JP2003129648A - Manufacturing method of borderless tatami, and borderless tatami - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress occurrence of looseness and wrinkle of the tatami facing of a borderless tatami in the side direction. SOLUTION: The length L of the tatami facing 1 in the side direction is cut to L1 , shorter than stretch length 1 of the tatami facing in the side direction of a board member 2 (L1 <1). Then, the tatami facing 1 is grappled by a chuck 25, heated by a heater or the like (not shown), and pulled by the chuck 25, thereby extending the tatami facing 1. Thus, the length L1 of the tatami facing 1 in the side direction is increased to L1 ', longer than the stretch length 1 of the tatami facing of the board member 2 in the side direction (L1 → L1 ', and L1 '>=1). Finally, the tatami facing 1 is cooled to be tightened. The length L1 ' of the tatami facing 1 in the side direction is decreased by the cooling to adhere the tatami facing 1 to the board member 2, and thus the length L1 ' is substantially equal to the stretch length 1 of the tatami facing (L1 ≈1). Apparent length L1 ' of the tatami facing 1 becomes a length substantially equal to the stretch length 1 of the tatami facing due to this contraction. However, the tatami facing 1 tries to contract further, residual internal stress 33 occurs in the stretch direction of the tatami facing 1 in the tatami facing 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tatami mat table when laying tatami mats having the same size and shape into a tatami mat having an inner size slightly smaller than the outer size of an assembly in which several tatami mats are closely attached. The present invention relates to a tatami mat having a function of removing looseness generated in the tatami mat.

[0002]

2. Description of the Related Art Traditionally, tatami mats are generally manufactured according to Japanese Industrial Standards (J
The mats fitted with natural rush are often used.

A tatami floor stipulated in the Japanese Industrial Standards (JIS) uses a core material which is a combination of an insulation board, a polystyrene foam, a straw material, etc. as a basic core material, and a cushioning material on this surface, if necessary. And a tatami mat with a thickness of 50-55 mm with a protective material is used on the back side.

The size of this tatami mat is measured by measuring the inner size of the frame formed by folding the tatami mat in the Japanese-style room at the site, and determining the size of each tatami mat accordingly. Therefore, the dimensions of each tatami mat are different even in the same room.

For the tatami mats that are stretched on the surface of the tatami floor, artificial grasses such as textiles made of resin products and paper products are used in addition to the natural grasses. This tatami mat is woven by weaving yarns such as cotton yarn or hemp yarn with weft yarns which are natural rush or artificial rush. By providing this warp inside the tatami mat, it becomes easy to apply tension in the direction of the gusset when the tatami mat is stretched on the tatami mat.

There are two types of tatami mats, one is a rim tatami with a rim and the other is a rimless tatami with no rims on the side surface. The rimless tatami is used when a simple and flat space is desired. In the case of this rimless tatami, the processing of the tatami mat on the side surface is different from that of the rimmed tatami. That is, in the tatami mat with edges, the edge part of the tatami mat is cut at the side surface, and the cut part is covered with the edge to perform the edge processing. The edge is processed by turning the to the back of the tatami floor.

A conventional method of tensioning the tatami mat in such a rimless tatami mat will be described below with reference to FIG.

First, as shown in FIG. 16 (a), the tatami mat 1
01 is cut larger than the tatami floor 102.

Next, the corners of the tatami mat 101 and the warp threads 107
Hot melt is applied to the protruding gusset portion 112 to prevent fraying.

Next, as shown in FIGS. 16B and 16C, the tatami mat 101 is stretched on the tatami mat 102 in the direction of the gusset through which the warp 107 passes. That is, tension is applied to the tatami mat 101 in the direction of the gusset, and then the tatami mat 101 is fixed on the back surface 113 side of the tatami floor 102 by fixing by conventional thread sewing processing or fixing using staples in recent years, so-called stapler fixing. .

Next, as shown in FIGS. 16 (d) and 16 (e), the tatami mat 101 is stretched on the tatami floor 102 in the lateral direction in which the warp threads 107 do not pass. In the case of a tatami mat with a rim, the tatami mat 101 is cut along the end surface of the tatami floor 102, and then the edges are sewn, but in the case of a tatami without a rim, the tatami mat 101 is bent along the end surface of the tatami floor 102 in the direction of the kamachi. Similarly to the tatami mat 10
1 is fixed on the back surface 113 side of the tatami floor 102.

