JP2003253860A - Tatami mat base for thin tatami mat, thin tatami mat and their manufacturing methods - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide high shape stability under usage load conditions in spite of a low cost and light weight by using materials suiting recycling. <P>SOLUTION: The tatami mat base 5 is formed by covering a pair of polyester films with a thickness of 50-200 μm and a METSUKE (basis weight) of 100-450 g/m<SP>2</SP>applied or impregnated with polyethylene on both front and back faces of a core material with a thickness of 2-30 mm and a METSUKE (basis weight) of 2-5 kg/m<SP>2</SP>comprising an aggregate of mixing 60-80 wt.% of polyester fiber and 20-40 wt.% of a double fiber binder formed by winding or covering polyester based fiber on an outer circumference of polyester fiber with a higher melting point than the polyester based fiber, and conducting thermo compression bonding by hot press and cold press. For example, 11 mm is suitable for the thickness of the core material 2. A tatami mat thickness can be changed by changing the thickness of the core material 2, but it is preferable that an entire thickness of the thin tatami mat 1 is small. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a thin tatami mat suitable for recycling.

[0002]

2. Description of the Related Art A conventional thin tatami mat is an idea of thinning a tatami mat by providing a tatami floor in which foam sheets are sandwiched between the upper and lower sides of an insulation board and the upper and lower sides are sandwiched by medium-quality fiberboard. The above-mentioned thin tatami mat requires a complicated internal structure, resulting in high cost and complicated production process, and is not a structure suitable for recycling.

Therefore, inventions such as Japanese Patent Laid-Open No. 2000-64567 have been proposed. The invention described in Japanese Patent Laid-Open No. 2000-64567 uses a fiberboard as a tatami floor, and arranges a tatami mat on the surface of which natural grass is woven, and a tatami edge 3 is provided along the long side. This fiberboard has a polyester fiber of 3 to 10 denier and a melting point lower than that of the polyester fiber, and a low melting point polyester fiber of 3 to 10 denier is 1: 1.
It is manufactured by thermoforming the non-woven fabric mixed in step 2 at a temperature intermediate between the melting points of the two.

By the way, as shown in FIG. 5, in the final step of a general tatami mat production facility, both ends of the originally straight board 100 are sandwiched between the machines 101, and the board 100 is forcibly bent downward to cover the board 100 with the tatami mat 102. In that state, both ends of the board 100 are sewn with the tatami thread 103. Tatami thread 1
When the stress is released after sewing with 03, the board 10 is repulsed.
0 becomes straight, and the tatami mat 102 is in a stretched state. This stretched state is absolutely indispensable for general tatami mats. However, the conventional tatami floor made of polyester fiber board is too hard, and the cushioning property of the tatami mat is poor, and the tatami thread is difficult to pass through or cracks. On the other hand, some tatami floors made of polyester fiberboard have poor rigidity,
With this, cushioning may be secured,
The tatami thread digs into the fiberboard, causing the fiberboard to be torn or broken, which is disadvantageous in terms of durability. Therefore,
Since the conventional tatami floor made of polyester fiber board cannot withstand the fixation by the tatami thread, the present condition is that the tatami mat is simply attached to the tatami floor with an adhesive. Then, of course, there is a problem that the tatami mat will be wrinkled and cannot be manufactured as a general tatami mat with a tatami mat.

[0005]

Therefore, according to the present invention, it is possible to sew a tatami thread of a polyester fiber type tatami using an existing tatami sewing facility, and realize a simple structure, low cost, shape stability, and easy recycling. It is to be.

[0006]

In view of the above-mentioned problems, the tatami mat floor according to claim 1 has 60 to 80% by weight of polyester fibers and a polyester having a melting point lower than that of the polyester fibers on the outer circumference of the polyester fibers. A basis weight of 2 kg / m ^{2 to} 5 kg / consisting of an assembly in which 20 to 40% by weight of a double fiber binder wrapped or coated with a base fiber is mixed.
Both sides of the m ² core material are coated or impregnated with a thermoplastic resin and have a thickness of 50 to 200 μm and a basis weight of 100 g / m ² to 4
A pair of polyester films of 50 g / m ² are thermocompressed and laminated on the upper and lower sides of the core material, and the thickness is set to 2 to 30 mm. According to the invention described in claim 1, the tatami floor containing the polyester fiber can be used as a general tatami mat, and the tatami thread can be sewn by the tatami sewing equipment, and the simple structure, low cost, shape stability, and easy recycling can be achieved. Can be realized.

