JP2003172017A - Laying tile-shaped artificial tatami mat - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laying tile-shaped artificial tatami mat in which separation from the backing material of an imitation rush at the end section of a tatami-mat facing is prevented. <P>SOLUTION: In the laying tile-shaped artificial tatami mat in which the tatami-mat facing containing the imitation rush composed of a thermoplastic resin as weft and the backing material on the tatami-mat facing through an adhesive layer are laminated, the tatami-mat facing is composed by a plain weaving. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tile-shaped artificial tatami mat, which is constructed by laying a plurality of sheets in combination to form an artificial tatami mat. Regarding artificial tatami mats.

[0002]

2. Description of the Related Art Tatami mats are the basis of Japanese resident culture, have been used as ancient rugs, and are now widely and generally used.

[0003] Further, the traditional tatami mats have been used for a fashionable appearance by combining a plurality of sheets on a part of the floor and laying them to give an attractive appearance.

As the artificial tatami mats, there have been proposed artificial tatami mats that can be easily washed and tatami mats that are less likely to swell (see, for example, Patent Document 1-2).

The above conventional laid floor tatami mat is shown in FIGS. FIG. 4 is a plan photographic view showing the shape of fibers in a conventional tatami mat, FIG. 5 is a fabric structure diagram of FIG. 4, FIG. 6 is a cross-sectional view of the weft side of FIG. 4, and FIG. FIG. 3 is a perspective photograph showing the shape of fibers for explaining the peeling of the imitation grass from the backing material at the front end of the tatami mat, which has occurred in the laid tatami mat.

In the figure, reference numeral 1 indicates a tatami mat, and the tatami mat 1 has a structure in which it is adhered to a backing material 3 via an adhesive 2. Further, the tatami mat 1 is composed of a weaving structure of warp yarns 4 made of thermoplastic resin fibers and weft yarns 5 made of imitation grass. A space is formed between the warp 4-1 and the adjacent warp 4-2, and a weft 5-1 made of imitation grass is raised and sinks every two spaced warps to form a structure that intersects. The adjacent weft yarns 5-2 corresponding to the weft yarns 5-1 are sunk, floated and crossed to form a so-called changed plain weave design. The distance L1 between the warp yarn 4-1 and the adjacent warp yarn 4-2 is usually about 7 mm, and the one circulation length L2 of the weft yarn 5-1 or the weft yarn 5-2 is 28 mm.
In contrast to the front and rear, as shown in FIG. 4, the space between the weft 5-1 and the weft 5-2 is so tight that the warp 4 cannot be seen from the front side, and the weft 5-1 or the weft 5- The part where 2 is sunk on the back side cannot be seen from the front side.
Therefore, as shown in FIG. 6, when viewed from the tatami mat cross section on the weft side, the floating weft 5-1 on the adjacent front side and the sinking weft 5-2 on the back side are in a double structure state. The sunken weft 5-2 present on the back side is adhered to the backing material 3 by the adhesive 2, but the floating weft 5-1 or the weft 5-2 on the front side is not coated with the adhesive 2. As shown in FIG. 7, it is easily peeled off from the backing material 3 due to an external force to project from the surface, impairing the appearance of the tatami mat, and making it easier for the imitation grass protruding from the tatami mat to trip over. Was causing problems.

[0007]

[Patent Document 1] Japanese Patent Laid-Open No. 2001-227142 (page 1)

[0008]

[Patent Document 2] Japanese Patent Laid-Open No. 2002-4553 (first
page)

[0009]

DISCLOSURE OF THE INVENTION An object of the present invention is to solve the above-mentioned conventional problems and to provide an artificial tatami mat which is a standing tile in which the imitation grass at the front end of the tatami mat is prevented from peeling from the backing material. is there.

[0010]

In order to achieve the above object, the present invention adopts the following configurations. That is, (1) a tatami mat containing imitation grass made of a thermoplastic resin as a weft, and an artificial tile tatami mat in which a backing material is laminated on the tatami mat with an adhesive layer, the tatami mat is formed by plain weaving. A tile-shaped artificial tatami mat that is characterized by being constructed.

(2) The artificial tiled tatami mat of the above-mentioned (1), wherein the imitation grass is made of a foamed thermoplastic resin.

(3) The stationary tile-like artificial tatami according to (1) or (2), wherein one circulation length intersecting with the warp of the weft is 16 mm or less.

(4) The stationary tile-like artificial tatami according to any one of the above (1) to (3), characterized in that the weft yarns in the cross section of the tatami-mat are substantially formed in a single structure.

