JP2002309760A - Core material for thin tatami mat and thin tatami mat using it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a core material for a thin tatami mat satisfactory needle piercing property, sufficient bending rigidity for sewing a tatami surface with less warping, and proper heating transmitting performance with less dimensional change by heat or moisture so as to be usable for floor heating at a low manufacturing cost, and a tatami mat using it. SOLUTION: The core material for thin tatami mat comprises paper boards of 0.1-2 mm in thickness adhered to both sides of a plastic corrugated board of 3-10 mm in thickness.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a core material for thin tatami mats and a thin tatami mat using the same.

[0002]

2. Description of the Related Art In recent years, the style of tatami mats has been strongly supported while the lifestyle has been westernized, and tatami mats have been installed on the floorboards of homes or in exhibition halls or inn halls. There are not a few cases where tatami mats are laid on the floor to form a Japanese-style room. The tatami floor of such a tatami mat or a tatami mat is usually applied to the Japanese Industrial Standards (JI
It is a building material tatami floor whose dimensions and shape are determined by SA 5914).

When a conventional tatami floor made of natural straw as a core material is laid in a reinforced concrete building having high airtightness for a long time, moisture stays in the core material, and pests such as ticks are removed. As a cause of propagation, those having a core made of a synthetic resin plate that does not absorb moisture are widely used (see JP-A-6-317003 and JP-A-3-63352).

[0004]

Since the thickness of the tatami floors of the above-described building materials reaches 5 to 6 cm, for example,
If the floor is laid in a Japanese-style room adjacent to a living room with a wooden floor, there will be a step of 5 to 6 cm between the surface of the wooden floor and the tatami mat. The thickness of the sill or rising frame provided must also be set to 5 to 6 cm, and these sills or rising frames become obstacles to walking. In particular, it is a remarkable problem for elderly people with physical disabilities and persons with physical disabilities.

Therefore, it has been proposed to reduce the overall thickness of the building material tatami floor by reducing the thickness of the core material. However, since such a thin building material tatami floor has low bending rigidity, it is difficult for humans to walk. When the tatami mat is pressed, a warp is generated, and the warp increases as the tatami mat is used for a long time, which impairs the appearance. Further, there is a problem that the end of the tatami mat protrudes upward, thereby hindering walking.

As a method of solving these problems, a tatami floor component material obtained by bonding and integrating a plate-like body having a density of 0.02 to 0.5 g / cm ³ and a fiber reinforced resin sheet (Japanese Patent Laid-Open No. Hei 11-1999).
336307) has been proposed, but this method requires the use of a fiber-reinforced resin sheet, so that the cost must be increased, and the disposal of waste is limited to landfill. It is the current situation. Further, a plate-shaped core portion formed by molding a rigid plastic foam into a plate having a thickness of 7 to 15 mm, and a sheet of paper which is attached to both sides of the plate-shaped core portion and lined with a synthetic resin film on at least one side. Although a lightweight core material for thin tatami mats (Japanese Patent Application Laid-Open No. 11-22160), which is characterized by being constituted by a reinforcing face material, has been proposed, but since a hard resin foam is used, the heat insulating performance is reduced. And it is not suitable for use on floor heating.

[0007] The present invention has been made in view of the above problems, and has a low manufacturing cost, good needle stickability,
A core material for thin tatami mats that has sufficient bending rigidity to sew the tatami mat surface, has little dimensional change due to heat and moisture, has an appropriate heat transfer performance, and can be used for floor heating. It is intended to provide a thin tatami mat using the same.

[0008]

The core material for thin tatami mat according to claim 1 is characterized in that a cardboard having a thickness of 0.1 to 2 mm is bonded to both sides of a plastic cardboard having a thickness of 3 to 10 mm. Is what you do. In this case, the plastic corrugated cardboard and the paperboard are bonded via an adhesive, but the adhesive may be partially applied in consideration of cost, or may be used in combination with heating. It may be something.

According to this core material for thin tatami mats, the manufacturing cost can be kept low, and since the bending rigidity is increased by bonding the paperboard to the plastic cardboard, the warpage is improved, and the tatami mat is sewn. The required bending stiffness can be easily obtained, and the use of plastic cardboard and paper makes it easy to pierce the needle when making floors, and the plastic cardboard has an appropriate thermal conductivity. Therefore, it is possible to obtain a tatami mat having excellent performance as a tatami mat for floor heating.