Here, the melting point of the polyester fiber is 200.
C. or higher is preferable. The double fiber binder is preferably spiral type polyester fiber, core-sheath type polyester fiber and the like. This is obtained by spirally winding a polyester core fiber with a spiral fiber (for example, copolyester or the like), or covering a polyester core fiber with a spiral fiber (for example, a copolyester). The melting point of the polyester core fiber which is the core of the double fiber binder is also preferably 200 ° C. or higher. Although the polyester fiber and the double fiber binder are mixed, the weight ratio of the double fiber binder is preferably in the range of 20 to 40%. The polyester fiber and the polyester core fiber are preferably 3 to 40 denier, and the spiral fiber is preferably 3 to 20 denier. The softening point of the spiral fiber or the coated fiber is 60 to 150 ° C,
Particularly, 70 to 100 ° C. is preferable. The thickness of the core material is 2mm-3
It is 0 mm, preferably 5 mm to 15 mm, particularly preferably 7 mm to 12 mm. The thickness of the tatami floor is the thickness of the core material plus the thickness of the pair of polyester films. The basis weight of the core material is preferably ² to 5 kg / m ² . The density of the core material can be changed depending on the application. The polyester fiber may be polyethylene terephthalate (PET), and the double fiber binder may be PET fiber. Recycling can be promoted by removing the polyester film from the tatami floor and opening the core material.
The polyester fiber may be genuine or recycled. The melting point of the polyester film is preferably 200 ° C. or higher (for example, 250 ° C. to 280 ° C.). Basis weight of the polyester film 100g / m ² ~450g / m ² is preferred. The thickness of the polyester film is 50 μm to 200
μm is preferred. If the thickness of the polyester film is too thick, it becomes unsuitable as a tatami mat, and if it is too thin, its strength is insufficient. The low melting point thermoplastic resin applied to or impregnated into the polyester film has a melting point of 80 ° C to 200 ° C.
Particularly, 80 ° C to 130 ° C is preferable. Polyethylene or the like is preferable because the thermoplastic resin functions as an adhesive. The tatami mat has a porous structure and has hardness and cushioning properties that enable it to be sewn with tatami thread. Even with the same basis weight, the density increases as the denier number of the polyester fiber decreases, and conversely, the density decreases as the denier number of the polyester fiber increases.

The thin tatami mat of claim 2 comprises polyester fiber,
And a dual fiber binder on the outer periphery of the polyester fiber was or coated wound low melting polyester fibers than the polyester fibers made of cotton mixing assemblage, basis weight of the core material of 2Kg / m ² ~5Kg / m ² on both sides, thickness was coated or impregnated with a thermoplastic resin is mass per unit area in 50~200μm laminated by thermocompression bonding a pair of polyester films of 100g / m ² ~450g / m ² up and down of the core material, thickness On the tatami floor for thin tatami mats with 2 to 30 mm
A tatami mat and a tatami mat are attached. As a result, the same problem as in claim 1 can be solved. The interpretation of the lexical terms is based on claim 1. Here, the thickness of the tatami floor is preferably 2 mm to 30 mm, and particularly preferably 7 mm to 12 mm. The thickness of the tatami mat is 10mm-35mm, especially 14mm-16mm
Is preferred.

A method of manufacturing a tatami mat floor according to claim 3 is 60
Approximately 80% by weight of polyester fiber is mixed with 20-40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound or coated around the outer periphery of the polyester fiber, and the mixed weight is 2 Kg. /
Molded into a mat of m ^{2 to 5} kg / m ² , the front and back surfaces of the mat are coated or impregnated with a thermoplastic resin, and the thickness is 50 to 200.
or basis weight in μm is sandwiched up and down polyester film ^{100g / m 2 ~450g / m 2} , or surrounds, and heat compression of the low melting point while pressing the mold in a hot press at 120 to 250 ° C. in the vertical direction The polyester fiber and the thermoplastic resin are melted, the shape is fixed and the tatami relief portion is formed as necessary while embossing with a cold press at 5 to 45 ° C., and the mat and the polyester film are pressure-bonded to each other to have a thickness of The feature is that the tatami floor is set to 2 to 30 mm. As a result, the same problem as in claim 1 can be suitably solved. When providing a convex portion on the cold press,
At the same time as compressing the blended cotton and the non-woven fabric, it is possible to form the tatami-surface relief portion in one step. Claims 1 and 2 are applied to the interpretation of the word. By the hot press,
The melting point is set so that the polyester fiber and the polyester film are insoluble but the low melting point polyester fiber and the thermoplastic resin are soluble. The number of mats vertically sandwiched or surrounded by the polyester film may be one, or a plurality of mats may be laminated. Hot press temperature 120 to 250 ° C (here, 190
C.) and the pressure is preferably 5 MPa to 40 MPa. The temperature of the cold press is preferably 5 to 45 ° C (here, 30 ° C), and the pressure is preferably 5 MPa to 40 MPa.