(5) The above (1) to (1) characterized in that a polyolefin resin is used as the thermoplastic resin.
The standing tile-shaped artificial tatami according to any one of (4).

(6) The above-mentioned (1) to (1), wherein the weft yarn made of imitation grass of the tatami-mat is adhered on the back side of the tatami-mat by a backing material of a heat-fusible resin
The standing tile-shaped artificial tatami according to any one of (5).

(7) The floor-standing tile-shaped artificial tatami according to (6), wherein a polyolefin resin is used as the heat-fusible resin.

(8) The backing material comprises at least one selected from a thermoplastic resin sheet, a thermoplastic resin foam sheet, and a non-woven sheet, and any one of the above (1) to (7). Tile artificial tatami mats as described in.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS An artificial tatami mat according to an embodiment of the present invention will be described with reference to FIGS.

FIG. 1 is a plan photographic view showing the shape of the fibers of the floor-standing tile-like artificial tatami mat of the present invention, FIG. 2 is a fabric structure diagram of FIG. 1, and FIG. 3 is a cross-sectional view of the weft side of FIG. Is.

In the figure, reference numeral 1 indicates a tatami mat, and the tatami mat 1 has a structure in which it is adhered to a backing material 3 via an adhesive 2. In addition, the tatami mat 1 is circulated with two warp yarns 4 made of a thermoplastic resin fiber and two weft yarns 5 made of imitation grass, and each yarn is formed into a plain weave design in which each yarn rises and falls and intersects. There is. Warp 4 adjacent to warp 4-a
The distance L3 from −b is preferably 8 mm or less,
More preferably, it is 3 to 6 mm. Also, the weft 5-
The one circulation length L4 of a or the weft 5-b is preferably 16 mm or less, and more preferably 6 to 12 mm. As shown in FIG. 1, the space between the weft yarns 5-a and the weft yarns 5-b may be so tight that the backing material cannot be seen from the front side.

In the present invention, two warps 4 and two wefts 5 made of imitation grass circulate, and each yarn is formed into a plain weave design in which the yarns float up and down and intersect with each other. As shown in, when viewed from the cross section of the tatami mat on the weft side,
The weft thread 5-a and the weft thread 5-b have a single structure, and are adjacent weft threads 5-a and 5-
Both b are adhered to the backing material 3 by the adhesive 2.
Therefore, neither the weft yarn 5-a nor the weft yarn 5-b is peeled off from the backing material 3 due to an external force, and the backing material 3 is firmly held.
Will be glued to. It should be noted that, as shown in FIG. 1, unlike the prior art, in the present invention, the warp can also be viewed from the front side.

In the present invention, examples of the thermoplastic resin used as the imitation grass forming the weft of the tatami mat include:
Olefin resins such as polypropylene, polyethylene, copolymers of propylene and ethylene, polyamide resins,
Examples include polyester resins, acrylic resins, and mixed resins thereof, but polyolefin resins are preferably used. These resins can be appropriately selected and used from those generally marketed.

In the present invention, the imitation grass is preferably made of a foamed thermoplastic resin. The foaming degree of the foamed thermoplastic resin is not particularly limited, but the density after foaming is preferably 10 to 99% of the density before foaming, and more preferably 1
It is 0 to 50%. By controlling the degree of foaming in such a range, an artificial tatami mat excellent in fiber-making property, strength, and abrasion resistance can be obtained.

The foamed thermoplastic resin can be obtained by a known method. For example, it can be obtained by a method of mixing a thermal decomposition type foaming agent. The timing of foaming is not particularly limited, and for example, imitation grass may be produced using a foamed thermoplastic resin, or may be foamed after the imitation grass is produced.

The type of foaming agent is not particularly limited, and a general-purpose foaming agent, for example, a pyrolytic foaming agent can be used. Specifically, for example, azodicarbonamide, baking soda and the like are preferably used. By using the foamed imitation grass, the flexibility and texture of the artificial tatami mat can be improved.

Further, it is effective to add an inorganic filler in order to make the texture of the imitation grass close to that of the natural grass. Examples of the filler include calcium carbonate, titanium oxide, potassium chloride, and hydroxide. Magnesium, magnesium stearate, magnesium carbonate, talc, silica-based filler and the like can be used. Among these inorganic fillers, calcium carbonate is particularly preferable. Further, a pigment for producing a tint can be added.

