JP2007308948A - Thin tatami mat substrate and thin tatami mat having the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a thin Tatami mat substrate which exerts sufficient bending rigidity and insusceptible to environmental fluctuation such as temperature and moisture, and to provide a thin Tatami mat having the thin Tatami mat substrate. <P>SOLUTION: According to the structure of the Tatami mat, a core (1) is formed of a polyolefin resin rigid foam which has bubbles orientated in a thickness direction ("Zetron" manufactured by Sekisui Chemical Co., Ltd., having a thickness of 7 mm), and a cushion layer (8) formed of a polyethylene foam having a thickness of 2 mm ("Pef" manufactured by Toray Co., Ltd., having an expansion ratio of 30 times) is arranged on the core (1). Further a paper board having a thickness of 2 mm ("MF Sheet" manufactured by Marusan Paper MFG. Co., Ltd.) is laid on a lower surface of the core (1) as the paper board (4), and a craft paper polypropylene cloth 10×10 (manufactured by Sumoto Paper Co., Ltd.) is arranged under the paper board (4) as a rear sheet (5). Then all the Tatami mat components are stitched together in one body with threads (6) at a stitch interval of 40 mm and a feeding pitch of 50 mm, by using a Tatami mat manufacturing machine ("Chemi Pet" manufactured by Kyokuto Sanki Co., Ltd.). In this manner the thin Tatami mat substrate of a 3×6 board (910×1,820 mm) is manufactured. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a thin tatami floor, which is a component of a thin tatami mat devised to solve the problem of a step between a Japanese-style room and a Western-style room in a Japanese-Western eclectic type house, and a thin tatami mat having the same.

  In a Japanese-Western style house where both Japanese-style and Western-style rooms are installed, a normal tatami mat has a predetermined thickness (about 55 mm, JIS A 5914 (building material tatami floor)), so there is a step between the Japanese-style room and the Western-style room. It was. In recent years, so-called barrier-free houses have attracted attention, and even in Japanese and Western eclectic-type houses, thin tatami mats with a thickness smaller than conventional tatami mats ( Thickness: 7-30 mm) has been developed.

  Thus, when the tatami structural member is thinned, lack of rigidity of the tatami is inevitable.

  As a thin tatami core material having sufficient bending rigidity, Patent Document 1 describes a thin tatami core material in which a paperboard is bonded to the front and back surfaces of a synthetic resin foam with an adhesive. That is, since the synthetic resin foam alone has insufficient rigidity as a tatami core material, the rigidity is ensured by bonding and integrating the paperboard.

  Further, Patent Document 2 discloses a thin tatami mat that can disperse concentrated loads due to heavy objects such as a bed by integrally joining a surface member to the upper surface of the polyolefin resin foam layer on the tatami surface side. The core material is described.

  All of these patent documents aim at improving rigidity and dimensional stability by bonding and integrating a reinforcing surface material such as paperboard on the surface of the foam, but the synthetic resin foam layer and paperboard constituting the core material are used. The degree of dimensional fluctuation differs depending on environmental fluctuations such as temperature and humidity (board paper is more affected by expansion and contraction due to environmental fluctuations than rigid resin foam). For this reason, in the configuration in which both members are bonded together by the entire surface adhesion with an adhesive, there is a possibility that phenomena such as push-up, warpage, and skiing may occur due to environmental fluctuations.

In addition, in the structure of Patent Document 1, the thickness of the core material is set to 9 m or less with respect to the product tatami thickness of 15 mm, so that the core material and the tatami surface of the tatami surface are improved for the purpose of improving walking ability and sitting comfort. Although a cushion layer is provided between them, the thickness of the cushion layer is about 1 mm due to the limitation of the thickness of the tatami mat, and the resulting product is a so-called hard tatami mat.
JP 2001-182297 A JP-A-9-256607

  An object of the present invention is to provide a thin tatami floor that can obtain sufficient bending rigidity and is not affected by environmental fluctuations such as temperature and humidity, and a thin tatami mat having the same, in view of the above-described actual situation. .

