generally used for cleaning purposes, for example in the case of training as a doormat, scraper or rug for cleaning the shoes before entering rooms, in the form of carpeting for equipping vestibules, foyers or the like, in the form of tapes, pads or the like mechanical or manual cleaning of surfaces etc.

Insofar as the aforementioned mats are used as floor mats, rugs, etc., they were previously made from natural fibers, such as coconut or sisal fibers or the like, and more recently from synthetic fibers, e.g. B. produced as needle felt. Such fiber mats are intended on the one hand to wipe off the dirt from the footwear, and on the other hand to retain the wiped off dirt within the fiber structure. There is a tendency towards synthetic fibers, since they rot less quickly, are more hygienic and dry faster when they get wet. Furthermore, it has been recognized that the cleaning effect can be improved by using bristles instead of fiber material which are arranged perpendicular to one another in a parallel position. A disadvantage here is the inadequate retention of dirt, since the stripped dirt particles spatter.

As already mentioned, the first-mentioned fiber mats include simple needle felt mats, in which needled tangled fibers on the back by compression, fusing, Spraying or application of a binder are held to form a carrier layer. Furthermore, this includes mats which are formed from a pile fabric, for example from polypropylene, in which the pile weft or the pile chain is cut into bristle-like fibers (DE-GM 7 738 685).

Mats with a bristle structure are also known in a large number of embodiments. The bristles in the form of bristle strips are mechanically fixed either in strip-shaped or box-shaped holders (DE-OS 2 347 790, DE-PS 2 530 974, DE-OS 2 555 125, US-PS 2 805 437) or also in support grids (DE-AS 1 003 930). In this case, either falling of the stripped dirt onto the floor is deliberately accepted or sufficiently large chambers are provided between individual bristle strips to collect the dirt. Furthermore, it is known to provide roller-like brushes directly next to one another with intermeshing bristles (DE-AS 1 931 548 and 1 654 104). With these bristle mats, reasonably good dirt retention is guaranteed. However, all of the above-mentioned embodiments are very complex in terms of production technology and therefore expensive.

In another group of similar construction (DE-GM 7 520 299 and 7 443 282), the carrier layer is formed from large-area plastic injection molded parts with chamber-like depressions, bristles being placed on the upper edge of the chambers delimiting the webs. These embodiments are intended to ensure that the dirt stripped from the bristles collects in the chambers. These floor mats are only functional if they have a dense bristle covering all over. It is complex in terms of production technology, if not at all impossible to apply the large number of bristles on the relatively small end faces of the webs of the carrier material.

In view of these circumstances, it has also been proposed (US Pat. No. 3,886,620, DE-GM 6 909 246) to inject the entire floor mat in one piece from plastic, so that the bristles are made of the same material as the support structure. Retention chambers for the dirt are also provided here. Sprayed bristles are known to be relatively soft and must have a relatively large diameter for manufacturing reasons alone. In addition, they have to be tapered to the tip in order to be able to be removed from the injection molding tool. In addition to the fact that these floor mats also require a considerable amount of production, they cannot be satisfactory from an application point of view because of the soft bristles, since they flip over and no longer stand up.

Another development was therefore to attach plastic bristles manufactured in the usual manner in bundles to a fabric as a carrier layer by melting the bristle bundles at their fastening ends and pressing them onto the fabric so that the melt penetrates into the fabric structure. After cooling, the bristle bundle sits on the tissue carrier layer (DE-US 2 335 468). These mats are not able to cope with the great stress that occurs with floor mats or machine-operated devices with brush bands or discs. Instead, it is also known to melt the bundles of bristles at their base and to connect the individual bundle bases with a lattice structure, this lattice structure then being additionally foamed or extrusion-coated in order to obtain a full-area carrier web (DE-OS 2,109,972, U.S. Patent 3,798,699). Here too, due to the necessarily large distance between the individual bristle bundles, adequate dirt retention is not guaranteed. Moreover, in all known embodiments with a large distance between the bristle bundles or bristle strips, the surefootedness is poor.