A method for manufacturing a thin tatami mat according to claim 4 is 60-80.
20% to 40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound or coated on the outer periphery of the polyester fiber is mixed with the weight% of the polyester fiber, and the basis weight of the mixed fiber is 2 kg / m 2. ^2-5
Molded into mats kg / m ^2, or a thickness of the front and back surfaces of the mat thermoplastic resin is applied or impregnated with the basis weight in 50~200μm sandwiched up and down polyester film 100g / m ² ~450g / m ² , Or surrounded, 12 from the top and bottom
The polyester fiber and the thermoplastic resin having a low melting point are melted by hot-pressing with a hot press at 0 to 250 ° C., and the shape is fixed and if necessary tatami while pressing with a cold press at 5 to 45 ° C. The relief part is formed,
The mat and the polyester film are pressure-bonded to each other to form a tatami mat having a thickness of 2 to 30 mm, and a moisture-proof sheet, a tatami mat, and a tatami mat are attached to the tatami mat. Interpretation of the terms refers to claims 1 to 3.
As a result, the same problem as in claim 3 can be suitably solved.

The tatami mat floor according to claim 5 is 60-80.
Weight% polyester fiber and outer circumference of polyester fiber
A polyester fiber having a lower melting point than the polyester fiber
20-40 wt% double fiber wrapped or coated with
The basis weight is made up of a mixture of fibrous binder and
2 kg / m²~ 4Kg / m²Thermoplastic resin on both sides of the core material
With a thickness of 10 to 50 μm coated or impregnated with
20 g / m²~ 100g / m ²A pair of polyester nonwoven fabric
The core material is laminated on the top and bottom by thermocompression bonding, and the thickness is 2 to 30 mm.
It is characterized by being set to.

According to a sixth aspect of the present invention, the thin tatami mat includes polyester fiber and
And a dual fiber binder on the outer periphery of the polyester fiber was or coated wound low melting polyester fibers than the polyester fibers made of cotton mixing assemblage, basis weight of the core material of 2Kg / m ² ~4Kg / m ² on both sides, thickness was coated or impregnated with a thermoplastic resin is mass per unit area in 10~50μm laminated by thermocompression bonding a pair of non-woven polyester fabric of 20g / m ² ~100g / m ² up and down of the core material, thickness 2-3
It is characterized in that a moisture-proof sheet, a tatami mat, and a tatami mat are attached to a tatami mat floor set to 0 mm.

A method of manufacturing a tatami mat floor according to claim 7 is 60
Approximately 80% by weight of polyester fiber is mixed with 20-40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound or coated around the outer periphery of the polyester fiber, and the mixed weight is 2 Kg. /
Molded into a mat of m ^{2 to 4} kg / m ² , the front and back surfaces of the mat are coated or impregnated with a thermoplastic resin, and the thickness is 10 to 50 μm.
basis weight or sandwiched up and down polyester nonwoven 20g / m ² ~100g / m ² in m, or surrounds, 12 from above and below
The polyester fiber and the thermoplastic resin having a low melting point are melted by hot-pressing with a hot press at 0 to 200 ° C., the shape is fixed and the tatami mat is pressed as necessary while being pressed with a cold press at 5 to 45 ° C. The relief part is formed,
The mat and the non-woven fabric are pressure bonded to each other to have a thickness of 2 to 30.
The feature is that the tatami floor is set to mm.

A method for manufacturing a thin tatami mat according to claim 8 is 60-80.
20% to 40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound or coated on the outer periphery of the polyester fiber is mixed with the weight% of the polyester fiber, and the basis weight of the mixed fiber is 2 kg / m 2. ² to 4
Molded into mats kg / m ^2, or a thickness of the front and back surfaces of the mat thermoplastic resin is applied or impregnated with the basis weight in 10~50μm sandwiched up and down polyester nonwoven 20g / m ² ~100g / m ² Or, it surrounds and is 150-2 from the up-and-down direction.
The low melting point polyester fiber and the thermoplastic resin are melted by hot pressing while embossing with a hot press at 00 ° C., and the shape is fixed and the tatami relief part as necessary while embossing with a cold press at 5 to 45 ° C. Is formed, and the mat and the non-woven fabric are pressure-bonded to each other to form a tatami floor having a thickness of 2 to 30 mm, and a moisture-proof sheet, a tatami mat, and a tatami mat are attached to the tatami mat. .