In order to solve the above-mentioned problems, the thin tatami floor of the present invention is arranged on at least one side of a core material, the core material, and has a basis weight (US basis weight) of 600 to 1800 g / m ² , a tensile strength of 5 kgf or more, It is a thin tatami floor that is integrally sewn with a paperboard having an elastic modulus of 150 MPa or more.

  In the thin tatami floor of the present invention, the core material is made of a synthetic resin foam or an insulation board, and a rigid sheet made of an organic polymer material is laminated on at least one surface thereof, and a paper sheet is formed on at least one surface of the core material with the rigid sheet. Thin tatami floors with laminated materials are preferred.

  Furthermore, a thin tatami floor in which a cushion layer is laminated on at least one side is preferable.

  In the thin tatami floor of the present invention, the core material is made of a synthetic resin foam or an insulation board, the core material has a rigid sheet made of an organic polymer material on at least one surface, and a paper material on at least one surface of the core material. A thin tatami floor is preferably laminated.

  Furthermore, a thin tatami floor in which a cushion layer is laminated on at least one side is preferable.

In the thin tatami floor of the present invention, it is preferable that the paper material has a weight per unit area (70 square meters) of 70 to 280 g / m ² .

  Moreover, the thin tatami of this invention is a thing of thickness 10-30mm which provided the tatami surface on the upper surface of the said thin tatami floor of this invention.

In the thin tatami floor of the present invention, a paperboard having a basis weight (US basis weight) of 600 to 1800 g / m ² , a tensile strength of 5 kgf or more, and an elastic modulus of 150 MPa or more is disposed on at least one side of the core material. Therefore, sufficient bending rigidity can be obtained.

  Further, since the entire constituent members of the thin tatami floor are integrated by sewing, there is no possibility of causing a phenomenon such as pushing up, warping, and skiing even if a dimensional change occurs due to an environmental change such as temperature and humidity.

  The present invention will be specifically described with reference to the drawings.

  FIG. 1 shows an example of a tatami floor configuration according to the present invention.

  The thin tatami floor according to the present invention has a paper material (2) on the core material (1), a cushion layer (8) on the paper material (2), and a paperboard (4) below the core material (1). The back sheet (5) is arranged on the back, and the whole is integrally sewn with the thread (6). By arranging the paper material (2) on the core material (1) in this way, the rigidity can be improved. On the other hand, when a cushion layer is disposed on the core material (1) and a paper material is disposed thereon, a sufficient rigidity improvement effect cannot be obtained. Further, in this case, since the uneven surface is continuous by floor-sewing, there is a risk that a sound will be produced when the manufactured tatami surface is stepped on. Therefore, the paper material (2) is disposed on the core material (1), and the cushion layer (8) is disposed thereon.

  Sewing is performed using a flooring machine ("Kemipet" manufactured by Kyokuto Sangyo Co., Ltd., "Asuka" manufactured by Tokai Kikai Co., Ltd.). The needle interval (interval of needles in the width direction) is 30 to 60 mm, and the feed pitch (interval of needles in the length direction) is 40 to 70 mm. When the needle interval and feed pitch exceed these ranges, the integration of each member of the laminate is weakened, resulting in a decrease in rigidity and a greater change due to environmental effects such as the temperature of the single member. Cause warping. Preferably, the whole is sewn and integrated with a needle interval of 45 mm or less and a feed pitch of 50 mm or less. Preferable yarns are synthetic resin yarns such as vinylon yarn (“Kuremon” manufactured by Kuraray Co., Ltd.) and polypropylene yarn (“Rilen” manufactured by Sekisui Molding Co., Ltd.). Wearing is possible.

  FIG. 2 shows an example of the core material (1). In this example, the core material (1) is made of an insulation board or a synthetic resin foam itself, and has a thickness of 5 to 25 mm. As the synthetic resin foam, a polyolefin resin hard foam described in JP-A-2003-48288, in which bubbles are oriented in the thickness direction, is preferably used because of its excellent rigidity. If this thickness is too thin, rigidity cannot be ensured. For example, a 7 mm thick core material is desirable as a core material for 15 mm tatami mat finished for barrier free.

