Method of making a brush-type mat and the mat produced thereby

Abstract

An improved mat is formed of a supporting base layer constituted at least in part by a cured biodegradable plastic reinforced by a mesh fabric, into which layer a plurality of closely spaced lengths or tufts of fibrous materials are embedded so as to extend up therefrom, the mat being produced by providing an uncured layer of that plastic material at an assembly station into which mesh fabric, preferably pre-coated with the plastic, is embedded in the plastic layer, and where thereafter the lower ends of the tufts of fibrous material are inserted lengthwise, the plastic thereafter being cured.

I claim:  
     
         1 . The method of making a brush-type mat in which lengths of fibrous material extend upwardly from a base layer of plastic into which said lengths are partially embedded, said method comprising conveying substantially continuous lengths of said fibrous material to a cutting station where the material is cut into short lengths, conveying said short lengths to an assembly station, providing at said assembly station a layer comprising plastic and a mesh fabric embedded therein, said plastic being uncured and sufficiently fluid so that said short lengths can be inserted thereinto, at said assembly station partially inserting said short lengths into said layer so that said short lengths extend therefrom, and conveying the thus assembled plastic, mesh fabric and upstanding lengths to a curing station where said plastic is cured.  
     
     
         2 . The method of  claim 1 , in which said plastic is biodegradable.  
     
     
         3 . The method of  claim 1 , in which said plastic is predominantly biodegradable natural rubber latex.  
     
     
         4 . The method of  claim 1 , in which said uncured plastic comprises a mixture of styrene-butadiene rubber latex, natural rubber latex and stabilizer.  
     
     
         5 . The method of any of claims  1 ,  3  or  4 , in which said mesh fabric is formed of a substance from the group consisting of jute and cotton.  
     
     
         6 . The method of any of claims  1 ,  3  or  4 , forming said layer by coating said mesh fabric with said plastic before said mesh fabric reaches said assembly station, and thereafter embedding said mesh fabric in a layer of said plastic formed at said assembly station.  
     
     
         7 . The method of  claim 1 , in which said plastic layer comprises styrene butadiene 3-10 parts, natural rubber 40-60 parts, and polyvinyl acetate 10-2 parts, all parts by weight.  
     
     
         8 . The method of making a brush-type mat in which lengths of fibrous material extend upwardly from a base layer of plastic into which said lengths are inserted, which method comprises: 
 (a) conveying substantially continuous lengths of said fibrous material to a cutting station where the material is cut into short lengths and conveying said lengths to an assembly station;    (b) forming a layer of uncured plastic at said assembly station;    (c) conveying a mesh fabric to said assembly station and there embedding said mesh fabric into said plastic layer;    (d) at said assembly station partially inserting said short lengths into said plastic layer so that said short lengths extend therefrom; and    (e) conveying the assembly of plastic layer, mesh fabric and upstanding lengths to a curing station where said plastic is cured.    
     
     
         9 . In the method of  claim 8 , coating said mesh fabric with said plastic while it is being conveyed to said assembly station.  
     
     
         10 . A brush-type mat comprising a supporting base layer comprising a cured biodegradable plastic layer and a substantially co-extensive layer of mesh fabric embedded therein and, extending upwardly from said base layer, a plurality of closely spaced lengths of fibrous material the lower ends of which are embedded and retained within said plastic layer.  
     
     
         11 . The mat of  claim 10 , in which said mesh fabric is formed of a material from the group consisting of jute and cotton.  
     
     
         12 . The mat of either of claims  10  or  11 , in which said plastic predominantly comprises natural rubber.  
     
     
         13 . The mat of either of claims  10  or  11 , in which said plastic comprises a mixture of styrene-butadiene rubber, natural rubber and stabilizer.  
     
     
         14 . The mat of  claim 10 , in which said plastic layer comprises styrene butadiene 3-10 parts, natural rubber 40-60 parts, and polyvinyl acetate 10-2 parts, all parts by weight.