The edgeless tatami having the tatami mat surface stretched as described above is laid in the tatami mat frame while compressing each side of the tatami mat so as not to move in the frame formed by the tatami mat stack.

[0013]

In recent years, the number of prefabricated houses in which members are manufactured in factories has increased in recent years, and the interior has become a model,
The floor dimensions of Japanese-style rooms are becoming common. Among them, it has been proposed to produce tatami mats with the same size and shape at the factory and fit them in the tatami mats.However, even in the case of prefabricated houses that are factory-manufactured, the tatami mats are not It cannot be a right-angled quadrilateral. For example, the inner dimensions of the tatami mats for 6 tatami mats may differ by up to 15 mm, and the corners of the frame formed by the tatami mats are completed at a right angle. Not done. For this reason, when the tatami mat is fitted into this frame, the side surface of the tatami mat is excessively compressed, resulting in loosening and wrinkles on the tatami mat table and edges, which is unattractive, and the tatami mat table is easily damaged.

In the case of a rimless tatami mat, looseness and wrinkles occurring on such a tatami mat are likely to occur in the lateral direction where it is difficult to apply tension because there is no warp with high tensile strength when the tatami mat is stretched.

When such looseness or wrinkle occurs on the tatami mat, a problem such as movement of the tatami mat when a person walks may occur and the danger may increase.

[0016] Therefore, an object of the present invention is to provide a method of manufacturing a rimless tatami, in which slacks and wrinkles are less likely to occur on the tatami mat, particularly in the lateral direction, and to provide the rimless tatami.

[0017]

In order to achieve the above object, in the method for manufacturing a rimless tatami of the present invention, the board member is fixed by a fixing portion on the side surface or the back surface to cover the front surface side. In the method for manufacturing a rimless tatami mat having a tatami mat tatami mat, tension is applied to the tatami mat so that the stress remains in the tension direction between the opposing side surfaces other than the gusset portion in the tatami mat after being stretched on the board member. It is characterized by including a residual stress applying step of tensioning the tatami mat on the board member while applying the stress.

According to the method for producing a rimless tatami of the present invention as described above, since the tatami mat is stretched on the board member while applying tension to the side face of the tatami mat, the tatami mat is also stretched in the tatami mat after being stretched on the board member. The stress remains in the direction. Therefore, it is possible to suppress loosening and wrinkles that tend to occur between the side surfaces of the tatami mat.

Further, in the method for manufacturing a rimless tatami of the present invention, the expansion / contraction rate of the tatami mat is 5% or more and less than 25%, and each side of the tatami mat in a stretched state within the range of the expansion / contraction ratio is fixed to the board member. It may be fixed to the part.

Further, in the method for producing a rimless tatami of the present invention, the tatami mat is a heat-shrinkable resin which shrinks by heating, and after fixing each side of the tatami mat in the stretched state to the fixing portion of the board member, As the residual stress applying step, the tatami mat may be heated to be brought into close contact with the board member.

Furthermore, the method for producing a rimless tatami of the present invention is
The tatami mat is a water-absorbent resin grass, and after fixing each side of the tatami mat in a water-absorbed state to the fixing part of the board member, as a residual stress applying step, the tatami mat is dried and brought into close contact with the board member. Good.

Further, in the method for producing a rimless tatami of the present invention, the water absorption rate of the water absorbent resin grass may be 5% or more and less than 25%, and the tension is within the range of 100N to 500N. Good.

The tatami mat of the present invention is a rimless tatami mat manufactured by the method for manufacturing a rimless tatami mat of the present invention, and the tatami mat has a polypropylene-based, polystyrene-based, polyethylene-based, or polyethylene terephthalate-based resin. It is characterized by consisting of.

As described above, the rimless tatami of the present invention has a tatami mat made of a resin of polypropylene, polystyrene, polyethylene, or polyethylene terephthalate, after being stretched on the board member, except for the kamati portion. Since the tatami mat is stretched on the board member while applying tension to the tatami mat so that the stress remains in the pulling direction also between the opposing side faces, loosening or wrinkling between the side faces of the tatami mat is unlikely to occur.

In the rimless tatami of the present invention, the core material of the board member may be made of a resin foam having an expansion ratio of 2 to 40.