  FIG. 3 shows another example of the core material. In this example, the core material (1) is made of an insulation board or a synthetic resin foam, and a rigid sheet (7) made of an organic polymer material is laminated on both upper and lower surfaces thereof. The organic polymer material constituting the rigid sheet (7) may be paper or a synthetic resin sheet, but preferably has a tensile strength of (0.5 to 150 kgf). A polyethylene sheet stretched in a uniaxial direction is particularly preferred. The lamination method of the rigid sheet (7) may be adhesion, sewing or the like. The thickness of the rigid sheet (7) is 5 to 25 mm. As the synthetic resin foam in which the rigid sheets (7) are laminated as described above, those described in JP-A-2003-48288 are preferably used.

  The cushion layer (8) functions to improve the sound insulation performance as well as to improve the comfort and comfort of stepping. As a material for the cushion layer (8), a synthetic resin foam having a foaming ratio of 10 to 40 times, a nonwoven fabric such as a needle punch, or soft cardboard such as paperboard ("MF sheet" manufactured by Marusan Paper Industries Co., Ltd.) is used. If the cushion layer (8) is too thin, the softness is impaired. If the cushion layer (8) is too thick, the sound insulation is improved. However, in the finish of the tatami mat, the floor edge is rounded at the corner of the heel part, which is not preferable. Therefore, the preferred thickness of the cushion layer (8) is about 2 mm.

The paper material (2) can be improved in rigidity by being laminated on the core material (1). If the basis weight of the paper material (2) is too small, the effect of improving the rigidity is reduced. Conversely, if the basis weight is too large, the rigidity is improved but the thickness is affected. That is, if the basis weight of the paper material is increased without changing the total thickness of the tatami mat, the other members become thinner, so that the treading feeling is lowered, and the obtained tatami mat becomes a hard tatami mat. Therefore, kraft paper with a basis weight of 70 to 280 g / m ² is desirable.

The paperboard (4) reinforces the rigidity of the core material (1). A paperboard having a basis weight (US basis weight) of 600 to 1800 g / m ² , a tensile strength of 5 kgf or more, and an elastic modulus of 150 MPa or more is desirable. If the basis weight of the paperboard is too small, sufficient rigidity cannot be obtained, and if it is too large, the rigidity is improved, but the machinability at the time of tatami processing is deteriorated.

  The back sheet (5) works to prevent tearing by the sewing thread for flooring and to improve the thread hook. In addition, the same effect can be obtained for tacking sewing, flat stitching, and reverse stitching. The back sheet (5) also contributes to moisture prevention from the floor base. The material for the back sheet (5) is preferably kraft paper + polypropylene cloth 10 × 10 (unit: PP yarn is driven vertically every 10 mm by 25 mm × 25 mm).

  A thin tatami mat is manufactured by laminating a tatami mat on the front side of the tatami floor and winding and fixing the tatami mat to the back side at both short sides of the tatami mat.

  The method of fixing the tatami surface may be a method using sewing and tucker. However, since the core material is a foam, the holding force of the tucker needle is small, so that the sewing process is desirable.

  Next, in order to describe the present invention more specifically, some examples of the present invention and comparative examples for comparing with the examples will be given.

Example 1
In FIG. 4, as the core material (1), a polyolefin resin rigid foam (“Zetron” manufactured by Sekisui Chemical Co., Ltd., thickness 7 mm) in which bubbles are oriented in the thickness direction was used.

  On the core material (1), a cushion layer (8) made of a polyethylene foam having a thickness of 2 mm ("Pef" manufactured by Toray Industries Inc., expansion ratio: 30 times) was disposed. On the lower surface of the core material (1), 2 mm thick paperboard ("MF sheet" manufactured by Marusan Paper Industries Co., Ltd.) was placed as the paperboard (4). Kraft paper polypropylene cloth 10 × 10 (manufactured by Sumoto Paper Co., Ltd.) was arranged as a back sheet (5) under the paperboard (4). The whole was sewn together with a thread (6) with a needle spacing of 40 mm and a feed pitch of 50 mm using a floor maker (“Kemipet” manufactured by Kyokuto Sangyo Co., Ltd.). In this way, a thin tatami floor (3 × 6 plates (910 × 1820 mm)) was produced.

