A method of manufacturing safety horseshoes

Abstract

A method of manufacturing a horseshoe comprising placing a first rubber blank onto a heated base mould plate 2A; placing a rigid core on the first rubber blank; placing a second rubber blank on the ri

Description

FIELD OF INVENTION The present invention relates to the method of manufacturing horseshoes and to horseshoes produced by this method. More especially, a method of manufacturing rubber coated horseshoes which consists of a rubber mould, such that a rigid insert is encased by rubber. BACKGROUND TO THE INVENTION Horseshoes are accessories designed to protect horse hooves during wear. Horseshoes are typically made from hard materials such as metals and are typically nailed to the underside of the hooves. One of the issues with horseshoes is that they can come loose over time and can break off during use. If this comes off during a fast-paced exercise, there is a strong likelihood of gravely injuring the horse’s legs as well as the jockey. To rectify this issue, manufacturers have developed horseshoes with soft exterior shells such as rubber or plastic and a hard metal core. In the event these particular horseshoes come loose, the damage caused by them coming loose is minimised greatly. Therefore, these soft-shell horseshoes provide adequate protection to the horse during use and act as a safety product for horses and jockeys. Rubber horseshoes are typically manufactured by adhering pieces of rubber around the metal core. The problem with this method of manufacture is that the rubber can break off easily during use, exposing the metal and thus increasing the likelihood of damages. Furthermore, rubber horseshoes also tend to wear down quicky due to disproportional and uneven bottom surfaces. This leads to certain areas of the horseshoe wearing down quicker than others, exposing the metal core, and thus increasing the likelihood of causing damage to the horse and the jockey. It is the object of the present invention to provide a method of manufacturing moulded rubber horseshoes which seeks to alleviate the aforementioned problems. The method of manufacturing aims to provide a safety rubber horseshoe which cannot come loose or break during use as the shoe is one uniform piece, thus completely minimising the damage typically caused by horseshoes. The inventor has successfully run a rubber and plastics company for the last 55 years and used his knowledge and background to develop this invention. The inventor has owned horses in the past for many years and has a passion for not only horses but their rider’s safety as well, leading them to develop the product many years ago. However, due to a car accident and prioritising their health first, they have only conceptualised, tested and created prototypes in the recent years. The inventor is a member of the Institute of Patentees and Inventors. They have focused on and patented inventions related to safety products, most notably an anti-slip saddle pad which has saved many lives and accidents since its conception, leading it to being recognised and winning awards worldwide. In addition to this, they have developed a plethora of high-quality safety products which span a range of different sports. The success in the inventor’s products has led to them obtaining good reputation and respect as a safety product inventor. STATEMENTS OF INVENTION According to one aspect of the invention, there is provided a method of manufacturing a horseshoe , the method comprising the steps of: placing a first rubber blank onto a heated base mould plate; placing a rigid core on the first rubber blank; placing a second rubber blank on the rigid core; placing a top mould plate on the second rubber blank to compress and mould the rubber blanks around the core; curing the rubber such that it hardens around the core; and removing excess rubber from the cured horseshoe product. Preferably, the method is carried out using a high temperature and pressure rubber press. Preferably, the core is made from a hard metal. Alternatively, the core is made from a hard plastic material. Preferably, the method further comprising the step of coating the core with a rubber adhesive. Preferably, removal of excess rubber is carried out by means of a water jet. Alternatively, or additionally, the removal of excess rubber is carried out by means by the utilisation of a bladed tool. Preferably, one or both mould plates carry a tread design. Preferably, the rubber is cured to a 70-90 Shore A hardness. BRIEF DESCRIPTION OF THE DRAWINGS One embodiment of the invention will now be described with reference to the accompanying figures in which: Figure 1 is a plan view of the bottom mould plate; Figure 2 is a plan view of the corresponding top mould plate; Figure 3 is a perspective view of one side of the horseshoe constructed in accordance with the invention; and Figure 4 is a perspective view of the other side of the horseshoe of figure 3. DESCRIPTION OF THE INVENTION The horseshoe is manufactured through compression moulding of rubber (natural or synthetic), utilising a heated mould 2 which is generally shaped as a horseshoe. The mould comprises a bottom plate 2A and a top plate 2B (as shown in Figures 1 and 2). The bottom plate further comprises guiding pins 4, which correspond to guiding apertures 6 located on the top plate. In the figures shown, the mould 2 comprises three guiding pins and corresponding guiding apertures. The bottom and top plates can be configured to provide a different design of tread on surface 8 of the horseshoe depending on the situation the shoe will be used in. In the example shown in the