The rimless tatami of the present invention has a thickness of 0.1 mm to 0.5 m, which is composed of fibers and synthetic resin continuous in one direction.
The sheet member of m may be laminated on both sides of the core material.

Further, the edgeless tatami of the present invention may be a composite sheet in which fibers of two sheet members are laminated so that the fiber directions thereof are substantially orthogonal to each other, and the composite sheet is laminated on both sides of the core material.

In the rimless tatami of the present invention, the fiber is glass fiber, the synthetic resin is polypropylene resin, polystyrene resin, or polyester resin, and the volume content of glass fiber is 30% or more and 80% or more. It may be less than.

[0029]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS (First Embodiment) A schematic external perspective view of a rimless tatami of the present embodiment is shown in FIG. 1, a partial side sectional view of a gusset portion is shown in FIG. 3 is a partial side sectional view of FIG.

The rimless tatami mat of this embodiment has a core material 3 made of resin foam or the like, and a core material 3 for forming a skin-core structure.
A board member 2 having a composite sheet 4 added to both surfaces of the vehicle and a cushion material 5 made of a resin foam or the like on the outside of the composite sheet 4 for enhancing the feeling of treading.
And a tatami mat 1 that covers the entire surface of the board member 2 except the cushion material 5 on the back surface 13 side.

It is desirable that the board member 2 does not deform when a concentrated load is locally applied to the surface 10 such as a foot of a chair. Therefore, the core material 3 is preferably a resin foam and preferably has a 5% compressive strength of 4 kg / cm ² or less and 0.5 kg / cm ² or more. The expansion ratio of resin foam is more than 2 times 40
Less than double is desirable, and as the resin foam, polystyrene resin foam, polypropylene resin foam, polyester resin foam, polyethylene resin foam, etc. can be used, and it is particularly preferable to use polystyrene foam. Not as long. Further, the core material 3 may be made of an insulation board.

However, since the foam alone cannot withstand the local compressive load, it is preferable to form the skin-core structure by adding the double-sided skin layers of the core material 3. That is, it is preferable to add the composite sheet 4 to both surfaces of the core material 3 as described above. The composite sheet 4 constituting the skin layer may be a sheet having a thickness of 0.1 mm to 0.5 mm made of fibers and synthetic resin continuous in one direction, and this sheet may be made of a sheet made of the same material. A sheet obtained by laminating the fiber directions substantially at right angles may be used. These fibers may be glass fibers, or the synthetic resin is a polypropylene resin, a polystyrene resin, or a polyester resin, and the volume content of the glass fibers is 30% or more and less than 80%. Good. Further, as the composite sheet 4 constituting the skin layer, it is particularly desirable to use a pregron sheet made of Mitsui Chemicals, Inc., which is made of unidirectionally continuous glass fibers and polypropylene resin.
It is not limited to these. Further, it is desirable that these fibers have a linear expansion coefficient of 10 ⁻⁶ , low elongation and high tensile strength, but the present invention is not limited thereto. In addition to polypropylene, thermoplastic resin such as polystyrene, polyester and nylon can be used as the resin of the pregron sheet, but the resin is not limited to this.

The cushion material 5 is determined by the feeling of feeling of stepping, and is preferably made of resin foam, non-woven fabric, paper or the like, but is not particularly limited thereto. The thickness of the cushion material 5 is generally about 2 mm to 5 mm,
Polyethylene foam is often used as the resin foam, but the resin foam is not limited thereto. Although the cushion material 5 on the front surface 10 side is provided so as to cover the end portion of the tatami mat, the cushion material 5 on the back surface 13 side is not designed to cover the end portion of the tatami mat. In the present embodiment, the cushion material 5 is provided on both sides of the tatami mat as an example, but the present invention is not limited to this, and the cushion material 5 is provided only on the front surface 10 side or the back surface 13 side. It may be one that has been used.

The tatami mat 1 is a partially enlarged view of the cut surface of the gusset portion of the tatami mat 1 shown in FIG. 4, in which the resin weed 6 made of polypropylene or polyethylene, which has the property of being expanded by heating and contracting by cooling, is used as a weft. As shown in the drawing, a warp 7 made of cotton, hemp, or the like is passed perpendicularly to the woven resin grass 6. The tatami mat 1 is fixed to the board member 2 by a stacker 8. In addition, as a material for tatami mat 1,
A polystyrene type or a polyethylene terephthalate type may be used.