The imitation grass used in the present invention may be made of 100% thermoplastic resin, but may contain other components. For example, it may contain natural rush.

The imitation grass used in the present invention may have either a hollow structure or a solid structure. Further, various irregular cross-sectional shapes such as triangular, polygonal, multilobal, and elliptical can be used.

The tatami mat used in the present invention must contain imitation grass made of a thermoplastic resin as a weft thread. The proportion of imitation grass made of a thermoplastic resin in the weft is not particularly limited, but is preferably 50 to 100% by weight.

The tatami mat is preferably cut to an appropriate size, and a backing material is adhered to the tatami mat. The thickness of the tatami mat is preferably in the range of 1 to 5 mm. The backing material has a thickness of 2 mm or more, and the total thickness is 5 mm.
It is preferably at least mm. As a result, the artificial tatami mat can be provided with appropriate cushioning properties and elasticity, and can also be suitably used as a rug for barrier-free houses and the like.

The backing material is not particularly limited, but a thermoplastic resin sheet, a thermoplastic resin foam sheet,
And at least one selected from a non-woven sheet. Here, as the non-woven fabric sheet, felt or the like can be used.

As the thermoplastic resin sheet for the backing material, for example, an elastic resin sheet or a foam sheet made of a thermoplastic resin can be used. The use of this foam sheet is preferable because it can impart an appropriate cushioning property to the artificial tatami mat.

The thermoplastic resin used for the backing material is not particularly limited, but examples thereof include polyethylene, polypropylene, copolymers of propylene and ethylene and mixtures thereof, polyamide, polyester, polyacrylonitrile, copolymers and mixtures thereof. , Polyurethane, polystyrene, polyvinyl chloride and mixtures thereof can be used. As the elastic resin sheet, an elastic soft foam sheet made of such a thermoplastic resin is preferably used.

Further, as the non-woven fabric sheet, for example, one using short fibers or fiber scraps can be used. These can be obtained by, for example, a melt blow manufacturing method or a spun bond manufacturing method, and can be more preferably used as long as they are entangled with fibers.

It is possible to further laminate a non-slip sheet on the back surface of the backing material. The non-slip sheet may be any sheet as long as it has the property of ensuring the adhesion and fixing property of the tatami mat structure to the floor, and therefore a sheet made of a polymer having viscoelasticity is used. For example, an elastic polymer and a rubber elastic polymer are preferably used, and among them, an ethylene vinyl acetate copolymer is preferably used.

The foam sheet used as the backing material preferably has a foaming ratio of 2 to 30 times, more preferably a hard resin such as a polyolefin resin or an ethylene vinyl acetate copolymer. Foam sheets are preferably used. Such a foam sheet is preferably 0.5 to 5 mm, more preferably 1 to 5 mm.
A laminate sheet having at least one layer, preferably a plurality of layers, having a thickness of 3 mm is used.

In the present invention, the backing material, which is held in its shape by the core material, is also used in the present invention. For example, a laminate of a thermoplastic resin sheet and a core material, specifically, a laminate structure of, for example, non-woven fabric sheet / core material / non-woven fabric sheet, thermoplastic resin sheet / core material / thermoplastic resin sheet, etc. Preferably used. As the core material, a material having shape retention is preferable, and for example, a material made of high-strength fiber such as a glass fiber woven fabric or a mesh sheet is preferably used.

In the present invention, it is preferable that the weft yarn of the imitation grass of the tatami mat is fused on the back side of the tatami mat with a backing material of a heat-fusible synthetic resin. That is, by attaching and heating a heat-fusible backing material made of a heat-fusible synthetic resin on the back surface of the tatami mat, the weft thread made of imitation grass of the tatami mat may be bonded on the back surface side of the tatami mat. Then, a backing material may be laminated and the backing material may be fused integrally with the tatami mat by heating to bond the tatami mat and the backing material. Here, the heat-fusible synthetic resin is not particularly limited, but when the imitation grass and / or the backing material is a polyolefin resin, a resin such as a polyolefin resin or an ethylene vinyl acetate copolymer is preferably used.

On the other hand, the adhesion between the tatami mat and the lining material is as follows.
For example, a rubber-based, epoxy-based, urethane-based, or silicon-based adhesive can be used depending on the material of the tatami mat or the backing material, but it is particularly preferable to use a polyolefin-based resin.

