JP2024022166A - tatami - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a tatami mat which has excellent long-term durability and can be cut more easily by hand using a cutter knife than a tatami mat using an insulation board as a constituent material of the core material.

SOLUTION: Provided is a tatami mat laid on a structural floor as an alternative to a flooring material, whose dimensions can be adjusted according to the construction site by manually cutting a core material and a surface material covering the core material using a cutter knife. The tatami mat includes the plate-shaped core material and the surface material that wraps the core material. The core material is a single-layer felt board with a thickness of 5 to 12 mm and a density of 110 to 180 kg/m³. The thickness of the surface material is 1 to 4 mm, and the thickness of the entire tatami mat is 10 to 14 mm.

SELECTED DRAWING: Figure 1

COPYRIGHT: (C)2024,JPO&INPIT

Description

Application for application of Article 30, Paragraph 2 of the Patent Act was filed. Tatami was disclosed on March 31, 2020. The tatami mats were sold on June 24, 2020. The tatami mats were sold on July 26, 2020.

The present invention is laid on a structural floor as an alternative to flooring materials, and the core material and the surface material covering the core material are cut manually using a cutter knife, so that the dimensions of the tatami can be adjusted according to the construction location. Regarding tatami mats.

Patent Document 1 or Patent Document 2 below discloses a tatami mat that can be cut with a cutter knife. Patent Document 1 describes a core material in which each layer is laminated from top to bottom in the order of a moisture-impermeable sheet, a wood board, and a moisture-impermeable sheet. The moisture-impermeable sheet is made by bonding paper to both the front and back sides of a synthetic resin film such as polyethylene. The wood board material is a board material such as an insulation board.

Patent Document 2 discloses a tatami floor in which non-stretchable sheets are laminated on the front and back surfaces of an insulation board. The tatami floor is covered with a tatami face provided with a backing material. An embodiment in which a cushioning material is arranged between the backing material and the tatami floor is also disclosed.

Japanese Patent Application Publication No. 11-336303 Japanese Patent Application Publication No. 2020-94479

It is said that the tatami mat described in Patent Document 1 or Patent Document 2 can be cut with a cutter knife. However, all tatami mats use insulation board as the core material. Although insulation boards can be cut by repeatedly applying and pulling the blade of a cutter knife over and over again, it is difficult to say that anyone can cut them easily. For example, an experienced tatami craftsman or other person may be able to cut tatami mats with ease, but it is difficult to cut tatami mats by DIY (Do It Yourself) at home. In such cases, it is difficult to easily cut the tatami.

The present invention provides tatami mats that have excellent long-term durability and can be cut more easily by hand using a cutter knife than tatami mats that use insulation board as the core material. The purpose is to provide.

This tatami is laid on structural floors as an alternative to flooring materials, and the core material and the surface material covering the core material are cut by hand using a cutter knife, allowing the size of the tatami to be adjusted according to the construction location. The tatami mat includes a plate-shaped core material and a surface material that wraps the core material, and the core material is a single-layer felt board with a thickness of 5 to 12 mm and a density of 110 to 180 kg/m ³ . The above problem is solved by using a tatami mat whose surface material has a thickness of 1 to 4 mm and the entire tatami has a thickness of 10 to 14 mm.

The above-mentioned tatami mat is made of a single-layer felt board with the core material having the above-mentioned predetermined thickness and the above-mentioned predetermined density, and the thickness of the tatami face and the entire tatami mat are set to the predetermined thickness. Therefore, it can be easily cut by hand without using a special cutting machine or the like.

The physical properties of the tatami mat are not particularly limited, but preferably, a load of 1 kg is applied in the vertical direction to the blade of the cutter knife, and the blade of the cutter knife is moved laterally at a speed of 1.5 m/min. When cutting the core material by bringing the blade into contact with the core material, the number of times the core material is cut is 1 to 2 times.

The physical properties of the tatami mat are not particularly limited, but preferably, a load of 1 kg is applied in the vertical direction to the blade of the cutter knife, and the blade of the cutter knife is moved laterally at a speed of 1.5 m/min. When the blade is brought into contact with the core material and the core material is cut, the load required to pull the blade in the lateral direction is 2.8 to 3.7 kg.

The above-mentioned tatami mat preferably has the following configuration. That is, in addition to the front material and the core material, the tatami mat further includes a nonwoven fabric sheet placed on the back side of the core material, and an anti-slip material placed on the back side of the nonwoven fabric sheet, and the tatami mat further includes It is preferable to consist of only four items in total: the raw material, the core material, the nonwoven fabric sheet, and the anti-slip material. According to this configuration, the tatami mat can be more easily cut using the cutter knife.

According to the present invention, tatami mats have excellent long-term durability and can be easily cut by hand using a cutter knife, compared to tatami mats that use insulation board as the core material. can be provided.