The tatami mat has a thickness t ₁ of about 30 mm used as a thin tatami mat in addition to the 55 mm to 60 mm tatami mat defined by Japanese Industrial Standards, and further, a 15 mm thin tatami mat having the same thickness as the floor flooring. However, the tatami mat of the present embodiment may have any thickness.

Generally, when the tatami mat thickness t ₁ is 60 mm, the thickness t ₂ of the core material 3 is about 40 mm, when t ₁ is 30 mm, t ₂ is 20 to 25 mm, and when t ₁ is 15 mm, t ₂ Is 7
10 mm is preferable, but not limited to this.

The size of the tatami mat may be any of the commonly used ones for 5 and 7, and for the main room, and in the case of a module display, 0.8 m module and 1 m module are recommended, but other modules are recommended. It can also be used.

The tatami section 12 and the side surface section 11 of the tatami mat of the present embodiment having the above-described structure are processed into a taper shape in the direction in which the back surface 13 side is narrowed. Because of this, the gusset part 12
Then, the tatami-mat 1 covering this portion has an upper end 9 on the front surface 10 side.
The lower end 9b on the back surface 13 side with respect to a is retracted by L ₁ . Similarly, in the tatami mat 1 which covers the side surface portion 11 as well, the back surface 13 side is set back by L _{2 with} respect to the front surface 10 side.

This taper processing facilitates the laying of the tatami mat when laying the tatami in a frame having four sides formed by the tatami mats 20a and 20b, as shown in FIG. That is, in order to prevent the tatami from moving within the frame when the tatami mat is laid in the tatami mating frame, the tatami mat is narrower than the length f on the surface 10 side when the tatami mat, h, and h are brought together. The tatami mats, e, and F are pushed into the inside dimension f ′ of the gathering 20b so that the tatami mats are firmly fitted in the gathering but the end of the tatami mat is simply cut off at a right angle. With such a shape, it is difficult to fit the tatami mat in a narrow frame. Therefore, by attaching a taper on the mating side to the tatami as described above,
It is easy to push the tatami mat into the frame.

The retracted amounts L ₁ and L ₂ of the gusset portion 12 and the side surface portion 11 in this embodiment may be different or the same.

Next, a method for forming a tatami mat on the rimless tatami of the present embodiment having the above structure will be described with reference to the flowchart shown in FIG. 6 and FIGS.

First, the tatami mat 1 is cut into the shape shown in FIG. 8 (step 50). The length L of the side surface direction of the tatami facing 1 shown in FIG. 8, Tatami upholstered side direction of the board member 2, as shown in FIG. 7 (a) shorter than the length l, cut into L ₁ (L ₁
<L).

In addition, when fixing to the board member 2, the tatami mat 1
Each corner of tatami mat 1 is a, so that there is no overlapping part of
Cut like a ', b, b', c, c ', d, d'.

Next, hot melt is applied so as to prevent the corners a to d'and the sides e and f of the tatami-mat 1 from fraying to prevent fraying (step 51).

Next, as shown in FIG. 9, the four sides e of the tatami mat 1
While holding ~ h with the chuck 25 and heating it with a heater (not shown) or the like, the chuck 25 holds A, A ′, B,
The tatami mat 1 is extended by pulling it in the direction of B '(step 52). As a result, in the tatami mat 1 made of the resin grass 6 having the property of being extended by heating, as shown in FIG. 7B, the length L _{1 in} the lateral direction of the tatami mat ₁ is the tatami mat covering in the lateral direction of the board member 2. It extends to L ₁ ′, which is longer than the length l (L ₁ → L ₁ ′, L ₁ ′ ≧ l). The length of the tatami mat 1 in the sill direction is not extended as much as the lateral direction because the warp 7 is passed in the sill direction, but is in a tensioned state.

Next, with the tatami mat 1 in the extended state, the board member 2
11 and after welding the corners a and a ′, b and b ′, c and c ′, d and d ′ of the tatami mat 1 as shown in FIG. 10 (welding part 30), as shown in FIG. By stacking the stacker 8 on the back surface 13 side of the tatami mat 1, the tatami mat 1 is fixed to the board member 2 as shown in FIG. 7C (step 5).
3).