The invention according to claim 9 is characterized in that a cushion sheet is interposed between the tatami floor and the tatami mat, and the method for manufacturing a thin tatami mat according to claim 7 or 8 is preferable. Since a cushion sheet is provided, the tatami mat floor preferably has a thickness of 7 to 9 mm and a tatami mat thickness of 14 to 16 mm. The cushion sheet is preferably urethane foam, polyethylene or polyethylene terephthalate non-woven fabric, a sheet, or the like.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A thin tatami mat 1 according to a first embodiment will be described below with reference to FIG. This thin tatami mat 1 is a tatami mat floor 5 which is a laminated board in which PET films 3 and 4 are thermocompression bonded to both front and back surfaces of a core material 2 in which polyethylene terephthalate (hereinafter abbreviated as PET) fibers, which are polyester, are assembled, It is composed of a moisture-proof sheet 6 provided on the back surface of the floor 5, a tatami mat 7 attached to the tatami floor 5, and a tatami edge 8.
In FIG. 1, tatami yarns 24, 27, 29 (see FIG. 4) are not shown.

The tatami floor 5 is made of 60 to 80% by weight of PET fiber.
(Melting point 250 ° C to 280 ° C) and linear PET fiber
From the PET fiber on the outer periphery of (melting point 250 ° C to 280 ° C)
Wrap around PET fiber with low melting point (softening point 75 ℃)
Or coated with 20-40% by weight of dual fiber binder
It is made of a mixture of cotton and has a thickness of 2 to 30 mm
Injury 2Kg / m²~ 5Kg / m²On both sides of the core material of
Len (melting point 130 ° C) applied or impregnated has a thickness of 50
~ 200μm and basis weight is 100g / m²~ 450g / m ²One
A pair of PET films are coated on the top and bottom of the core material and hot
It is formed by thermocompression bonding with a press and a cold press.
The thickness of the core material 2 is preferably 11 mm, for example. Core material 2
The tatami mat thickness can be changed by changing the thickness of the tatami mat.
It is preferable to reduce the thickness. The core material 2 is too hard
When molded and made more rigid, the cushioning property is impaired and tatami mats are used.
Is unsuitable as On the other hand, make the core material 2 too soft
If the rigidity is reduced to lower the shape stability,
Becomes unsuitable. Therefore, the PET film 3,
By stacking 4 pieces, the tatami floor 5 is set to an appropriate hardness.
You can Core without adding PET films 3 and 4
If you make a tatami mat with the material 2 alone, fit it into the tatami frame
And, due to variations in dimensions, the surface of the tatami mat will be uneven.
There is a possibility that it may not be preferable depending on the installation conditions.
It

It is preferable that the PET films 3 and 4 have a melting point equal to or higher than that of the PET fiber of the core material 2.
C. or higher is preferable, and for example, 250 to 280.degree. C. is preferable. Low melting point polyethylene (melting point is 130 ° C.) is applied or impregnated on the PET films 3 and 4, and is integrated with the core material 2. The thickness of the PET films 3 and 4 is preferably 50 μm, for example. As a result, even if the tatami floor 5 is fitted into the tatami frame, no unevenness is generated on the surface. The PET films 3 and 4 may be polypropylene films instead of PET.

Examples of the moisture-proof sheet 6 include thermoplastic resins such as polypropylene, polyethylene and polyethylene terephthalate (PET). Examples of the tatami mat 7 include Japanese paper tatami mat, polypropylene, polyethylene, and straw mat tatami mat. The tatami mat 8 may be a common material such as nylon. In the case of the straw mat tatami mat and the Japanese paper tatami mat, the total thickness can be 2.0 mm, and in the case of the scientific tatami mat, the thickness can be 2.5 mm, but not limited to this. The thickness of the tatami floor 5 is, for example, the cushion sheet 31.
(See FIG. 4 (a)), it is preferable to be 7 mm to 9 mm, and without the cushion sheet 31, 11 mm to 12 mm is preferable. The thickness of the thin tatami mat 1 is preferably 15 mm, for example.

The thin tatami mat 1 described above has the following advantages. (1) The PET films 3 and 4 can be peeled off from the tatami floor 5 to recycle the core material 2. Waste can also be reduced. (2) Cushioning and shape stability can be obtained by pressure-bonding the core material 2 and the PET films 3 and 4. Since a suitable rigidity characteristic with respect to density is obtained, it is possible to sew with a tatami thread. (3) The core material 2 and the PET films 3 and 4 are odorless,
No harm from harmful chemical substances such as VOC. (4) It has high elasticity and breathability, and it is difficult for moisture to accumulate. The PET films 3 and 4 provided with air holes have air permeability.

The method of manufacturing the thin tatami mat 1 is as follows:
(B) Tatami production process is divided into two. (A) A tatami mat production process will be described with reference to FIGS. 2 and 3. (1) Original single process As shown in Figure 2 (a), melt the recycled chips of PET bottles,
It is formed into PET fiber, and the fiber is used as a cotton-like aggregate 10. Since the technique of forming a cotton-like aggregate follows various general techniques, the details are omitted.

(2) Blending Process As shown in FIG. 2 (b), a block-shaped aggregate of compressed fibers is opened by a fiber-opening machine (not shown) to form open fibers 11.