Comparative Example 1
In FIG. 5, instead of the paperboard (4) in Example 1, a cushion layer (3) made of polyethylene foam having a thickness of 2 mm (“Pef” manufactured by Toray Industries, Inc., expansion ratio: 30 times) was disposed. Other configurations were the same as in Example 1 to produce a thin tatami floor.

Comparative Example 2
In FIG. 6, the paperboard (4) is bonded to the lower surface of the core material (1) using a hot melt adhesive, the cushion layer (8) is bonded to the upper surface of the core material (1), and the lower surface of the paperboard (4) is The sheets (5) were each stuck with a tacker. Other configurations were the same as in Example 1 to produce a thin tatami floor.

Example 2
In FIG. 7, as the core material (1), a polyolefin resin hard foam (“Zetron” manufactured by Sekisui Chemical Co., Ltd., thickness 7 mm) in which bubbles are oriented in the thickness direction was used.

A 220 g / m ² K liner is placed as a paper material (2) on the core material (1), and a 2 mm thick polyethylene foam ("Pef" manufactured by Toray Industries, expansion ratio: 30 times) A cushion layer (8) was arranged. On the lower surface of the core material (1), 2 mm thick paperboard ("MF sheet" manufactured by Marusan Paper Industries Co., Ltd.) was placed as the paperboard (4). Kraft paper polypropylene cloth 10 × 10 (manufactured by Sumoto Paper Co., Ltd.) was arranged as a back sheet (5) under the paperboard (4). The whole was sewn together with a thread (6) with a needle spacing of 40 mm and a feed pitch of 50 mm using a floor maker (“Kemipet” manufactured by Kyokuto Sangyo Co., Ltd.). In this way, a thin tatami floor (3 × 6 plates (910 × 1820 mm)) was produced.

Example 3
In FIG. 4, a paper tube base paper having a thickness of 2 mm was used as the paperboard (4). Other configurations were the same as in Example 1 to produce a thin tatami floor.

Example 4
In FIG. 7, a paper tube base paper having a thickness of 2 mm was used as the paperboard (4). Other configurations were the same as in Example 2 to produce a thin tatami floor.

Example 5
In FIG. 8, the core material (1) was stretched uniaxially to a polyolefin resin hard foam (Sekisui Chemical's “Zetron”, thickness 7 mm) in which bubbles were oriented in the thickness direction, as shown in FIG. A synthetic sheet (7) made of a polyethylene sheet is laminated. Other configurations were the same as in Example 1 to produce a thin tatami floor.

Example 6
In FIG. 9, the core material (1) was stretched uniaxially to a polyolefin resin hard foam (Sekisui Chemical's “Zetron”, thickness 7 mm) in which the cells were oriented in the thickness direction, as shown in FIG. A synthetic sheet (7) made of a polyethylene sheet is laminated. Other configurations were the same as in Example 2 to produce a thin tatami floor.

Performance evaluation test About each thin tatami floor produced by Examples 1-6 and Comparative Examples 1-2, the test which evaluates a tension test, a temperature influence, and the sound insulation performance was done.

-Tension test The tension test was performed as shown in FIG. That is, the thin tatami floor (A) to be tested was placed on the test table (10), and one end of the thin tatami floor (A) was stopped at one end of the test table (10) by the stopper (11). Attach the string (13) to the other end of the thin tatami floor (A), extend the string (13) to one end, hang it on the pulley (14), and then attach the weight (14) to the tip of the string (13) It was. Thereby, gravity (indicated by an arrow B in the figure) due to the weight (14) becomes a load (indicated by an arrow C in the figure) that pulls up the other end of the thin tatami floor (A). The weight of the weight (14) when the other end of the thin tatami floor (A) was lifted was evaluated as the critical tension of the thin tatami floor.

