Title of Invention

A MACHINE FOR BACKING CARPET

Abstract

TITLE; A MACHINE FOR BACKING CARPET. A MACHINE FOR BACKING CARPET COMPRISES: BASE PLATES, HEATERS, AN INDUCTION MOTOR, AND A GEAR BOX ASSEMBLY; WHEREIN THE BASE PLATE COMPRISES A TOP PLATE AND A BOTTOM PLATE WHICH ARE FIXED TO THE FRAMES AND A CENTER PLATE WHICH IS MOVEABLE IN THE VERTICAL DIRECTION IN BETWEEN THE TOP PLATE AND BOTTOM PLATE; THE HEATERS ARE FITTED TO THE TOP PLATE; AND THE SAID INDUCTION MOTOR AND SAID GEAR BOX ASSEMBLY ARE FITTED TOTHE BOTTOM PALTE TO MOVE THE CENTER PLATE IN THE VERTICLE DIRECTION.

Full Text

Present invention relates to a machine for backing carpet. More particularly, in the present invention a carpet or such thick fabric like mattresses, blankets, etc. is backed, With polymer sheet and textile fabric, if necessary, and the Said backing is done by the machine for backing carpet or such thick fabric material. In the conventional process for backing of carpet or such thick fabric materials like mattresses, blankets, etc. are bonded manually with multiple backing textile fabrics by means of chemical coatings such as latex. Carpets or such thick fabric materials like mattresses, blankets, etc. are also bonded with polymer sheet. Carpets or such thick fabric materials are laid, such that the back surface of the carpet or such thick fabric materials like mattresses, blankets, etc. is on top and polymer sheet is spread on the backside of the carpet or such thick fabric materials like mattresses, blankets, etc. Optionally, the polymer sheet may also be covered with textile fabric. The polymer sheet is then bonded manually on the backside of the carpet by a heated roller rolled over the polymer sheet which softens under heat and gets bonded to the back side of the carpet. This conventional manual process of bonding polymer sheet to the carpet is tedious because of the involvement of manual labour and at least 7 to 8 hours is required for proper bonding of the carpet with polymer sheet. An object of the present invention is to introduce a machine which will heat the polymer sheet prior to bonding the same on to the back surface of the carpet or such thick fabric like mattresses, blankets, etc. The machine for backing carpet has three plates of which the upper plate and the bottom plate are fixed to the iron frames at four corners of the machine. The position of the center plate is adjustable in between the top plate and bottom plate by a screw rod arrangement attached with the center plate. The position of the center plate is adjustable in the verticle direction along the frames of the machine by the screw rod mechanism which is moved up and down by an induction motor through a bevel assembly which is attached to the gear box assembly. The screw rod, fixed to the center plate, is meshed with an internal gear of the bevel assembly. At every corner edges of the center plate , a ball bearing is fixed . The bevel gears are rotated by the gear box assembly which is driven by the induction motor through a motor pulley and a v-belt coupled inbetween the said gear box assembly and the induction motor. Heater(s) are also fixed to the upper surface of the top plate for heating the top plate to a temperature not more than 280 deg. C. The heated top plate heats the polymer sheet for proper bonding of the polymer sheet onto the back surface of the carpet. The upper surface of the top plate is covered with glass wool for minimizing heat loss. A thermocouple is used for controlling the temperature of the top plate. A digital timer is also attached with the centre plate for monitoring the dwelling time of the top plate on the polymer sheet for proper bonding of the same on the backside of the carpet. The temperature and the dwelling time required for bonding the polymer sheet depends on the size of the carpet. According to the present invention there is provided : A machine for backing carpet or such thick fabric material comprises: base plates, heaters, an induction motor, and a gear box assembly ; wherein the base plate comprises a top plate and a bottom plate fixed to the frames and a center plate which is moveable in the vertical direction in between the top plate and bottom plate ; the heaters are fitted to the top plate ; and the said induction motor and said gear box assembly are fitted to the bottom plate. The invention is now described in detail with reference to the accompanying drawings. Fig. l shows the machine for backing carpet. Fig. 2 shows