JP2003064853A - Manufacturing method of shaded tatami facing and shaded tatami facing manufactured by it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a shaded tatami facing having an uneven pattern formed on the surface and three-dimensional visual and tactile feelings and to provide a manufacturing method for the shaded tatami facing for maintaining the formed uneven pattern substantially permanently and easily applying printing to a recess part. SOLUTION: Ink paper 2 is placed on the tatami facing 1 impregnated with a thermoplastic synthetic resin emulsion and dried, and the tatami facing 1 and the ink paper 2 are set in a hot-pressing machine 3. The hot-pressing machine 3 is constructed of an upper press die plate 4, a press upper plate 5, and a press base 6 and a press rubber plate 7 in the lower part. The press upper plate 5 and the press base 6 include heaters 5a and 6a individually. After a temperature is increased to a predetermined temperature, the tatami facing 1 and the ink paper 2 are clamped and hot-pressed. In this way, an embossment consisting of recess parts 8 and projection parts 9 is machined and the recess parts are colored in the tatami facing.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a shaded tatami mat by hot pressing and printing, and a shaded tatami mat produced by the method.

[0002]

2. Description of the Related Art Conventionally, as a tatami mat which has been decorated, a pattern is formed by weaving like a checkered table or a flower, a colored tatami mat using dyed rush, or an embroidered screen. Printed tatami mats are known.
In addition, the rush grass fabric is sandwiched between the metal mold plate and the press rubber plate on which the uneven pattern is formed and heat-pressed to form an uneven pattern composed of a compressed flat portion and a swollen pattern portion on the grass surface. It is known to obtain a plain embossed pattern, a printed or woven embossed pattern (see JP-A-58-104264).

By the way, a three-dimensional tatami mat, which is not only a pattern pattern usually applied to a flat tatami mat, but also an uneven pattern on the surface, is visually and tactilely more decorative and has a touch. It is required as a product that enriches life from the viewpoint of sensitivity such as touch.

[0004]

However, in the method of forming the floating pattern as described above, the use of the tatami-mat in the real life, the repeated pressure on the surface, or simply, the rush of the grass over time. There is a problem that the formed uneven pattern becomes thin due to the original properties such as water absorption / release. There is also a demand for a method of printing and forming an uneven pattern more easily. The present invention is to solve the above-mentioned problems, forming a concavo-convex pattern on the surface, both visually and tactilely, it is a more three-dimensional tatami mat, and the concavo-convex pattern formed is semipermanently retained. Another object of the present invention is to provide a method of manufacturing a shaded tatami mat that can be printed more easily in the concave portion, and a shaded tatami mat manufactured by the method.

[0005]

In order to solve the above-mentioned problems, the present invention provides an impregnation step of impregnating a tatami-mat with a thermoplastic synthetic resin emulsion, and an ink paper placed on the tatami-mat after the above-mentioned steps. A method for producing a shaded tatami mat comprising an embossing process for coloring the concave portions formed on the tatami mat by hot pressing with a template and forming a shade on the tatami mat, and a shaded tatami mat produced by this method. is there.

In this method, a tatami-mat surface is impregnated with a thermoplastic synthetic resin emulsion, ink paper is put on the tatami mat,
Since the template is hot pressed, the shape of the embossed portion is memorized in the thermoplastic synthetic resin, and the printing is performed simultaneously with the hot pressing. Since the shape of the embossed part is memorized in the thermoplastic synthetic resin impregnated with rush,
Compared with the case of embossing with natural grass, the irregular shape is maintained almost semi-permanently for a much longer time. Further, since the ink is used to print the concave portion at the same time as the heat and pressure, it is possible to perform the printing more easily than in the case where the conventional process is performed separately. Furthermore, since only the concave portion is printed, even when the tatami mat is used in real life, the contact portion of the printed portion is less in contact wear and the coloring lasts longer.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION A method for manufacturing a shaded tatami mat according to an embodiment of the present invention will be described below with reference to FIGS.

First, the steps of the method for manufacturing a shaded tatami mat will be described with reference to FIG. In the first step of the present production method, the grass on the tatami mat is impregnated with the thermoplastic synthetic resin emulsion (S1). Usually, the whole tatami mat is impregnated by immersing it in a thermoplastic emulsion.
Alternatively, the impregnation may be performed by applying.

In the next step, the tatami mat which is impregnated with the thermoplastic synthetic resin emulsion is heated and dried (S2). Here, from the tatami-mat table impregnated with the thermoplastic synthetic resin emulsion, unnecessary solvent is evaporated and dried, and the temperature is raised to a temperature suitable for hot-pressing, for example, around 180 ° C.