[0010] The core material for thin tatami according to claim 2 has a thickness of 3 to 1
The present invention is characterized in that a cardboard having a thickness of 0.1 to 2 mm obtained by laminating a synthetic resin film having a thickness of 1 to 40 μm on at least one surface is bonded to both front and back surfaces of a 0 mm plastic cardboard. By laminating a synthetic resin film on at least one surface of the paperboard, it is made to have water resistance, prevents the intrusion of moisture from under the floor and moisture from the top, it is possible to suppress the dimensional change of the paperboard,
It is possible to obtain a tatami mat having higher dimensional stability.

As described above, an adhesive may be used to bond the plastic cardboard and the paperboard. However, when the plastic cardboard comes into contact with a synthetic resin film, heat welding can also be used.

[0012] In the core material for thin tatami mat according to the third aspect, the thickness is 3 to
It is characterized in that 0.1 to 2 mm thick paperboard impregnated with a water-resistant resin component is adhered to both sides of a 10 mm plastic cardboard. According to this method, it is also possible to prevent moisture from entering the paperboard, to suppress a dimensional change of the paperboard, and to obtain a tatami mat having higher dimensional stability.

According to a fourth aspect of the present invention, the paperboard has a basis weight of 10
0~600g / m ^2, and the thin tatami core material of claim 1, wherein the flexural rigidity per 1m wide in the long side direction is equal to or is 20 × 10 ⁴ N · cm ² or more By using, it is possible to achieve both water resistance, bending stiffness, and needle piercing properties.

According to a fifth aspect of the present invention, since the plastic cardboard and the paperboard are bonded by heat sealing, the use of an adhesive is not required, so that the cost is reduced and the bonding between the two is firmly maintained. Warpage is less likely to occur.

As described in claim 6, a protective layer is disposed on the upper surface of the tatami floor component according to any one of claims 1 to 5,
A tatami floor is constructed by arranging a backing material on the lower surface, and a thin tatami mat formed by sewing and integrating the tatami table so that tension is added to the tatami table when the tatami table is provided on the tatami table has a low manufacturing cost and water resistance. It is a thin tatami mat that is excellent, has less warpage, and can be used for floor heating.

[0016]

Embodiments of the present invention will be described below with reference to the drawings. As shown in FIG. 1, a core material 1 for thin tatami mats is formed on a plastic cardboard 4 having a synthetic resin sheet 3 thermally fused to upper and lower surfaces of a synthetic resin sheet 2 having irregularities. 5 is obtained by bonding and integrating a paperboard 6 on which a laminate 5 is laminated.

When bonding the two, an adhesive may be used, but fusion by heat may be used. If the adhesive is used by utilizing the heat at the time of manufacturing the plastic cardboard,
This is a cost advantage.

The material of the plastic cardboard 4 is as follows.
Although not particularly limited, for example, polystyrene, polyethylene, polypropylene, phenol, urethane, vinyl chloride resins and the like can be used,
From the viewpoint of moldability, recyclability, and waste disposal properties, polyethylene-based and polypropylene-based resins are preferable, and in view of dimensional stability against heat, polypropylene-based resins are more preferable.Polypropylene resins mixed with fillers such as talc and mica are preferable. Most preferred.

The thickness of the plastic cardboard is 3 to 10 m
m is preferably 4 to 8 mm. If it is thinner than 3 mm, warpage is likely to occur, and if it is thicker than 10 mm, there is no point in forming a thin tatami mat.

The paperboard 6 preferably has high strength in order to secure the bending rigidity required for sewing the tatami mat, and examples thereof include cardboard liner base paper and paper tube base paper. The thickness of the paperboard is preferably from 0.1 to 2 mm, more preferably from 0.2 to 1.5 mm. If it is 0.1 mm or less, sufficient strength cannot be obtained, and warpage tends to occur,
If the thickness is more than 2 mm, the purpose of the thin tatami mat will be deviated, and the needle sticking property will be deteriorated.

The basis weight of the paperboard is 100 to 600 g / m ^2.
Is preferably 200 to 500 g / m ² . Is more preferred.
If it is less than 100 g / m ² , sufficient strength cannot be obtained, and warpage is likely to occur. If it is more than 500 g / m ² , there are disadvantages such as poor needle piercing even though the strength is sufficient.

The material of the synthetic resin film 5 is not particularly limited as long as it can provide a function of preventing moisture from entering from the front and back surfaces, and is not particularly limited. It is preferable to use a material similar to plastic corrugated cardboard because recycling is easy.