the mechanism for moving the center plate in a verticle plane. Fig. 3 shows the center plate in lower position. Fig. 4 shows the center plate in raised position. Fig. 5 shows the trapezoid frame supporting the carpet. The machine for backing carpet comprises four frames{3D at four corners of the machine, base plates (5,6,7), heaters(8), induction motor(lO), gear box assembly(14) and a reversible switch(3). The base plates comprises of top plate(7), center plate(6) and bottom plate(5). Heaters(8) are attached to the top plate(7) which is fixed to the frames(31). Heaters heat the top plate to a maximum temperature of 280 deg. C for proper bonding of the polymer sheet with the carpet. However, the temperature required for bonding the polymer sheet and the dwelling time of the top plate on the polymer sheet of the carpet depends on the size of the carpet . A digital timer(1) is used for measuring the dwelling time. The top plate is covered with steel wool to minimize heat loss from the heated top plate. Preferably, but not essentially, four strip heaters of 750 W each are used to attain the requisite temperature for heating the polymer sheet and bonding the same with the carpet. The number of strip heaters and the power of each heaters depends on the size of the carpet. Moreover, various types of heaters, other than the strip heaters, may be used without departing from the scope of the invention. The center plate(6) comprises four ball bearings(45) fixed at the corner edges of the center plate such that the ball bearings(45) graces the frame(31) surfaces of the machine. A screw rod(15) is also fixed to the center plate. A 3-phase induction motor (10) and a gear box assembly(14) are supported by the bottom plate(5). A reversible switch (3), a thermocouple (4) , and a switch for the thermocouple (2) are fixed to one of the side plate situated near the bottom plate(5) of the machine . The induction motor(10) drives a motor pulley(11) which in turn induces drive to the gear box pulley(13) of the gear box assembly(14) by means of a v~belt(12) placed over the motor pulley(11) and gear box pulley(13). The gear box assembly(14) subsequently rotates a bevel assembly(30). The bevel assembly is preferably, but not essentially, 18T/48T. However, other teeth ratio of bevel assembly can also be used without deviating from the scope of the invention. An internal gear(32) is placed in the housing of upper bevel(i.e. 48T). The other end of the said screw rod(l5) is meshed with the internal gear(32) of the said upper bevel . As the bevel gear rotates, it makes the screw rod(15) to move up and down and inturn the center plate also moves up and down in the vertical direction in between the top plate and bottom plate. This direction of movement of the screw rod(15) is controlled by the reversible switch(3). Carpet(42) with polymer sheet on the back surface is placed on a trapezoid frame(40), provided with pin fabric gripper(41) which permits stretching cum orientation of the carpet. The trapezoid frame is subsequently placed on the center plate, such that polymer sheet is exposed towards the top plate and on top of the polymer sheet a textile material covering the polymer sheet may also be placed. The center plate is subsequently raised, by activating the induction motor and selecting the proper position of the reversible switch, till the surface of the polymer sheet presses against the heated top plate. The heated top plate melts the polymer sheet and the polymer sheet gets bonded with the carpet under heat and pressure. The temperature of the top plate is monitored by a thermocouple (4) . Once the predetermined temperature of the top plate is reached, the thermocouple disconnects the heater. The polymer sheet is kept pressed for a predetermined duration for proper bonding. The reversible switch position is changed and the center plate is subsequently lowered by rotating the bevel assembly in the opposite direction by means of induction motor and the trapezoid frame with the carpet is taken out of the machine for backing carpet and a hand roller is rolled over the backing cloth or the polymer sheet for uniform bondage of the polymer sheet over the entire cross-section of the carpet. It is evident that the invention relating to the machine for backing carpet with polymer sheet as described above may be modified in order to achieve the same result without departing from the scope of the invention. I Claim: 1. A machine for backing carpet comprises: base plates(5,6,7), heaters(8), an induction motor(10), and a gear box assembly(14); wherein the base plate comprising a top plate (7) and a, bottom plate(5) which are fixed to the frames(9) and a center plate(6) which is moveable in the vertical direction in between the top plate and bottom plate ; the heaters(8) are fitted to the top plate(7); and the said induction motor (10) and said gear box assembly(14) are fitted to the bottom plate(5). 