It is a sectional view showing the structure of one embodiment of the tatami mat of the present invention. FIG. 2 is a bottom view of the tatami mat in FIG. 1; It is a front view of the cutting device used in the core material cutting test. FIG. 4 is a perspective view of the cutting device of FIG. 3;

Hereinafter, one embodiment of the present invention will be described with reference to the drawings. The embodiments and usage examples shown below are merely examples of the present invention, and the technical scope of the present invention is not limited to the illustrated embodiments.

FIG. 1 shows a cross-sectional view of a tatami mat 1 according to this embodiment. The tatami mat 1 of this embodiment includes a plate-shaped core material 11 and a surface material 12 that wraps the core material 11. The tatami mat 1 further includes a nonwoven fabric sheet 13 arranged on the back side of the core material 11 and an anti-slip material 14, and the tatami mat 1 further includes the front material 12, the core material 11, the nonwoven fabric sheet 13, and an anti-slip material 14. It is composed of only four items including anti-slip material 14.

The tatami mat 1 is laid on a structural floor as a substitute for flooring material. As the structural floor of a building, slabs are generally used for buildings made of reinforced concrete, and plywood is used for buildings made of wood. A flooring material made of wood, tile, a synthetic resin material with a decorative layer imitating the appearance of wood, etc. is laid on the structural floor. The thickness of the flooring material is 12 mm. In the case of Japanese-style architecture, tatami mats are laid on top of the structural floor. The typical thickness of tatami mats laid on structural floors is 55 to 60 mm.

The thickness of regular tatami mats is greater than the thickness of the flooring material, so regular tatami mats cannot be laid in rooms designed for flooring materials. Since the tatami mat 1 of this embodiment has a total thickness of 10 to 14 mm, it can be suitably used as a flooring material for a room designed for flooring material. As a result, a room designed on the assumption that it is a Western-style room can be made into a room using tatami mats 1 as the flooring material. It is also possible to remove the tatami mat 1 and replace it with a known flooring material. Note that the thickness of the entire tatami includes the thickness of the surface material, core material, nonwoven fabric sheet, and anti-slip material.

The tatami mat 1 of this embodiment is made by manually cutting a core material 11 and a surface material 12 covering the core material using a cutter knife so that the dimensions of the tatami mat can be adjusted according to the construction location. When laying the tatami 1, the tatami 1 can be easily cut manually using a cutter knife according to the size of the room. Since cutting tatami 1 does not require a lot of force or special tools, when doing DIY tatami laying work, you can cut tatami 1 at the construction site according to the size of the room and cut tatami 1. can be laid without any gaps. Furthermore, when a craftsman is laying tatami mats, they can more easily cut the tatami mats at the construction site.

The core material is a single-layer felt board with a thickness of 5 to 12 mm and a density of 110 to 180 kg/m ³ . By setting the thickness to 5 to 12 mm and the density to 110 to 180 kg/ ^m3 , we ensure the long-term durability necessary for the core material of tatami mats, and the tatami mats can be easily cut by hand using a cutter knife. It becomes possible to do so. The core material consists of a single layer of felt board. If the core material is made by laminating two felt boards, the felt boards may peel off at the joint, or the joint between the felt boards may create resistance when cutting with a cutter knife, hindering the cutting process. be. By making the felt board a single layer, it is possible to eliminate the problems of peeling and resistance during cutting.

If the density of the core material falls below the above range, the long-term durability of the tatami will decrease, and the tatami will become sagging due to continuous loads such as body weight input to the tatami, and the cushioning properties of the tatami will deteriorate. more likely to be lost. If the density of the core material exceeds the above range, it will be difficult to manually cut the tatami using a cutter knife.

The method for manufacturing the core material is not particularly limited, and may be any known method for manufacturing felt boards. For example, a felt board can be obtained by mixing a synthetic fiber web with a thermosetting resin such as a phenolic resin as a binder and compressing the mixture while applying heat.

The above core material is prepared by applying a vertical load of 1 kg to the blade of a cutter knife, moving the cutter knife blade laterally at a speed of 1.5 m/min, and bringing the blade into contact with the core material. When cutting the core material, the core material can be easily cut 1 to 2 times. The direction in which the tatami mat is cut is not particularly limited, and may be, for example, either vertically or horizontally.

The above core material is prepared by applying a vertical load of 1 kg to the blade of a cutter knife, moving the cutter knife blade laterally at a speed of 1.5 m/min, and bringing the blade into contact with the core material. When cutting the core material, the load required to pull the blade in the lateral direction is 2.8 to 3.7 kg, so it has easy cutting properties. The direction in which the tatami mat is cut is not particularly limited, and may be, for example, either vertically or horizontally.

The fibers constituting the felt board are not particularly limited, but include chemical fibers such as polyester fibers, polypropylene fibers, and nylon fibers. Among them, polyester can be suitably used because it has properties such as being resistant to insect damage, having low water absorption, high quick drying properties, and being resistant to deterioration due to sunlight. It is preferable that 90 to 100% by mass of the constituent materials of the felt board be polyester fibers.