(3) Weighing process The open fiber 11 and the double fiber binder 12 are weighed respectively, and the open fiber 11 is 70% by weight, and the double fiber binder 12 is added.
Is 30% by weight. The weight ratio of the double fiber binder 12 is preferably 20 to 40% by weight. The open fiber 11 corresponds to the PET fiber described above, and the double fiber binder 12 corresponds to the PET fiber wound with a spiral fiber. The core material 2 is an open fiber 11 (melting point 250 ° C. to 28 ° C.).
(0 ° C.) and the double fiber binder 12 as raw materials. The double fiber binder 12 is, for example, a composite fiber in which spiral fibers (softening point 75 ° C.) using a low melting point component having a lower melting point than core fibers (melting point 250 ° C. to 280 ° C.) are wound. As an example, an ordinary PET fiber component is used for the core fiber, a PET fiber having a lower melting point than that is used for the spiral fiber, and the difference in melting point between the core fiber and the spiral fiber is a predetermined temperature difference (for example, 175 ° C.). The composite fiber set to is mentioned.

(4) Blending process As shown in FIG. 2 (c), the weighed double fiber binder 12 is added to the open fiber 11 weighed in the above (3) and blended by a mixer (not shown).

(5) Combing process As shown in FIG. 2 (d), the blended fiber 13 blended in (4) above is passed through between two rolls 14 around which needles are provided, and the fiber direction is aligned and quantified. The thin non-woven fabric 15 is formed.

(6) Matte forming step By a rocking device (not shown) for feeding the continuously formed thin nonwoven fabric 15 while rocking in the traveling direction,
As shown in FIGS. 2 (d) and 3 (e), the non-woven fabric 15 is shifted and diagonal overlapping weights are set. If the swing width of this rocking device is narrowed, the basis weight becomes large, and if the swing width of this rocking device is widened, the basis weight can be set small. Next, as shown in FIG. 3 (e), the non-woven fabric 1 thus laminated.
6 is sent to the hot air drying oven 17, compressed with hot air of 120 ° C. to 250 ° C. to reduce the bulk, and cooled in the cold air oven 18 to form one mat 19. The thickness of the mat 19 is adjusted by adjusting the melting amount of the double fiber binder 12 with the amount of hot air. The mat 19 may be sent to the next step as it is, but may be returned to the step of FIG. 2D and the treatment may be repeated. After cooling, the mat 19 is cut with a slit blade and measured.

(7) Hot pressing process As shown in FIG. 3 (f), a plurality of mats 19 (two here)
The mat 19 is wrapped around or sandwiched around the mat 19 or specific surfaces (for example, upper and lower surfaces) with the PET film 21. This is hot-pressed at a temperature of 180 ° C. and a pressure of 5 MPa.
Heat compression molding is performed at 40 MPa. 30 seconds to 12 at this stage
Pressing for 0 second melts the low-melting-point spiral fibers and polyethylene around the double fiber binder 12. The hot press 20 includes an upper die 20a and a lower die 20b.
The temperature of the hot press is preferably 150 to 250 ° C,
For example, it is 180 ° C. Distance bar (not shown)
Adjust the thickness with. The basis weight of the mat 19 is 2 kg / m ² ~ 5
Kg / m ² is preferred. When setting the basis weight and 3 Kg / m ^2, the basis weight is superposed 2 sheets of mats 1.5 Kg / m ^2.
Here, it is preferable to stack 1 to 3 sheets in consideration of workability. The PET film 21 used here is 100 g / m ² ~
450 g / m ² is preferred. Polyethylene (melting point 130 ° C.) is applied to the surface of the PET film 21. Other details of the manufacturing method of the PET film 21 are omitted. When the mat 19 and the PET film 21 are hot-compressed by hot pressing, the low melting point PET fiber polyethylene and polyethylene in the double fiber binder are melted and the mat 19 and the PET film 21 are melted.
And the PET film 21 is thermocompression-bonded.

(8) Cold press process The cold press 22 shown in FIG.
2a and the lower die 22b, and the upper die 22a or the lower die 22b is provided with the die 22d having the convex portion 22c. The cold press 22 fixes the shape by pressing (pressing) the object to be pressed by cooling after hot pressing. When the convex portion 22c is provided, the tatami mat release portion 23
Is formed at the same time as the shape is fixed by cold pressing. Three convex portions 22c are formed for a half tatami mat, and two tatami mats are made at the same time. Convex portion 22c
If there are two, it is for one tatami mat. The die 22d is appropriately changed according to the size of the tatami mat. Cold press temperature is 3
The pressure is preferably 0 MPa and 5 MPa to 40 MPa. The convex portion 22c is provided as necessary, and the convex portion 22c
A flat die 22d without c may be used. In that case, the tatami mat escape portion 23 is formed by another process such as cutting. The thickness or density can be finally adjusted with a distance bar (not shown). It is preferable that the hot press 20 and the cold press 22 form one conveyor line. Thus, the tatami floor 5 has a porous structure in which the PET film 21 is laminated on the mat 19. The manufactured tatami floor 5 is shown in FIG. 3 (g).