2. A machine for backing carpet as claimed in claim 1, wherein the top plate (7) is covered with glass wool for preventing heat loss from the top plate. 3. A machine for backing carpet as claimed in claim 1, comprises a thermocouple (4) attached to one of the side plate near the bottom plate. 4. A machine for backing carpet as claimed in claim 1, comprises a reversible switch(3) for controlling the direction of movement of the center plate(6). 5. A machine for backing carpet as claimed in claim 1, wherein the gear box assembly(14) comprises gear box pulley(13). 6. A machine for backing carpet as claimed in claim 1, wherein the induction motor(10) comprises a motor pulley(11) which, is. coupled to the gear box pulley (13) of the gear box assembly(14) by means of a V-belt(12) to drive the gear box assembly(14) 7. A machine for backing carpet as claimed in claim 1 comprises a switch(2) for the thermocouple(4). 8. A machine for backing carpet as claimed in claim 1, wherein the gear box assembly(14) comprises a bevel assembly(30). 9. A machine for backing carpet as claimed in claim 1 wherein the said hejters(8) are strip heaters. 10. A machine for backing carpet as claimed in claim 1 wherein an internal gear (32) is meshed in the upper bevel of the bevel assembly(30). 11. A machine for backing carpet as claimed in claim 1, comprises a screw rod (15) of which one end is attached to the center plate(6) and the other end of the said screw rod is meshed in the internal gear(32). 12. A machine for backing carpet as claimed in claim 1 wherein a ball bearing(45) is fixed to each of the four corner edges of the center plate(6). 13. A machine for backing carpet as claimed in claim 1 comprises a digital timer(1) for measuring the dwelling time of the center plate(6) pressed against the top plate(7). 14. A machine for backing carpet as claimed in claim 1, comprises: a bottom plate(5), a center plate(6) and a top. plate(7) fixed to the frames(9); wherein the said center plate is moveable along the verticle direction and a screw rod(15) is., attached to the center plate ; four strip heaters (8) of 750 W each are fitted to the* top plate(7) for heating to a temperature not more than 280 deg. a thermocouple(4) for monitoring the temperature of the top plate; an induction motor(10) for driving a gear box assembly(14) which in turn rotates a bevel assembly(30), having 18T/48T teeth ratio, through a V-belt(12) wherein the said screw rod(15) is meshed in the internal gear(32) of the upper bevel having 48T ; a reversible switch(3) for controlling the direction of movement of the center plate ; a digital timer for measuring the dwelling time of the center plate against the top plate. 15. A machine for backing carpet substantially as herein before described with reference to the accompanying drawings. Dated this 8th day of December 2004. ( S. CHATTERJEE ) Of Datta & Associates Agent for the Applicant 1. A machine for backing carpet comprises: base plates(5,6,7), heaters(8), an induction motor(10), and a gear box assembly(14); wherein the base plate comprising a top plate (7) and a, bottom plate(5) which are fixed to the frames(9) and a center plate(6) which is moveable in the vertical direction in between the top plate and bottom plate ; the heaters(8) are fitted to the top plate(7); and the said induction motor (10) and said gear box assembly(14) are fitted to the bottom plate(5).

Documents:

803-KOL-2004-CORRESPONDENCE.pdf

803-KOL-2004-FORM 27-1.1.pdf

803-KOL-2004-FORM 27.pdf

803-KOL-2004-FORM-27.pdf

803-kol-2004-granted-abstract.pdf

803-kol-2004-granted-claims.pdf

803-kol-2004-granted-correspondence.pdf

803-kol-2004-granted-description (complete).pdf

803-kol-2004-granted-drawings.pdf

803-kol-2004-granted-form 1.pdf

803-kol-2004-granted-form 18.pdf

803-kol-2004-granted-form 2.pdf

803-kol-2004-granted-form 26.pdf

803-kol-2004-granted-form 3.pdf

803-kol-2004-granted-form 5.pdf

803-kol-2004-granted-letter patent.pdf

803-kol-2004-granted-reply to examination report.pdf

803-kol-2004-granted-specification.pdf