The thickness of the synthetic resin film 5 is 0.1-40.
μm, preferably 1-20 microns. This is sufficient as long as the adhesiveness with the plastic cardboard can be exhibited. For example, when adjusting the synthetic resin film 5 by coating / coating, even if it is thinner, the adhesive strength is obtained by heat fusion. May be enough. The same applies to the case where the paperboard is impregnated with a water-resistant resin component.

The bending stiffness in the longitudinal direction of the core material 1 for thin tatami mat obtained in this manner is at least 20 × 10 ⁴ N · cm ² per 1 m of width where the tatami mat can be easily sewn. And more preferably 22 × 10 ⁴ N · cm ² or more. The bending stiffness is determined by performing a bending test according to JIS K7221-1995, and multiplying the bending elastic modulus by a second moment of area per 1 m width.

When a tatami floor is constructed using the core material 1 for thin tatami mats of the present invention, a protective layer is appropriately arranged on the upper and lower surfaces, and a backing material is arranged on the lowermost surface and integrated by sewing. be able to. For example, as shown in FIGS. 2 and 3, a protective layer 9 is disposed on the upper and lower surfaces of the core material 1 for thin tatami mats, a backing material 10 is disposed on the lowermost surface, and the tatami mat 7 is sewn on a tatami floor 11 integrated with sewing. The edges 8 can be sequentially sewn to form a thin tatami mat.

Next, the method for producing a core material for thin tatami mats of the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples.

As characteristics of the core materials for thin tatami mats of Examples 1 and 2 and Comparative Example 1 shown below, the bending stiffness per 1 m width, dimensional stability, and sewability of the tatami mat were measured according to the following methods. .

(1) Flexural rigidity: JIS K7221-19
A bending test was carried out according to No. 95, and the bending elastic modulus was multiplied by a second moment of area per 1 m width to obtain a bending test.

(2) Dimensional stability: JIS A1437A
The test was performed according to the law. 8 at temperature 20 ° C and humidity 30%
After holding for 4 hours, 90% at 60 ° C for 4 hours, hold for 8 hours,
Thereafter, the temperature is adjusted to 20 ° C. and 30% in 4 hours. This was repeated three cycles, and the dimensional change before and after the test was measured.

(1) Sewability of tatami mat surface: A foamed polyethylene sheet having a thickness of 1 mm is laminated on the upper surface of the core material for thin tatami mats, and a foamed polyethylene sheet having a thickness of 2 mm and a backing material are arranged on the lower surface, and sewing is performed. After the integrated tatami floor was used, the tatami table was sewn on the tatami floor using an automatic upholstering machine while applying tension so that wrinkles did not enter the tatami table, and the finished condition at that time was visually observed, The case where there was no problematic problem was indicated by “×”, and the case where there was a problematic problem in practical use was indicated by “x”.

Example 1 A material in which 5% by weight of talc was mixed with polypropylene was heated and melted. Immediately after a sheet having a width of 1 m and a thickness of 0.65 mm was extruded from an extruder, the sheet was subjected to irregularities through a vacuum forming roll. A 0.35 mm sheet extruded separately from an extruder was fused on both sides of the sheet to form a plastic corrugated cardboard. Immediately after that, a 20 μm thick polypropylene film was laminated on both sides to form a cardboard liner base paper (tsubo). 320
g / m ² ) was bonded and bonded to both sides of the plastic cardboard by heat fusion, and then cut into a piece having a length of 1820 mm and a width of 910 mm.
mm and a thickness of 6.3 mm were obtained. Table 1 shows the properties of the core material for thin folding obtained at this time.

Example 2 10% by weight of polypropylene
The talc-mixed material was heated and melted. Immediately after extruding a sheet having a width of 1 m and a thickness of 0.65 mm from an extruder, the sheet was subjected to concave and convex processing through a vacuum forming roll.
Separately, a 0.2 mm sheet was extruded from an extruder and fused to form a plastic corrugated cardboard. Immediately thereafter, a 20 μm-thick polypropylene film was laminated on both sides of the base paper for paper tube (basis weight 500 g / m ² ). Was adhered and integrated on both sides of a plastic cardboard by heat fusion and then cut to obtain a core material for a thin tatami mat having a length of 1,820 mm, a width of 910 mm, and a thickness of 7.0 mm. Table 1 shows the properties of the core material for thin folding obtained at this time.