The tatami mat production process described above has the following advantages. (1) P by hot press 20 and cold press 22
Since the ET core material 2 and the PET film 21 are pressure-bonded to each other, no adhesive is required. In addition, by setting the basis weight of the tatami floor 5 appropriately, the tatami mat has a strength that can endure tatami. (2) Low cost. (3) The production process can be simplified. (4) The tatami mat release portion 23 can be formed by the cold press 22.

The (B) tatami mat production process will be described with reference to FIG. (1) Moisture-Proof Sheet Stitching Process As shown in FIG. 4A, the tatami floor 5 and the moisture-proof sheet 6 are sewn together with a tatami thread 24 using a tattoo sewing machine (not shown) to form a suture board 25. If necessary, the cushion sheet 31 may be sewn on the upper surface of the tatami floor 5 as indicated by the dotted line.

(2) Cutting process As shown in FIG. 4 (b), the cutter 26 of the width determining machine (not shown)
Then, the both ends in the length direction (the side on which the tatami mat escape portion 23 is provided) are cut. This is because the edges of the PET board manufactured by the hot pressing and cold pressing steps (7) and (8) may have uneven molding. In case of half tatami mat, it is cut vertically and divided into two. There is no need to divide it for one tatami mat. The tatami mat escape portion 23 does not need to be specially cut, and as described above, it is formed into a predetermined portion at both ends in the longitudinal direction of the back surface by the minimum necessary vertical cutting.

(3) Tatami table sewing process As shown in FIG. 4 (c), the tatami table 7 is provided on the side of the sewing board 25 in the width direction.
Wrap and attach the tatami thread 27 using a front stitch machine (not shown).
Sew on.

(4) Length cutting step As shown in FIG. 4 (d), both ends in the width direction are cut into a taper with a circular saw 28.

(5) Tatami edge sewing process As shown in FIG. 4 (e), the tatami edge 8 is formed so as to cover the cut surface of (4).
Is attached and sewn with the tatami thread 29 by an edging machine (not shown).

(6) Finishing (Corner Pressing) Process As shown in FIG. 4 (f), the edges are sewn and hot-melt adhesive 30
Adhere with and sew the back further. Figure 5 shows the tatami thread sewing.
As shown in, the tatami floor is bent.

The tatami mat production process described above has the following advantages. (1) The tatami mat can be sewn after bending the tatami floor 5 by using the existing tatami sewing equipment. (2) A strong and durable thin tatami mat can be obtained by the tatami sewing process.

Next, the thin tatami mat 201 of the second embodiment will be described.
It The thin tatami mat 201 of the second embodiment is similar to that of the first embodiment.
On both front and back sides of the core material 2 in which polyester fibers are aggregated.
Instead of the PET films 3 and 4 that are thermocompression bonded, polyester
Laminated non-woven fabric 203a, 204a by thermocompression bonding
The thin tatami mat floor 205 is fitted with a moisture-proof sheet, tatami mat and tatami mat.
It was attached. In the second embodiment,
Of the core material 202 composed of tellur fiber and double fiber binder
The basis weight is 2 kg / m²~ 4Kg / m²Is preferred, especially 2.5
~ 3.5Kg / m ²Is preferred. Unit weight of polyester non-woven fabric
20g / m²~ 100g / m², Especially 20g / m²~ 50g /
m²Is preferred. The thickness of polyester non-woven fabric is 10 μm ~
50 μm is preferable, and particularly in the range of 10 μm to 20 μm.
It is suitable. Polyester nonwoven fabric 203a on the core material 202,
The temperature of the hot press when thermally compressing 204a is 120
-200 degreeC is preferable. Polyester used here
Nonwoven fabric 221 is preferably manufactured by the spunbond method.
Good The thin tatami mat 201 of the second embodiment and its manufacturing method will be described.
Except that the above is almost the same as the first embodiment.
The indication and explanation are incorporated.

Further, the thin tatami mat 301 of the third embodiment will be described. In the tatami floor 305 of the thin tatami mat 301 of the third embodiment, as shown in FIG. 6, the core material 302 is a PET board mainly composed of PET fibers, and the polyester nonwoven fabric 303a, The structure is such that 304a is thermocompression-bonded, and both front and back surfaces are surrounded by PET films 303 and 304. A thin tatami mat 30 of the third embodiment is obtained by attaching a moisture-proof sheet, a tatami mat table, and a tatami edge to this tatami mat floor 305.
It is 1. The polyester fabric non-woven fabrics 303a and 304a and the PET films 303 and 304 are based on the basis weights, thicknesses, and the like of the first and second embodiments.