Finally, the tatami mat 1 is tightened by cooling the tatami mat 1 by a cooling means (not shown) (step 54). By this cooling, the length L ₁ ′ of the tatami mat 1 extended in step 52 in the lateral direction is contracted, and the tatami mat 1 is brought into close contact with the board member 2, whereby the tatami mat length l is increased as shown in FIG. 7D. Is approximately equal to (L ₁ ≈l). Due to this contraction, the apparent length L ₁ 'of the tatami-mat ₁ becomes approximately equal to the tatami-mat length l, but since it tries to shrink more than that, inside the tatami-mat 1 the residual internal stress is increased in the direction in which the tatami-mat 1 stretches. 33 occurs. Therefore, the tatami mat 1 is stretched on the board member 2 without looseness.

The heating and stretching by the chuck 25 may be carried out in both the lateral direction and the gusset direction, or may be carried out only in the lateral direction. Further, the stretching amount may be different or the same depending on the direction.

The residual internal stress 33 is 100 to 500.
It is in the range of N, particularly preferably in the range of 300 to 450 N, and more preferably in the range of 250 to 400 N.

As described above, according to the method of this embodiment, the tatami mat 1 is stretched on the board member 2 while applying tension so that the residual internal stress 33 is generated in the tatami mat 1 as shown in FIG.
Tatami, e, and f are laid in the inner dimension f'of the tatami mat 20b, which is narrower than the length f on the surface 10 side when the tatami, e, and f shown in FIG. Even if,
It is possible to suppress loosening and wrinkles on the surface 10 of the tatami mat 1.

Particularly, in the case of the tatami mat tensioning method of this embodiment,
In the case of a rimless tatami mat, strong tension is applied in the direction of the gusset through which the warp threads 7 pass, and there is little tension in the side direction without the warp threads 7. It is possible to effectively suppress loosening and wrinkles on the tatami mat. (Second Embodiment) A method for laying a tatami mat on a flat tatami mat according to the present embodiment will be described with reference to the flowchart shown in FIG. 12 and FIG.

First, the tatami mat 71 is replaced by the tatami mat 1 of the first embodiment.
Similarly to, is cut into a shape as shown in FIG. 8 (step 60). The tatami mat 1 of the first embodiment uses a material that expands by heating and contracts by cooling, whereas the tatami mat 71 uses a material that contracts by heating.
The length L of the tatami mat 71 in the lateral direction is also cut to L ₂ which is the same as the tatami mat length l in the lateral direction of the board member 72 or longer than the l as shown in FIG. 13A (L ₂
≧ l).

Since the structure of the board member 72 of this embodiment is the same as the structure of the board member 2 described in the first embodiment, detailed description thereof will be omitted.

Next, hot melt is applied so that each corner and each side of the tatami mat 71 will not be frayed, and the fraying is prevented (step 61).

Next, cover the board member 72 with the tatami mat 71,
After welding the corners of the tatami mat 71, the tatami mat 71 is fixed to the board member 72 (step 62).

Finally, the tatami mat 71 is tightened by heating the tatami mat 71 by a heating means (not shown) (step 54). By this heating, the length L ₂ of the tatami-mat 1 in the side direction is thermally contracted, and the tatami-mat 71 is brought into close contact with the board member 72.
As shown in (c), when the length L ₂ of the tatami mat 71 in the lateral direction is longer than the tatami mat covering length l, it becomes substantially equal to the tatami mat covering length 1 (L ₂ ≈l). Due to this heat contraction, the apparent length L ₂ of the tatami-mat table 71 becomes substantially equal to the tatami mat-clad length l, but since it tries to shrink further, the tatami-mat table 71 has
Similar to the tatami mat 1 of the first embodiment, the residual internal stress 73 is generated in the direction in which the tatami mat 71 extends. Even when the length L ₂ of the tatami-mat 1 in the lateral direction is the same as the tatami-mat length 1, the tatami-mat 71
Is applied to the board member 72 while applying tension, and similarly, residual internal stress 73 is generated in the direction in which the tatami mat 71 is expanded. Therefore, the tatami mat 71 is stretched on the board member 72 without looseness.

The residual internal stress 73 is 100 to 500.
It is in the range of N, particularly preferably in the range of 300 to 450 N, and more preferably in the range of 250 to 400 N.