Comparative Example 1 Density: 30 kg / m ³ , thickness: 6 m
extruded polystyrene foam plate with a thickness of 20μ
The liner base paper for corrugated cardboard (basis weight 320 g / m ² ), on both sides of which a polypropylene film having a thickness of m is laminated, is cut with an EVA-based hot-melt adhesive, and then cut to a length of 1,820 mm, a width of 910 mm, and a thickness of 7.0 mm. Was obtained. Table 1 shows the properties of the core material for thin folding obtained at this time. [Comparative Example 2] A material obtained by heating and melting a material in which 5% by weight of talc was mixed with polypropylene, and extruding a sheet having a width of 1 m and a thickness of 0.65 mm from an extruder, and immediately passing the sheet through a vacuum forming roll immediately after the extruding process, both sides of the sheet Then, a 0.35 mm sheet extruded from an extruder was fused to form a plastic cardboard, and immediately thereafter, a kraft paper (basis weight 80 g / m ²⁾ having a 20 μm-thick polypropylene film laminated on both sides. ) Is bonded and integrated on both sides of a plastic cardboard by heat fusion, and then cut to give a length of 1,820 mm, a width of 910 mm, and a thickness of 6.1 mm.
Was obtained. Table 1 shows the properties of the core material for thin folding obtained at this time.

[0034]

[Table 1]

As shown in Table 1, Examples 1 and 2
Has a bending stiffness per 1 m width of 20 × 10 ⁴ N ·
cm ² , the dimensional stability is good, and it can be seen that there is no problem in the sewing property of the tatami mat. On the other hand, in Comparative Example 1, a liner base paper for corrugated board (basis weight of 320 μm) was prepared by laminating a polypropylene film having a thickness of 20 μm on both sides of an extruded polystyrene foam plate having a thickness of 6 mm as a core material for thin tatami mats.
g / m ² ) using an EVA-based hot melt adhesive, the core material for thin tatami was broken by the tension of the thread at the time of sewing the tatami mat. Comparative Example 2
In this example, paper (kraft paper, basis weight 80 g / m ² ) having a lower strength than that of the example is bonded and integrated by heat-sealing on both sides of a plastic corrugated cardboard. It was less than × 10 ⁴ N · cm ² , and the tatami floor could not withstand the tension at the time of sewing on the tatami surface, and the warp occurred greatly.

[0036]

According to the present invention, the manufacturing cost is low, the needle sticking property is good, the warpage is small, the bending rigidity is sufficient for sewing the tatami mat, and the dimensional change due to heat and moisture. It is possible to provide a core material for thin tatami mats, which has a small amount of heat, has an appropriate heat transfer performance, and can be used for floor heating, and a thin tatami mat using the same.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a core material for a thin tatami mat according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view in the width direction of the thin tatami mat according to the embodiment of the present invention.

FIG. 3 is a longitudinal sectional view of a thin tatami mat according to an embodiment of the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 core material for thin tatami mat 2 synthetic resin sheet having irregularities 3 synthetic resin sheet 4 plastic cardboard 5 synthetic resin film 6 paperboard 7 tatami mat 8 edge 9 protective layer 10 backing material 11 tatami floor

Claims (6)

[Claims] 1. A core material for thin tatami mats, wherein a cardboard having a thickness of 0.1 to 2 mm is adhered to both sides of a plastic cardboard having a thickness of 3 to 10 mm. 2. A plastic cardboard having a thickness of 3 to 10 mm, on both front and back surfaces, at least one surface having a thickness of 1 to 40 mm.
μm synthetic resin film laminated thickness 0.1 ~
A core material for thin tatami mats, which is made by bonding 2 mm paperboard. 3. A core material for thin tatami mats, characterized in that 0.1 to 2 mm thick paperboard impregnated with a water-resistant resin component is adhered to both sides of a plastic cardboard having a thickness of 3 to 10 mm. . 4. The paperboard has a basis weight of 100 to 600 g / m ² and a flexural rigidity of 20 m per width in the long side direction.
^{2. The method according} to claim 1, wherein the amount is not less than × 10 ⁴ N · cm ^2.
4. A core material for thin tatami mats according to any one of claims 1 to 3. 5. The plastic cardboard and the paperboard are bonded by heat fusion.
4. The core material for thin tatami according to 4. 6. A tatami floor with a protective layer disposed on an upper surface of the tatami floor component according to any one of claims 1 to 5, and a backing material disposed on a lower surface of the tatami floor. A thin tatami mat, wherein the tatami mat is sewn and integrated so that tension is applied to the tatami mat.