The present invention is not limited to the above-mentioned embodiments, and addition, replacement, conversion, deletion, modification, expansion, etc. of the technology are possible without departing from the technical idea of the present invention. Can be carried out, and modifications and the like thereof are also included in the technical scope of the present invention. A thermoplastic resin is applied to both front and back surfaces of a core material composed of a polyester fiber and a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound around or coated on the outer periphery of the polyester fiber. Alternatively, a tatami mat floor for thin tatami mats, characterized in that a pair of impregnated PET films or polyester non-woven fabric is laminated by thermocompression bonding above and below the core material, is preferable. A thin tatami mat characterized in that a moisture-proof sheet, a tatami mat table and a tatami mat are attached to the tatami mat floor. A thin tatami mat having a cushion sheet interposed between the tatami floor and the tatami mat is preferable.

[0040]

According to the inventions of claims 1 to 9,
Enables tatami thread sewing of polyester fiber tatami using existing tatami sewing equipment, uses materials suitable for recycling, and at the same time provides low cost and lightweight, yet high shape stability under load conditions. be able to. The industrial utility value of the present invention for the tatami industry is extremely high.

[Brief description of drawings]

FIG. 1A is a longitudinal sectional view of an end portion in a length direction of a thin tatami mat according to a first embodiment of the present invention, and FIG. 1B is a longitudinal sectional view of an end portion in a width direction.

FIG. 2 (a) to (d) are explanatory views of a tatami mat floor manufacturing process according to the embodiment of the present invention.

3 (e) to (g) are explanatory views of a tatami mat floor manufacturing process according to the embodiment of the present invention.

4A to 4F are explanatory views of a tatami mat manufacturing process according to the embodiment of the present invention.

5 (a) to (c) are explanatory views of a final step of a general tatami mat manufacturing step.

FIG. 6 is a sectional view of a tatami mat floor according to a third embodiment of the present invention.

[Explanation of symbols]

1 ... Thin tatami, 2 ... Core material, 3, 4 ... PET film, 7 ... Tatami table, 8 ... Tatami edges 3a, 4a ... Polyester nonwoven fabric

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Eiji Morishima             Aki Prefecture Anjo City Izumi-cho Kitaoki 4-4 Stock             Company within Takehiro F-term (reference) 2E220 AA07 AA09 AA11 AA23 AA26                       AA33 AA39 AA44 AA47 AA53                       AD06 BA01 BB03 DA07 EA04                       FA01 FA02 FA05 FA06 GA01X                       GA02X GA07X GA22X GA24X                       GA25X GA27X GA28X GA35X                       GB32X GB33X GB35X GB37X                       GB47X GB48X GB52X

Claims (9)