In contrast, the mat described at the outset (DE-PS 2 034 089) is satisfactory, at least in terms of application technology. It consists of a base material with a fiber layer in the form of tangled fibers made of relatively fine plastic fibers and a carrier layer fixing them. This fiber mat is embossed to form protective chambers by melting the fine plastic fibers and compressing them to a smaller thickness. Coarse fibers in the form of loops or bristles are needled onto the unprocessed elevations of the mat. This mat thus has on the one hand dirt-retaining chambers, and on the other hand consists on the elevations of fine plastic fibers and bristle-like fibers. This combination of fibers results in a particularly good wiping effect without the dirt - as with a bare bristle mat - splashing too much. Since the mat consists exclusively of plastic fibers, it can also satisfy in terms of hygiene. The disadvantage, however, is that the unordered bristles cannot produce the same brushing effect as with pure bristle mats. Because of their relatively large diameter, bristle-like fibers are also difficult to needle on. The bristles are also slightly depressed, since they are only perpendicular to the mat surface to a small extent, so that they do not fulfill their effect, or do so only unsatisfactorily.

The invention is based on the object of proposing a method for producing mats which allow the advantageous effects of fibers, on the one hand, and bristles, on the other, to be fully developed in terms of application technology, such a mat being furthermore to be able to be produced in a cost-effective manner.

Based on the method mentioned in the introduction, in which the mat consists of a base material predominantly made of plastic with a fiber layer and a carrier layer fixing this and fibers applied to the base material, bristle-like structure, this object is achieved in that the base material by heating the fibers and if necessary, the carrier layer is melted in regions and compacted up to or into the carrier layer to form depressions in the fiber layer, and that bristles are inserted into the depressions approximately in parallel position and are connected to the compacted base material by melting their ends.

The melting of the fibers and, if applicable, the carrier layer and the subsequent or subsequent densification results in the region of the depression in a stable base, primarily made of plastic, in which bristles, which are arranged approximately in a parallel position, are anchored by melting their ends. This gives a doormat in which the bristles are in the approximately vertical position that is important for their function, so that they can fulfill their optimal stripping and cleaning function. These bristles are otherwise within the uninfluenced fiber material of the fiber layer, so that the fibers also satisfactorily fulfill the assigned effect of stripping and dirt retention in all respects can. The melting of the bristle ends, the fibers and, if appropriate, the carrier layer provides a firm bond between all the components of the mat, so that a long service life is ensured in spite of the considerable stress, particularly with floor mats. This also applies to the bristles alone, which are not arranged individually and free-standing, as a result of which they would be trodden down, but are integrated and supported within the fiber structure, so that they are not subjected to excessive bending and bending forces over a large part of their length are.

The load-bearing function is not only taken over - as with conventional fiber mats - by the carrier layer of the base material, but also by the reinforced base of the depressions, which depending on their arrangement can be punctiform, strip-shaped, lattice-like or the like.

The manufacturing costs for such a mat are relatively low compared to the known embodiments, since the base material, which is produced in the usual way, is filled with the bristles in an exclusively thermal manner. These melting and, if necessary, welding processes can now be mastered by machine without any problems and can also be implemented in series production with high piece output.

In a preferred embodiment, the bristles are welded to the base material. For this purpose it is recommended to use bristles made of the same plastic as the fibers of the base material or a plastic with an appropriate affinity.

According to a further embodiment of the method according to the invention, the melted ends of the bristles are upset on the base material. This can be done in such a way that the melt at least partially penetrates between the fibers adjacent to the depression. In this process variant, fibers and bristles can also consist of very different materials. Practical tests have shown that, regardless of the type of connection, it is even possible to provide a portion of natural fibers within the fiber layer. Instead, it is also possible to press the melted fibers into the melt of the base material in order to allow the bristle melt to flow around, which likewise leads to a firm hold.

According to a further variant of the method, the fibers of the base material are melted over the height of the fiber layer in the edge region of the depression to form a kind of wall. This creates a kind of blind hole in which the bristles are inserted. The melted fibers form a lateral support for the bristles.

With the method according to the invention, mats can be produced in the form of webs or in the form of area-limited sections, so that all the possible uses for the material mentioned at the beginning can be exhausted.

The invention further relates to a mat for processing surfaces or for cleaning purposes, in particular a doormat, which consists of a base material predominantly made of plastic with a fiber layer and a carrier layer fixing this and of bristle-like structure applied to the base material.