Then, the ink paper is placed on the tatami mat which has been impregnated with the thermoplastic synthetic resin emulsion, dried and heated, and the tatami mat and the ink paper are set in a hot press machine (S3). Next, the upper and lower surfaces of these mold plates are hot pressed under a predetermined pressure and time (S4). As a result, embossing is performed on the tatami mat, and the concave portions formed on the tatami mat are colored by transfer from the ink paper to form a shadow on the tatami mat.

Next, the mold is released (S5). When processing a long tatami mat, it is fed to the hot press several times. Therefore, it is determined whether it is the end of the tatami mat (S
6) If it is not the end, perform sequential feeding, positioning, and setting (S7), hot pressing (S4), releasing (S5),
It is determined whether it is the end of the tatami mat (S6). In the case of the end of the tatami mat, the tatami mat is taken out (S8) and sent to the post-processing (S9). In the post-treatment, cooling, treatment of ink paper,
Other processes such as quality inspection and tatami mat production are performed.

Next, an embodiment in which a long tatami mat is processed by a flat type hot press machine will be described with reference to FIG. Figure 2 (a) shows
It is a figure corresponding to process S3 of FIG. The ink paper 2 is placed on the tatami mat 1 which has been impregnated with the thermoplastic synthetic resin emulsion, dried and heated, and is set in the hot press machine 3. Here, the hot press machine 3 is a flat plate type,
It comprises an upper part 3a and a lower part 3b.

FIG. 2B is a diagram corresponding to step S7 of FIG. In the case of this example, the tatami mat is supplied from the left side of the hot press machine and is fed to the right side in sequence, and the entire surface of the tatami mat is completed by three hot presses. In this figure, an unprocessed part is shown on the center and the left side, and a processed part 89 is shown on the right side.

Further, details of the processing will be described with reference to FIG. In FIG. 3A, the tatami mat 1 and the ink paper 2 placed on the tatami mat 1 are set in the hot press machine 3. The upper part 3a of the hot press machine 3 comprises a press template 4 and an upper press plate 5, and the lower part 3b comprises a press stand 6 and a press rubber plate 7. Further, heaters 5a and 6a are built in the press upper plate 5 and the press table 6, respectively. These heaters 5a and 6a are used for raising the temperature of the tatami mat 1 or for heating during the treatment. Here, the tatami mat 1 is long, and an unprocessed portion on the left side and a concave portion 8 and a convex portion 9 which have already been processed to form a shadow are shown on the right side.

Next, in FIG. 3B, the tatami mat 1 and the ink sheet 2 are nipped and hot pressed by a press pressure supply means P (not shown). As a result, the tatami mat is embossed and the concave portions are colored.

Finally, in FIG. 3 (c), the pressure of the press pressure supply means P is removed, and the upper part 3a and hence the press template 4 are removed.
The mold release (S5) is performed by ascending and separating, and the tatami-mat 1 partially shaded is obtained. After that, in order to perform the shadow forming processing on the remaining portion, the sequential processing, the positioning, and the setting (S7) are performed, and the repeated processing is performed.

Next, an embodiment in which a long tatami mat is processed by a drum type hot press machine will be described with reference to FIG. Figure 4 (a)
[Fig. 3] is a diagram corresponding to step S3 of Fig. 1. Tatami table 1 that was impregnated with a thermoplastic synthetic resin emulsion, dried, and heated
Ink paper 2 is placed on the drum type hot press machine 3
It is set to 0. Here, the drum type hot press machine 30 is composed of an upper part 30a and a lower part 30b.

FIG. 4B shows steps S4, S5 and S of FIG.
It is a figure corresponding to 6 and S7. That is, in the drum type hot press machine 30, a series of processes are continuously performed while the upper portion 30a and the lower portion 30b are continuously rotated. In the case of this example, the tatami mat is supplied from the left side of the hot press machine and continuously fed to the right side. The processed part 89 is shown on the right.

Next, FIG. 5 shows a drum type hot press machine 30.
FIG. 6 is a detailed diagram of a process by. In FIG. 5, the tatami mat 1 and the ink paper 2 placed on the tatami mat 1 are being processed by the drum-type hot press machine 30. The upper part 30a of the drum-type hot press 30 comprises a press mold plate 4 and a press upper plate 5, and the lower part 30b thereof comprises a press stand 6 and a press rubber plate 7. Here, the tatami mat 1 is long, and the processed portion 89, which has already been processed and in which the shadow by the concave portion 8 and the convex portion 9 is formed, is on the right side.