[Claims] 1. A blend of 60 to 80% by weight of polyester fiber and 20 to 40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound or coated around the outer periphery of the polyester fiber. consisting assemblage having a basis weight on both sides of the core material of ^{2Kg / m 2 ~5Kg / m 2} , a thickness which is coated or impregnated with a thermoplastic resin is 50 to 200
basis weight is laminated by thermal compression bonding a pair of polyester films of 100g / m ² ~450g / m ² up and down of the core material with [mu] m, for thin tatami, characterized by comprising setting the thickness 2~30mm Tatami floor. 2. A basis weight of 2 kg / m ^{2 which} is composed of a mixture of polyester fibers and a double fiber binder in which polyester fibers having a melting point lower than that of the polyester fibers are wound or coated on the outer circumference of the polyester fibers. ~ 5
Both sides of the Kg / m ² core material are coated or impregnated with a thermoplastic resin to a thickness of 50 to 200.
basis weight is laminated by thermal compression bonding a pair of polyester films of 100g / m ² ~450g / m ² up and down of the core material with [mu] m, the thin tatami for tatami floor formed by setting the thickness to 2 to 30 mm, moistureproof A thin tatami mat with a seat, tatami mat and tatami mat attached. 3. A polyester fiber of 60 to 80% by weight is mixed with 20 to 40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound around or coated on the outer periphery of the polyester fiber, the該混cotton basis weight is formed into a mat of ^{2Kg / m 2 ~5Kg / m 2} , the both surfaces of the mat thermoplastic resin is coated or impregnated, basis weight thickness in 50~200μm is 100 g / m ² to 4
It is sandwiched between the top and bottom with 50 g / m ² of polyester film, or it is surrounded, and the above low melting point polyester fiber and thermoplastic resin are melted by hot pressing while hot pressing at 120 to 250 ° C. from above and below. The shape of the tatami mat is fixed by pressing a cold press at 5 to 45 ° C. and the tatami relief part is formed if necessary, and the mat and the polyester film are pressure-bonded to each other to set the thickness to 2 to 30 mm. A method for manufacturing a tatami mat floor, which is characterized by: 4. A polyester fiber of 60 to 80% by weight is mixed with 20 to 40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound around or coated on the outer periphery of the polyester fiber, the該混cotton basis weight is formed into a mat of ^{2Kg / m 2 ~5Kg / m 2} , a thickness of the front and back surfaces of the mat thermoplastic resin is applied or impregnated with the mass per unit area in 50~200μm 100g / m ² ~45
It is sandwiched between the top and bottom with 0 g / m ² of polyester film, or it is surrounded, and the above-mentioned low melting point polyester fiber and thermoplastic resin are melted by hot pressing while hot pressing at 120 to 250 ° C. from above and below. The shape of the tatami mat is fixed by pressing a cold press at 5 to 45 ° C. and the tatami relief part is formed if necessary, and the mat and the polyester film are pressure-bonded to each other to set the thickness to 2 to 30 mm. And a moistureproof sheet, a tatami mat and a tatami mat are attached to the tatami mat. 5. 60% to 80% by weight of polyester fibers and 20% to 40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fibers is wound around or coated on the outer periphery of the polyester fibers. A core material having a basis weight of ² Kg / m ^{2 to 4} Kg / m ² consisting of the above aggregates and coated with or impregnated with a thermoplastic resin has a thickness of 10 to 50 μm.
basis weight is laminated by thermal compression bonding a pair of non-woven polyester fabric of 20g / m ² ~100g / m ² up and down of the core material in m, for thin tatami, characterized by comprising setting the thickness 2~30mm Tatami floor. 6. A polyester fibers, with or coated dual fiber binder wrapped polyester fiber of low melting point than the polyester fibers to the outer periphery of the polyester fibers made of cotton mixing assemblage having a basis weight 2Kg / m ² ~ 4
Both sides of the Kg / m ² core material coated or impregnated with a thermoplastic resin have a thickness of 10 to 50 μm.
The basis weight is laminated by thermal compression bonding a pair of non-woven polyester fabric of 20g / m ² ~100g / m ² up and down of the core material thickness in the thin tatami for tatami bed of set to 2~30mm in m, the moisture-proof sheet , A tatami mat with a tatami mat and a tatami mat attached. 7. A polyester fiber of 60 to 80% by weight is mixed with 20 to 40% by weight of a double fiber binder in which a polyester fiber having a melting point lower than that of the polyester fiber is wound around or coated on the outer periphery of the polyester fiber, The mixed cotton is molded into a mat having a basis weight of ² Kg / m ^{2 to 4} Kg / m ² , and both sides of the mat are coated or impregnated with a thermoplastic resin, and the thickness is 10 to 50 μm and the basis weight is 20 g / m ^{2 to} 100.
It is sandwiched between top and bottom with g / m ² polyester non-woven fabric, or it is surrounded, and the above-mentioned low melting point polyester fiber and thermoplastic resin are melted by hot pressing while hot pressing at 120 to 200 ° C from the top and bottom. Then, the shape is fixed and the tatami relief portion is formed as necessary while pressing with a cold press at 5 to 45 ° C., and the mat and the non-woven fabric are pressure-bonded to each other to obtain a tatami floor having a thickness of 2 to 30 mm. A method for manufacturing a tatami mat floor, which is characterized by: 8. A polyester fiber of 60 to 80% by weight,
A polyester fiber having a melting point lower than that of the polyester fiber is wound around or coated on the outer periphery of the polyester fiber 2
And cotton mixing 0 to 40% by weight of the dual fiber binder, a該混cotton basis weight is formed into a mat of ^{2Kg / m 2 ~4Kg / m 2} , the both surfaces of the mat thermoplastic resin is coated or impregnated Thickness Is 10 to 50 μm and the basis weight is 20 g / m ^{2 to} 100 g
It is sandwiched between the upper and lower sides of a polyester non-woven fabric of 1 / m ² or surrounded, and is hot-pressed from above and below by a hot press at 120 to 200 ° C. to heat-compress to melt the low-melting polyester fiber and the thermoplastic resin. , While fixing the shape while pressing with a cold press at 5 to 45 ° C and forming a tatami relief portion as necessary, the mat and the non-woven fabric are crimped to form a tatami floor having a thickness of 2 to 30 mm, A method for producing a thin tatami, comprising attaching a moisture-proof sheet, a tatami mat and a tatami mat to the tatami floor. 9. A method of manufacturing a thin tatami mat according to claim 3, wherein a cushion sheet is interposed between the tatami floor and the tatami mat. .