The object of the invention is to further develop this known mat with a combined fiber and bristle structure in such a way that the application-technical advantages of both structures come into play to the full extent.

This object is achieved according to the invention in the aforementioned mat in that the base material of the fiber layer has depressions in some areas, the bottom of which is formed by melting the fiber layer and compacting up to or into the optionally melted carrier layer, and that bristles are inserted into the depressions approximately in parallel to one another and are fixed by melting their ends in the bottom of the depressions.

In some areas, the mat consists of a pure fiber layer, in other areas it consists of bristles which, as is usual with brush goods, are essentially perpendicular to the surface. The fibers can unfold their wiping and retention function for dirt unhindered, while the stronger wiping function of the bristles also has an effect, in particular also on profiled surfaces. The diameter and length of the bristles, as well as their material, can be selected as required. Furthermore, the bristles can be attached to the mat in any geometric arrangement. Bristles with different properties and effects can also be used in combination. Also special bristles, e.g. B. with abrasive filling for grinding and polishing purposes can be introduced into the mat material.

According to one embodiment, the bristles can be welded to the base material at the base of the depression be, optionally also have a widened foot at their ends inserted into the recess. In addition, this widened foot can extend between the fibers of the fiber layer adjacent to the depression and there provide additional anchoring of the bristles.

In a further embodiment of the invention, the depressions have wall-like stiffeners which are formed from fibers melted over the height of the fiber layer. This creates additional support and guidance for the bristles inserted into the recess.

According to one embodiment, the cross section occupied by the bristles is smaller than the cross section of the recess. As a result, a circumferential gap is formed between the bristles and the fiber layer, which is effective as a dirt retention chamber.

Instead, however, the cross section of the recess can be smaller than the cross section occupied by the bristles, so that there is a kind of interference fit of the bristles within the fiber layer, which in turn supports the bristles laterally.

The bristles can be used standing upright, in bundles or in strips in appropriately designed depressions of the base material. Here too, the configuration is primarily based on the respective application requirements.

Finally, the bristles can protrude above the surface of the fiber layer, be flush with it or end below the surface. In the 1st and 2nd case, the bristles become effective with each stripping process, while in the latter case they only develop their effect if a greater pressure is exerted on the fiber layer during the stripping process, that is to say the fiber layer is compressed accordingly.

• Figur 1 eine Ansicht eines Ausführungsbei­spiels der Matte in Form einer Fußmatte;
• Figur 2 - 5 je einen vergrößerten Detailschnitt verschiedener Ausführungsformen.

The invention is described below with the aid of some exemplary embodiments shown in the drawing. The drawing shows:

• Figure 1 is a view of an embodiment of the mat in the form of a doormat;
• Figures 2 - 5 each an enlarged detail section of different embodiments.

The doormat 1 shown in FIG. 1 in a schematic view has an essentially rectangular outline with rounded corners. It consists of a base material 2 of fibrous structure and bristles 3 inserted therein. Furthermore, a stiffening, possibly also slip-resistant base 4 can be attached to the back of the mat 1, but this is not part of the subject matter of the invention. The bristles can be arranged with one another in any geometry, as can their distribution on the surface of the mat. In FIG. 1, only individual round bristle bundles 5, crosswise arranged bristle strips 6 and linear bristle strips 7 are shown as examples. A mat can be filled with bristles of the same or different configuration.

The structure of the mat can be seen in more detail in FIGS. The base material 2 consists of a fiber layer 8, primarily of random fibers and a backing layer 9 fixing this on the back. The latter can be produced by compressing the fibers and applying a binder, by fusing the fibers or by applying a film-like cover layer or the like. The fiber layer 8 is melted in regions by heated molding tools and pressed down to the carrier layer 9, so that depressions 10 form. The melted fiber material and the carrier layer 9 form a reinforced base 11 at the bottom of the depression. Bristles are primarily inserted into the depression in a parallel position, which are melted at their ends 13 beforehand. With the melted end 13, they are placed on the base 11, which may also have melted. If the materials used for the fiber layer 8 and the bristles 12 can be welded, a homogeneous weld connection is formed on the base 11. In the exemplary embodiment shown in FIG. 2, the bristles 12 protrude beyond the surface 14 of the fiber layer.