As described above, according to the method of the present embodiment, the tatami mat 71 is stretched on the board member 72 so that the residual internal stress 73 is generated inside, and as in the first embodiment, in particular, It is possible to effectively suppress loosening and wrinkles of the tatami mat in the side direction that tends to occur when the rimless tatami mat is laid in the tatami mat frame. (Third Embodiment) A method of forming a tatami mat on a flat tatami mat of the present embodiment will be described with reference to the flowchart shown in FIG. 13 and FIG.

First, the tatami mat 91 of the present embodiment is also cut into a shape as shown in FIG. 8 similarly to the tatami mat 1 of the first embodiment (step 80). The tatami mats of the first and second embodiments are made of resin grass that expands and contracts by heating and cooling, whereas the tatami mats 91 of the present embodiment are used.
In addition to such resin grass, artificial grass made of paper or the like, or natural grass may be used. The length L of the tatami mat 91 in the side surface direction is cut to L _3, which is shorter than the tatami mat length L in the lateral direction of the board member 92 as shown in FIG. 15A (L ₃ > l). .

Since the structure of the board member 92 of this embodiment is the same as the structure of the board member 2 described in the first embodiment, detailed description thereof will be omitted.

Next, hot melt is applied so that the corners and sides of the tatami-mat table 91 are not frayed, and the fraying is prevented (step 81).

Next, both the gusset portions of the tatami mat 91 are fixed to the board member 92 with a stacker or the like (step 82).

Next, as shown in FIG.
The first side surface end portion 95, which is one of the side surface portions, is fixed to the board member 92 by a stacker or the like (step 83), and the second side surface end portion 96, which is the other side surface portion of the tatami mat 91, is chucked. It is gripped and fixed to the board member 92 with a stacker or the like while applying tension (step 84).

The apparent length L ₃ of the tatami mat 91 is shown in FIG.
As shown in (c), the length of the tatami mat is approximately equal to the length 1 of the tatami mat, but since the tatami mat 91 is mechanically tensioned and fixed to the board member 92 at step 84, the tatami mat 91 is fixed.
Tries to shrink. Therefore, as in the tatami mat of the first and second embodiments, the residual internal stress 93 is generated in the tatami mat 91 in the direction in which the tatami mat 91 extends. Therefore, tatami mat 9
1 is stretched on the board member 92 without looseness.

The residual internal stress 93 is 100 to 500.
It is in the range of N, particularly preferably in the range of 300 to 450 N, and more preferably in the range of 250 to 400 N.

As described above, according to the method of the present embodiment, the tatami mat 91 is stretched on the board member 92 so that the residual internal stress 93 is generated inside the first and second mats.
Similar to the embodiment described above, it is possible to effectively suppress the loosening and wrinkles of the tatami mat in the lateral direction, which are particularly likely to occur when the rimless tatami mat is laid in the frame of the tatami mat.

[0067]

As described above, according to the present invention, when the tatami mat is stretched on the board member, tension is applied to the tatami mat so that the opposite side surfaces other than the gusset portion in the tatami mat after tensioning the board member. In the meantime, the stress remains in the tensile direction. That is, since stress remains in the tension direction in the tatami mat even in the side direction where tension is hard to apply, in the case of a rimless tatami,
In particular, it is possible to suppress loosening and wrinkles that tend to occur between the side surfaces of the tatami mat, and to avoid the risk of the tatami mat moving when a person walks.

[Brief description of drawings]

FIG. 1 is a schematic external perspective view of a rimless tatami mat according to a first embodiment of the present invention.

FIG. 2 is a partial side sectional view of the gusset portion of the rimless tatami mat shown in FIG.

FIG. 3 is a partial side sectional view of a side surface portion of the rimless tatami mat shown in FIG.

FIG. 4 is a partially enlarged view of a cut surface of a gusset portion.

FIG. 5 is a plan view and a side cross-sectional view of the tatami mat in a state in which the tatami mat is spread in the tatami mat.

FIG. 6 is a flowchart illustrating how to stretch a tatami mat according to the first embodiment of the present invention.

FIG. 7 is a diagram illustrating how to stretch the tatami mat according to the first embodiment of the present invention.

FIG. 8 is a plan view of a cut tatami mat.