FIGS. 6A and 6B show a shaded tatami mat manufactured by the method of the present invention. As shown in FIG. 6 (a), the convex portion 9 of the tatami mat is a portion having the thickness and the shape of a normal grass which is not subjected to the thermocompression treatment, and the concave part 8 is the thermocompression treatment. Is a portion that has been compressed by, and the compressed shape is stored by the thermoplastic synthetic resin. In the recessed portion 8, the warp 1c, which is the internal structure of the tatami mat, appears to be raised due to heat and pressure, and this is also a part of the decoration. Coloring part 1
0 is a portion that is selectively colored in the concave portion 8. Embossing and coloring with hot pressure gives a tatami mat with the desired shading.

As shown in FIG. 6 (b), the normal tatami mat includes a pair of two substantially linear warp threads 1c and a weft thread arranged so as to bend the two warp threads 1c. It is composed of Narigus 1d. Also, the finish of the front surface 1a and the back surface 1b is usually the same.

The surface 1a is pressed and compressed by the convex portions of the press template 4 to form concave portions 8. In addition, the recessed portion 8 has colored portions 10a and 10b. In this case, the colored portion 10a is present in almost the entire area of the recessed portion 8 and the colored portion 10b is present in a part of the recessed portion 8. The ink of the ink paper 2 is intended to be printed only on the portion which is sandwiched and hot pressed by the hot press machine 3. Further, the ink paper having the ink only on the portion desired to be printed and colored is not on the entire surface of the ink paper 2. With this, it is possible to set the coloring pattern regardless of the shape of the concave portion 8. The back surface 1b is finished flat.

The present invention is not limited to the configuration of the above embodiment, and various modifications can be made. For example, in the hot-press machine, the one with a built-in heater is shown, but depending on the processing situation of the heating and drying step in the pretreatment,
It is also possible not to incorporate it, and the point is that the temperature of the tatami mat should be maintained at the temperature required during thermal processing depending on the characteristics of the thermoplastic synthetic resin used. When heating and drying the tatami mat that has been impregnated with the thermoplastic synthetic resin emulsion, in addition to processing it in a separate heating and drying oven and applying it to a hot press machine, a hot air or infrared heater processing unit is also provided on the transfer line of the hot press machine. It is also possible to provide in-line processing. Further, the ink paper to be used is one in which transfer printing is performed only on the hot-pressed portion, but various colors can be used in a single color or in a plurality of colors arranged. Further, in addition to partial printing as in the present embodiment, printing can be performed on the entire surface of the hot press. By combining various arrangements of colors and colored portions in accordance with the embossing irregularities to be created, a shaded tatami mat according to the application can be obtained.

[0024]

As described above, according to the present invention, since the tatami-mat surface is impregnated with the thermoplastic synthetic resin emulsion and hot pressed by the template, the shape of the embossed portion is stored in the thermoplastic synthetic resin. It has the effect of retaining its shape semi-permanently. Further, since the ink paper is placed and heat-pressed by the template, printing and heat-pressing are performed at the same time, so that the concave portion is surely colored, and there is an effect that the process is shortened as compared with pre-printing.

[Brief description of drawings]

FIG. 1 is a process flow chart of a method for manufacturing a shaded tatami mat according to the present invention.

2A and 2B are explanatory views of processing a tatami mat according to the present invention with a flat-type hot press machine.

3 (a), (b) and (c) are detailed diagrams of the same.

4 (a) and 4 (b) are explanatory views of processing a tatami mat according to the present invention with a drum-type hot press machine.

FIG. 5 is a detailed view of the above.

6A is a plan view of a part of a shaded tatami mat according to the present invention, and FIG. 6B is a sectional view taken along line I-I of FIG.

[Explanation of symbols]

1 tatami mat 2 ink paper 3,30 Hot press machine 4 Press template 8 recesses 9 convex part 10, 10a, 10b Coloring part

Continued front page    F-term (reference) 4D075 AC44 AE03 BB06Z BB23Z                       BB62X CB26 DA03 DB18                       DB20 DC38 EA13 EA17 EA33                 4F209 AD10 AG05 AH48 PA02 PB01                       PC01 PC05 PH02 PJ05 PJ06                       PN01

Claims (2)

[Claims] 1. An impregnation step of impregnating a tatami-mat with a thermoplastic synthetic resin emulsion, and an ink paper is placed on the tatami-mat after the above step, and heat is applied by a template from the upper and lower surfaces of the tatami-mat to form concave portions formed on the tatami-mat. A method for producing a shaded tatami mat, comprising the step of coloring and forming an embossed pattern on the tatami mat. 2. A shaded tatami mat produced by the method of claim 1.