Preferable examples of the tatami mat and the backing material are, for example, tatami mat / adhesive layer / polyethylene foam sheet or ethylene vinyl acetate copolymer foam sheet,
Alternatively, it is a combination of tatami mat / adhesive layer / polyethylene foam sheet or ethylene vinyl acetate copolymer foam sheet / skid sheet (ethylene vinyl acetate copolymer sheet), or tatami mat / adhesive layer / nonwoven sheet.

As the warp forming the tatami mat, a yarn made of thermoplastic resin fiber can be used. Thermoplastic resin fibers are generally fiber-forming resins such as olefin resins such as polypropylene, polyethylene, and copolymers of propylene and ethylene, polyvinyl chloride, polyamide resins, polyester resins, acrylic resins, and mixtures thereof. And a copolymer etc. can be used. Further, as such yarns, for example, monofilament yarns, multifilament yarns, spun yarns or the like can be used alone, or two or more yarns can be aligned and twisted.

[0042]

(Example 1) Imitation based on polypropylene containing polypropylene, which is an isotropically shaped inorganic filler such as calcium carbonate, a foaming agent azodicarbonamide, and a pigment, cyanine green chips. Using the woven grass as the weft and the polypropylene multifilament as the warp, in the plain weaving machine shown in FIG. 2, the spacing L3 between the warp and the adjacent warp is 4 mm, and one circulation length L4 intersecting the weft warp. Is 8 mm, width is 1000 mm, basis weight is 1.2 kg / tatami, thickness is 1 m
m, 100 m long tatami mat was woven, and a heat-fusible synthetic resin composed of ethylene vinyl acetate copolymer was used as a backing material on this tatami mat, and a polyethylene foam sheet was laminated as a backing material, and then heated to form a tatami mat. The backing material was melt-bonded and then cut into a length of 45 cm and a width of 45 cm to produce a standing tile-shaped artificial tatami mat. Three pieces of this artificial tile-like tatami mat were combined and laid on the floor. Since all the weft yarns on the tatami mat were firmly adhered to the backing material, they were not separated from the backing material by external force.

[0043]

EFFECTS OF THE INVENTION According to the present invention, it is possible to prevent the imitation grass from peeling from the backing material at the end of the tatami mat, and to stumbl at the exfoliated portion of the imitation grass protruding from the conventional tatami mat without spoiling the appearance of the tatami mat. I was able to solve problems such as becoming easier.

[Brief description of drawings]

FIG. 1 is a plan photographic view showing the shape of a fiber which is an example of a floor-standing tatami mat of the present invention.

FIG. 2 is a fabric structure diagram of FIG.

FIG. 3 is a cross-sectional view of the weft side of FIG.

FIG. 4 is a plan photographic view showing the shape of fibers in a conventional tatami mat.

5 is a fabric structure diagram of FIG. 4. FIG.

FIG. 6 is a cross-sectional view of the weft side of FIG.

FIG. 7 is a perspective photographic view showing the shape of fibers for explaining the peeling of the imitation grass from the backing material at the front end of the tatami mat, which has occurred in a conventional tatami mat.

[Explanation of symbols]

1: tatami mat 2: Adhesive 3: Lining material 4: Warp 5: Weft

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Claims (8)

[Claims] 1. A tatami mat containing artificial grass made of a thermoplastic resin as a weft, and a tile-like artificial tatami mat in which a backing material is laminated on the tatami mat with an adhesive layer, the tatami mat being made of plain weave. A tile-shaped artificial tatami mat that is characterized by being constructed. 2. The artificial tiled tatami mat according to claim 1, wherein the imitation grass comprises a foamed thermoplastic resin. 3. One circulation length intersecting with the warp of the weft is 1
The laid-down tile-shaped artificial tatami mat according to claim 1 or 2, wherein the artificial tatami mat is 6 mm or less. 4. The weft yarn in the cross section of the tatami mat is formed in a substantially single structure.
The tile-shaped artificial tatami mat as described in any of 1. 5. The stationary tile-shaped artificial tatami mat according to claim 1, wherein a polyolefin resin is used as the thermoplastic resin. 6. The underlay according to any one of claims 1 to 5, wherein the weft yarn made of imitation grass of the tatami-mat is adhered on the back side of the tatami-mat by a backing material made of a heat-fusible resin. Tile artificial tatami mat. 7. The stationary tile-shaped artificial tatami mat according to claim 6, wherein a polyolefin resin is used as the heat-fusible resin. 8. The backing material comprises at least one selected from a thermoplastic resin sheet, a thermoplastic resin foam sheet, and a non-woven fabric sheet.
The tiled artificial tatami mat according to any one of 7.