  The evaluation test is an evaluation method imitating the process of actually putting a tatami mat. As a result of performing a processing test for stretching a tatami mat with three tatami mat dealers, the critical tension that allows the tatami mat to be stretched without sagging was 10 kg or more. Even in this example, if the critical tension is 10 kg or more, Evaluated as applicable.

-Temperature effect test After placing the thin tatami floor to be tested under a condition of 10 ° C (low temperature) or 40 ° C (high temperature) in a constant temperature laboratory for 24 hours, dimensional change and warpage were measured. This test was conducted on a thin tatami mat with a tatami mat (natural Iwaso cotton warp second grade) and an edge (Omiya rim) sewn on a thin tatami floor. The size of the thin tatami mat is 1760 (cm ² ) × 8 (mm).

-Sound insulation test In accordance with JIS A 1440 (laboratory measurement method for light floor impact sound level reduction of floor finish structure on concrete floor), sound insulation in reverberation laboratory (specification: conforming to JIS A 1440, slab thickness: 150 mm) It was measured.

The results of the above tests are summarized in Table 1 below. Here, the result of the temperature influence test shows the amount of dimensional change when the condition is changed from a normal temperature (23 ° C.) dimension to a high temperature of 40 ° C. and a low temperature of 10 ° C. In addition, the amount of reduction in the measurement facility is calculated based on seven frequencies. The L value in the sound insulation test is a value calculated based on the assumption that the amount of reduction in the specimen is calculated on the site, preferably a value defined by L52 or less.

  As is clear from Table 1, in any of Examples 1 to 6, the critical tension is 10 kg or more, sufficient rigidity, and it is possible to process a tatami mat with a good finish in the tatami mat tension. it can. In addition, there are some cases in which a minute dimensional change is observed depending on the temperature, but even when the dimensional change occurs, no warpage is observed or the dimensional change is minute. Furthermore, since the L value is 52 or less, the sound insulation is also good.

It is a rough vertical sectional view which shows the example of the thin tatami floor of this invention. It is a schematic vertical sectional view showing an example of a core material. It is a schematic vertical sectional view showing another example of the core material. It is the schematic which shows the thin tatami floor of Example 1, 3. FIG. It is the schematic which shows the thin tatami floor of the comparative example 1. It is the schematic which shows the thin tatami floor of the comparative example 2. It is the schematic which shows the thin tatami floor of Example 2, 4. It is the schematic which shows the thin tatami floor of Example 5. FIG. It is the schematic which shows the thin tatami floor of Example 6. FIG. It is a side view for demonstrating the outline | summary of the tension test in an Example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Core material 2 Paper material 3 Cushion layer 4 Paperboard 5 Back sheet 6 Yarn 7 Rigid sheet 8 Cushion layer

Claims (7)

A core material and a paperboard which is disposed on at least one surface of the core material and has a basis weight (US basis weight) of 600 to 1800 g / m ² , a tensile strength of 5 kgf or more, and an elastic modulus of 150 MPa or more are integrally sewn. Thin tatami floor.   The thin tatami floor according to claim 1, wherein the core material is made of a synthetic resin foam or an insulation board, and a paper material is laminated on at least one surface of the core material.   Furthermore, the thin tatami floor of Claim 2 by which the cushion layer is laminated | stacked on at least one side.   The core material is made of a synthetic resin foam or an insulation board, a rigid sheet made of an organic polymer material is laminated on at least one surface thereof, and a paper material is laminated on at least one surface of the core material with the rigid sheet. Thin tatami floor as described in   Furthermore, the thin tatami floor of Claim 4 by which the cushion layer is laminated | stacked on at least one side. Thin tatami floor according to the paper material is any one of claims 2 to 5 is intended basis weight (basis weight) of 70~280g / ^{m 2.} A thin tatami mat having a thickness of 10 to 30 mm, wherein a tatami surface is provided on the upper surface of the thin tatami floor according to any one of claims 1 to 6.

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