JP2001107541A - Edgeless thin tatami mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an edgeless tatami mat having good appearance and having few steps such that the folds of a tatami face can be neatly brought into contact with itself even on its back. SOLUTION: A tatami face is formed by weaving an artificial rush made from a thermoplastic resin, and is cut in such a manner that while it is greater than a core by a predetermined width, both lengthwise and crosswise, its four corners are about equal to the corners of the core. Cutting lines are heat treated or adhesive treated to prevent loosening. After the four sides are folded back to wrap the core, the tatami face is secured to the core.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an edgeless thin tatami mat using imitation rush.

[0002]

2. Description of the Related Art In recent years, there has been an increasing demand for so-called thin tatami mats having less thickness than conventional tatami mats. This is attributable to barrier-free housing adapted to an aging society. In other words, in order to eliminate a step between the flooring and the tatami mat, the thickness of the tatami mat is made equal to the thickness of the flooring material to cope with the problem.

[0003] In recent condominiums and the like, most of them are between the boards (rooms with flooring such as flooring), and there are few tatami rooms. This is due to the limited use of tatami rooms due to furniture such as beds. However, elderly people are still unfamiliar with the life of chairs and often request tatami mats. In such a case, a simple tatami room is often provided by laying a thin tatami on part or all of the space between the boards.

Although the demand for thin tatami mats has been increasing for the above reasons, conventional tatami mats are manufactured by sewing a tatami mat using natural rushes onto a thin plate or plastic as a core material. It was done. Conventional tatami mats are about 55 mm thick, but these are about 10 to 25 mm.

Further, among such tatami mats, so-called borderless tatami mats are often used. This does not have an edge usually provided on a side perpendicular to the rush, and the shape is not limited, but there are many square types. This type is preferred when laying in a part of the flooring room.

[0006]

However, unlike the conventional tatami mat, it is necessary to fold the tatami mat at the four corners because it is necessary to fold the gusset to the back side without cutting the gusset even on the side perpendicular to the gusset unlike the ordinary tatami mat with a rim. It was difficult to cut and fix.

[0007] In the case of using an imitation rush made of a thermoplastic resin, a method may be considered in which after folding the tatami surface, the four corners are picked, and the overlapping portions are cut and fused. However, in this method, the heat-sealed portion inevitably rises or the color of the melted portion changes, resulting in poor appearance. In addition, since it is performed while picking, it is difficult to make the shape linear.
The back side of the tatami mat, which is not normally visible, but if the back side is noticeable before laying, the feeling is bad, and the product itself is viewed badly or the processing is considered bad. In addition, since it is difficult to fold a plastic rush exactly, a sag occurs when the rush is picked.

[0008]

In view of the above-mentioned situation, the present inventor has completed the present invention and has completed the present invention. It is a tatami table constructed by weaving an imitation rush, and although the width is made larger than the core material both vertically and horizontally, the four corners are cut so as to be almost equal to the corners of the core material, and the cut line is heat-treated or bonded to prevent fraying. Is performed, and then the four sides are folded so as to wrap the core material, and then the tatami mat is fixed to the core material.

[0009] Here, the thermoplastic resin means a resin whose viscosity can be reduced by heating to make it moldable. Polyolefin such as polypropylene is a typical example, but is not particularly limited. Of course, a mixture of various thermoplastic resins may be used. To this, a weathering agent, a pigment, a matting agent and the like which are usually mixed may be mixed.

[0010] The imitation rush made of thermoplastic resin is not limited as long as its main material is thermoplastic, and its production method is not limited. In short, it is only necessary to prevent fraying by heat. For example, any film may be used, such as a spirally wound film, a randomly folded film, a tubular shape, a rod shape, and the like.

The tatami mat is made by weaving the above-mentioned imitation rush, and the weave may be of any kind.
Not only the method currently woven with natural rush but also a completely new weave.

[0012] The core material is a portion that becomes the core of the tatami mat itself.
In the case of natural tatami mats, it is called a floor made of straw. Here, since it is a thin tatami mat, the thickness is 5 to 25 mm. The material may be any material such as a veneer plate or a plastic plate. A plastic foam or a plastic honeycomb shape may be used. The shape is rectangular, square or rectangular.

As the core material, a material in which an aluminum foil (sheet) or an iron foil is adhered to a plywood is also suitable. The thickness of the metal foil is preferably 0.1 to 0.5 mm, and the surface may be subjected to rust prevention such as painting. The metal foil serves to prevent moisture and moisture from entering the base member. This sheet may be commercially available, and does not require any special purity or precision.

The veneer board is a thin board made of timber, and a plurality of such boards are bonded with the fiber direction at right angles.
The thickness is not particularly limited, but is preferably about 5 to 10 mm. This plywood is a portion that becomes a base material of the tatami mat. Since the plywood has fibers at right angles, expansion and contraction due to moisture and temperature is very small. The use of the plywood having a small expansion and contraction and the prevention of moisture from entering the plywood with a metal foil are excellent for floor heating.
Usually, the metal foil is stuck on both sides of the veneer. This is to block moisture from both sides.