FIG. 9 is a diagram showing a state where the tatami mat is grasped by a chuck and pulled.

FIG. 10 is a schematic view showing welding of corner portions of a tatami mat of a rimless tatami mat.

FIG. 11 is a schematic diagram showing welding of the corners of the tatami mat and the fixing of the tatami mat to the board member.

FIG. 12 is a flowchart illustrating how to lay out a tatami mat according to the second embodiment of the present invention.

FIG. 13 is a diagram illustrating how to stretch a tatami mat according to the second embodiment of the present invention.

FIG. 14 is a flowchart illustrating how to stretch a tatami mat according to the third embodiment of the present invention.

FIG. 15 is a diagram illustrating how to stretch a tatami mat according to the third embodiment of the present invention.

FIG. 16 is a diagram for explaining an example of how to stretch a tatami mat in a conventional tatamiless tatami mat.

[Explanation of symbols]

1, 71, 91 tatami mat 2, 72, 92 boards 3 core material 4 composite sheets 5 cushion material 6 resin grass 7 warp 8 stacker 9a upper end 9b Lower end 10 surface 11 Sides 12 Kamachi part 13 Back side 20a, 20b tatami mating 25 Base material 30,94 chuck 31 welded part 33, 73, 93 Residual internal stress 95 First side end 96 Second side end

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Chiaki Maruko             580-32 Nagaura, Sodegaura-shi, Chiba Mitsui Chemicals, Inc.             Inside the company (72) Takashi Iiyama, inventor             580-32 Nagaura, Sodegaura-shi, Chiba Mitsui Chemicals, Inc.             Inside the company (72) Inventor Kojiro Shigetai             3-5 Kasumigaseki 3-chome, Chiyoda-ku, Tokyo             I Chemical Co., Ltd.

Claims (11)

[Claims] 1. A method for manufacturing a rimless tatami mat having a tatami mat fixed to a side surface or a back surface side of a board member and stretched so as to cover the front surface side, after being stretched on the board member. The tatami mat includes a residual stress applying step of stretching the tatami mat on the board member while applying tension to the tatami mat so that the stress remains in the tension direction between the opposing side surfaces other than the gusset portion in the tatami mat. A method of manufacturing a rimless tatami mat. 2. The expansion / contraction rate of the tatami mat is 5% or more and less than 25%, and each side of the tatami mat in a stretched state within the range of the expansion / contraction rate is fixed to the fixing portion of the board member. The method for producing a rimless tatami according to 1. 3. The tatami mat is a heat-shrinkable resin grass that shrinks by heating, and after fixing each side of the tatami mat in a stretched state to the fixing portion of the board member, as the residual stress applying step, The method for manufacturing a rimless tatami according to claim 1, wherein the tatami mat is heated and brought into close contact with the board member. 4. The tatami mat is a water-absorbent resin grass, and after fixing each side of the tatami mat in a water-absorbed state to the fixing part of the board member, the tatami mat is dried as the residual stress applying step. 2. The board member is brought into close contact with the board member.
The method for producing a rimless tatami described in. 5. The method for producing a rimless tatami according to claim 4, wherein the water absorption rate of the water-absorbent resin grass is 5% or more and less than 25%. 6. The method for manufacturing a rimless tatami according to claim 1, wherein the tension is within a range of 100 N to 500 N. 7. A rimless tatami mat manufactured by the method for manufacturing a rimless tatami according to claim 1, wherein the tatami mat is made of polypropylene, polystyrene, polyethylene, or polyethylene. A rimless tatami made of any one of terephthalate resins. 8. The expansion ratio of the core material of the board member is 2
The rimless tatami mat according to claim 7, wherein the tatami mat is made of a resin foam that is double or more and 40 times or less. 9. The rimless tatami according to claim 8, wherein a sheet member having a thickness of 0.1 mm to 0.5 mm made of fibers and synthetic resin continuous in one direction is laminated on both surfaces of the core material. 10. The rimless tatami according to claim 9, wherein a composite sheet laminated such that the directions of the fibers of the two sheet members are substantially orthogonal to each other is laminated on both surfaces of the core material. 11. The fiber is glass fiber, and the synthetic resin is polypropylene resin, polystyrene resin,
11. The rimless tatami according to claim 9 or 10, which is a polyester resin and has a volume content of the glass fiber of 30% or more and less than 80%.