FIG. 3 shows a modified embodiment, in which the fibers are again melted in regions to form a depression 10 and pressed together on the carrier layer 9. In this embodiment, however, the recess 10 has a somewhat larger cross section than it is occupied by the bristles 12, so that an annular space 15 is created which can act as a dirt chamber. Otherwise, in this exemplary embodiment the bristles 12 end approximately flush with the surface 14 of the fiber layer 8. The bristles 12 are in turn at their end opposite the usable surface melted and pushed up onto the bottom of the depression 10, so that the melt forms a kind of foot 16, which is welded to the base 11, if necessary, but is at least glued by the melting.

In the exemplary embodiment according to FIG. 4, the fiber layer 8 has not only been melted to form the reinforced base 11, but also to the side of the depression, so that a type of sleeve 17 is formed which guides the bristles 12 used laterally. The bristles 12 are in turn anchored here by melting their ends 13 on the base of the depression 10 in the region of the base 11.

In the exemplary embodiment according to FIG. 5, in which the base 11 has in turn been produced by melting and compressing the fibers of the fiber layer 8, a bundle of bristles 12 with a melted end is again inserted into the depression formed in this way and swaged on the base 11. As a result, the melt is forced outwards, so that a foot 18 is in turn formed. In a modification of the previously described embodiments, however, the melt penetrates into the fibers of the fiber layer 8, so that the bristles 12 are additionally anchored in the fiber layer 8 by means of the foot 18.

Claims (14)

1. A process for the production of mats for the processing of surfaces or for cleaning purposes, in particular floor mats, which consists of a base material mainly made of plastic with a fiber layer and a carrier layer fixing this and from fibers applied to the base material bristle-like structure, characterized in that Base material is melted in regions by heating the fibers of the fiber layer and optionally the carrier layer and compacted up to or into the carrier layer with the formation of depressions in the fiber layer, and that bristles are inserted into the depressions approximately in parallel position and by melting their ends with the compressed base material get connected. 2. The method according to claim 1, characterized in that the bristles are welded to the base material. 3. The method according to claim 1 or 2, characterized in that the melted ends of the bristles are upset on the base material such that the melt at least partially penetrates between the fibers adjacent to the recess. 4. The method according to claim 1 or 2, characterized in that in the edge region of the depression, the fibers of the base material are melted over the height of the fiber layer to form a kind of wall. 5. The method according to any one of claims 1 to 4, characterized in that the mat is made in the form of a web or in flat sections. 6. Mat for the processing of surfaces or for cleaning purposes, in particular doormat, consisting of a base material predominantly made of plastic with a fiber layer and a carrier layer fixing this and from fibers applied to the base material bristle-like structure, characterized in that the base material (2) in the fiber layer (8) has depressions (10) in some areas, the bottom of which is formed by melting the fiber layer and compacting it up to or into the optionally melted carrier layer (9), and that in the depressions (10) bristles (12) are approximately parallel to one another used and fixed by melting their ends (13) in the bottom of the recesses (10). 7. Mat according to claim 6, characterized in that the bristles (12) at the bottom of the recess (10) with the base material (2) are welded. 8. Mat according to claim 6 or 7, characterized in that the bristles (12) have a widened foot at their ends inserted into the recess (10). 9. Mat according to claim 8, characterized in that the widened foot (18) of the bristles (12) extends between the fibers (8) of the fiber layer (8) adjacent to the recess (10). 10. Mat according to one of claims 6 to 8, characterized in that the recesses (10) have wall-like stiffeners (17) which are formed from melted fibers over the height of the fiber layer. 11. Mat according to one of claims 6 to 10, characterized in that the cross section taken up by the bristles (12) is smaller than the cross section of the recess (10). 12. Mat according to one of claims 6 to 10, characterized in that the cross section of the recess (10) is smaller than the cross section occupied by the bristles (12). 13. Mat according to one of claims 6 to 12, characterized in that the bristles (12) are used individually, in bundles (5) or in strips (7) in appropriately designed recesses (10) of the base material (2). 14. Mat according to one of claims 6 to 13, characterized in that the bristles (12) project beyond the surface of the fiber layer (8), are flush with it or end below the surface.

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