figures, the tread is flat on either side. The rubber used is pre-mixed with a curing system which can provide a generally hard vulcanised rubber, this may be, but not limited to a 70-90 Shore A hardness. The rubber used is entirely natural or synthetic in composition. No other elastomeric materials are mixed into the rubber. The moulding process is carried out on rubber press at a high temperature and pressure. The top and bottom plates are attached to opposing ends of the rubber press through a suitable attachment means. A first rubber blank / pre-form is placed onto the heated bottom plate, upon which is placed a core (not shown). The core may be made from a hard metal such as steel or aluminium. Alternatively, the core can be made from a hard non-metallic material such as plastic. The core may be coated with a suitable rubber adhesive, to ensure that there is no movement of the core after manufacture. A second piece of rubber blank / pre-form is placed upon the core. Once placed, the heated top plate will descend until the guiding pins 4 engage with the corresponding guiding apertures. As the two plates come closer together, rubber blanks and the insert are moulded together to form the horseshoe with a uniform layer of rubber surrounding the hard core. The rubber is then cured at a specific temperature, in this part of the process, the rubber reaches its desired hardness. Once cured, any excess rubber is removed from the product through a suitable removal means. This for example may be, but not limited to using a blade or through the use of a water jet- In an alternate embodiment not shown, the first rubber blank and the core can be pressed together initially prior to placing the second rubber upon it. This ensures that the apertures in located on the core accurately align with the mould 2. The final product is shown in Figures 3 and 4, wherein a horseshoe 8 is formed which comprises a singular, uniform layer of rubber 10 entirely around the core. The rubber exterior of the horseshoe is less damaging if it impacts a person or horse if the horseshoe comes off whilst the horse is moving at speed. Apertures 12 are formed through the horseshoe to receive horseshoe nails to secure the horseshoe to the hoof of a horse in the traditional way. The geometry of the entrance of the apertures differs in shape to the geometry of the exit, this prevents the horseshoe nail from travelling deeper into the hoof and potentially damaging the horse. This for example may be, but not limited to, a square entrance aperture 12A and an annular exit aperture 12B. The horseshoe may comprise a rim or geometric protrusions (not shown), located adjacent to the exit apertures and upwardly extending from the outermost edge of surface 14 of the horseshoe. This keeps the hoof in place and prevents slipping during application of the horseshoe. The rim or geometric protrusions can be applied in the moulding process, wherein the moulding plates are designed to incorporate this design feature. The encapsulation of the inner core entirely within a rubber mould ensures that the horseshoe does not have any points of weakness where the sections of the rubber outer mould would otherwise be connected, which may fail to expose the metal core. The manufacturing technique provides a uniform, flat and even surface on both faces and sides of the horseshoe. These surfaces provide for an even, uniform abutment across the entire horseshoe mitigating the risk of the horseshoes becoming loose at one side. The rubber mould outer is formed with rounded edges and ends so not to have any sharp edges. In a further alternative embodiment (not shown), the horseshoe is manufactured by placing a rigid core generally shaped as a horseshoe in a chamber, filing the chamber with liquid rubber and then moulding the rubber around the core. The rubber (natural or synthetic) latex is cast around the core. Once solidified and cured, horseshoe 8 is formed comprising a singular, uniform layer of rubber 10 entirely around the core. It will be appreciated that the foregoing is merely exemplary of the manufacturing methods for horseshoes in accordance with the invention and that modifications can be readily made without departing from the true scope of the invention as set out in the claims.

Claims

1. A method of manufacturing a horseshoe, the method comprising the steps of:placing a first rubber blank onto a heated base mould plate;placing a rigid core on the first rubber blank;placing a second rubber blank on the rigid core;placing a top mould plate on the second rubber blank to compress and mouldthe rubber blanks around the core;curing the rubber such that it hardens around the core; andremoving excess rubber from the cured horseshoe product.

2. A method according to claim 1, wherein said method is carried out using a high temperature and pressure rubber press.

3. A method according to claim 1 or claim 2, wherein the core is made from a hard metal.

4. A method according to claim 1 or claim 2, wherein the core is made from a hard plastic material.

5. A method according to any one of claims 3 to 4, further comprising the step of coating the core with a rubber adhesive.

6. A method according to any preceding claim, removal of excess rubber is carried out by means of a waterjet.

7. A method according to any one of claims 1 to 5, wherein removal of excess rubber is carried out by means by the utilisation of a bladed tool.

8. A method according to any preceding claim wherein one or both mould plates carry atread design.

9. A method according to any preceding claims wherein the rubber is cured to a 70-905 Shore A hardness.

Images