Also, in order to improve cushioning properties,
A cushion material such as a nonwoven fabric may be inserted between the core material and the tatami mat. The thickness is preferably about 2 to 10 mm. Further, rubber or the like may be adhered to the back surface as a non-slip.

[0016] To make the width larger than the core material both vertically and horizontally,
It is to make the tatami table larger only at the folded part than the core material,
It is natural for a borderless tatami mat.

To cut the four corners of the tatami mat so as to be substantially equal to the corners of the core means to cut in advance the overlapping portions on the back surface of the core when folded. It is not necessary for the cut lines to exactly match on the back side, as long as they do not overlap, but if they are too far apart, the appearance is poor. Of course, it is necessary to cut the thickness of the core at a distance from the corner of the core. The cutting may be performed with a knife or scissors, or with a hot iron. In short, it is only necessary that the thermoplastic resin can be cut.

When the cut line is heat-treated, when the cut line is usually cut with a knife or the like, the rush falls off the warp from that portion and becomes frayed. To prevent this, heat (usually 1
(About 80 to 190 ° C., depending on the material of the rush). This can be done simply and easily with a hot iron. In addition, when the cutting is performed with a thermal iron as described above, if the fraying is prevented at the time of the cutting, the fraying can be prevented immediately after the cutting, so that the heat treatment is often not necessary again.

Also, in the bonding treatment, the adhesive is applied to harden the portion, and the rush falls off from the warp,
It prevents fraying. As the adhesive, a type in which the imitation rush is dissolved or a type in which the imitation rush is bonded with another member may be used. Although an α-cyanoacrylate-based instant adhesive cures quickly and is suitable, it is not limited.

Folding the four sides so as to wrap the core material is natural in the processing of the rimless tatami, but the tatami mat is folded back on the back surface of the core material (floor material). The tatami mats do not overlap on the back because they have been cut off.

To fix the tatami surface to the core means to fix the tatami surface to the core material on the back surface, and the fixing method may be a method such as tacking (stapling), sewing, bonding or the like.

Next, the imitation rush according to the second aspect will be described. One example of a method for producing this imitation rush is as follows:
The raw material tape from the inflation device is stretched by a first pinch roll while passing through a first heating device, and introduced into a second heating device. Irregular convergence by the second heating device. This is pulled by a second pinch roll and sent to a subsequent cutting step. If it is cut to a predetermined length in the cutting step, the process is completed. This imitation rush is woven and woven like a natural rush.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The thin tatami mat of the present invention will be described below in detail based on an embodiment shown in the drawings. FIG. 1 is a plan view of the back surface of one example of the thin tatami mat 1 of the present invention. Since the four corners are cut off, the tatami table 2 is in contact with the back surface without overlapping. Also,
The tatami mat 2 is fixed to the core 4 with a tucker 3.

2 to 4 show a method of manufacturing the thin tatami mat 1 according to the present invention. First, a core material 4 (in this example, a thickness of 6 mm, one side
81.5cm square) and wider (90cm in this example)
A tatami table 2 (square square) is prepared, a tatami table is placed face down, and a core 4 is placed thereon (FIG. 3). Next, the four corners of the tatami table 2 are cut as shown by the broken lines in FIG. In this example, thermal cutting is performed with a hot iron. Therefore, the heat treatment for preventing fraying can be performed immediately (almost simultaneously). At this time, the cut is made slightly smaller in consideration of the thickness of the core material. Then, the portion protruding from the core material may be turned back, and the four corners may be tacked as shown in FIG. Therefore, the tatami mats are not fused on the back surface.

[0025]

The thin tatami mat of the present invention described in detail above has the following great effects. 1) The four corners are cut off in advance and heat-sealed or bonded to make the back surface very clean. 2) There is little slack due to sticking after folding. 3) No fraying because the cutting line is fused or bonded by heat. 4) There is no overlap of imitation rush and there is almost no variation in thickness.

[Brief description of the drawings]

FIG. 1 is a bottom view showing an example of the thin tatami mat of the present invention.

FIG. 2 is a bottom view showing the method for manufacturing a thin tatami mat according to the present invention.

FIG. 3 is a bottom view showing the method for manufacturing a thin tatami mat according to the present invention.

FIG. 4 is a bottom view showing the method for manufacturing a thin tatami mat according to the present invention.

[Explanation of symbols]

 1 Thin tatami 2 Tatami mat 3 Tucker 4 Core material

Claims (3)

[Claims] 1. A tatami table formed by weaving an imitation rush made of a thermoplastic resin, the width of which is larger than the width of the core in both the vertical and horizontal directions, but the four corners are cut so as to be substantially equal to the corners of the core. Edgeless thin tatami mats, which are subjected to heat treatment or adhesive treatment to prevent fraying, and then folded around four sides so as to wrap the core material, and then the tatami mat is fixed to the core material. 2. The imitation rusher made of a thermoplastic resin comprises a tape-shaped body made of a thermoplastic resin stretched in a longitudinal direction,
2. The rimless thin tatami mat according to claim 1, wherein the thin tatami mat is irregularly convergently formed by being passed through a heating member forming a narrow gap, and a fused film is formed on the surface. 3. The thin tatami mat according to claim 1, wherein said core material is an aluminum veneer obtained by attaching an aluminum foil to a plywood plate.