The surface material is an exterior material that covers the core material, and has a sheet-like shape. The thickness of the surface material is 1 to 4 mm. Since the surface material is very thin, when cutting the tatami mat manually using a cutter knife, the surface material does not interfere with the cutting operation.

The constituent material of the surface material is not particularly limited, but may be composed of, for example, a woven or knitted fabric made of natural rush, paper, or a synthetic resin material. The woven or knitted fabric allows the blade of a cutter knife to easily pass through it, making it easier to cut the tatami mat.

The nonwoven fabric sheet 13 is attached to the back surface of the core material for the purpose of protecting the back surface of the core material, preventing the fibers of the core material from falling off, and improving the aesthetic appearance of the back surface of the tatami mat. The thickness of the nonwoven fabric sheet is not particularly limited, but may be, for example, 0.1 to 3 mm. With this thickness, the nonwoven fabric sheet will not interfere with the cutting process when cutting the tatami mat.

The constituent material of the nonwoven fabric sheet 13 is not particularly limited, but polyester fibers and polypropylene fibers can be used.

The tatami mat 1 includes a plate-shaped core material 11, a surface material 12 surrounding the core material 11, a nonwoven fabric sheet 13, and an anti-slip material 14. As shown in FIG. 2, the anti-slip material 14 is not disposed so as to cover the entire back surface of the non-woven fabric sheet 13, but is shaped to cover a part of the non-woven fabric sheet 13, and the remaining part is placed so that the non-woven fabric sheet 13 covers the tatami mat. It is preferable to expose it on the back side. By doing so, the influence of the anti-slip material on cutting the tatami can be reduced. In the example of FIG. 2, an anti-slip material 14 having a smaller area than the nonwoven fabric sheet 13 is attached to the back surface of the nonwoven fabric sheet 13. The anti-slip material 14 is not particularly limited, but may be in the form of a sheet with a thickness of 0.1 to 3 mm, for example. The constituent material of the anti-slip material is not particularly limited, but examples include sheet-shaped elastic materials such as silicone rubber, vulcanized rubber, and acrylic elastomer. Examples of the acrylic elastomer include acrylic block copolymers. The anti-slip material is not essential and may be omitted. In this case, the tatami mat is composed of only three items: a face material, a core material, and a nonwoven fabric sheet.

[Example]
A cutting test was conducted on the core material of Example 1 and the core materials of each comparative example below.

The configuration of the device used in the cutting test is shown in FIGS. 3 and 4. The cutting device 5 is a device for evaluating the ease of cutting the tatami mat when the tatami mat is cut manually using the blade of a cutter knife. The cutting device 5 includes a cutter knife blade 51, a fixed part 52 that fixes the blade 51, a slider 53 that holds the fixed part 52, and a rail part 54 that holds the slider 53 in a horizontally movable state. , a pair of support columns 55 connected to both ends of the rail portion 54, and a pair of grounding columns extending in a direction intersecting the support columns 55 and holding the support columns 55 from falling. 56, and a stopper 57 that is fixed to one foot and fixes the position of the tatami mat 7 placed on the polycarbonate board 6 on the workbench.

The fixing portion 52 is composed of two plate-like members. A cutter knife blade 51 is sandwiched between the two plate-like members and fixed with a screw. A total of four slide shafts 531 are provided above the fixed part 52 and project upward from the plate-like part 536. The base end of the slide shaft 531 and the base end of the fixed part 52 are each fixed to the plate-shaped part 536, the fixed part 52 is arranged below the plate-shaped part 536, and the slide shaft 531 is fixed to the plate-shaped part 536. It is arranged above the section 536.

The stopper 57 has a shape obtained by bending a plate, and includes a notch 571 in the middle for receiving the blade 51 of a cutter knife.

The slider 53 includes an L-shaped plate portion 532 and a total of four flanged linear bushes 533 that receive the slide shaft 531. The flange portion of the linear bush 533 is fixed to the L-shaped plate portion 532. The slide shaft 531 is inserted into the through hole of the linear bush 533, and a ring-shaped retaining member 534 is fixed to the slide shaft 531 that protrudes from the upper end of the through hole of the linear bush 533. The L-shaped plate portion 532 is provided with a rod-shaped handle 535 that is used when moving the slider 53 laterally.

As the linear bush 533, a product manufactured by Misumi Group Inc. (SLHFSW12) was used. This linear bushing includes an outer cylindrical portion, a cylindrical retainer coaxially built into the outer cylindrical portion, and a plurality of small diameter balls arranged between the outer cylindrical portion and the retainer. The through hole formed by the retainer communicates with the through hole provided in the plate-like portion 532. The slide shaft 531 is inserted into a through hole of the collar and a through hole of the plate portion 532.

The rail portion 54 is provided with a total of two protrusions 541 extending in the horizontal direction. Each protrusion 541 is provided with a recess 542 on its upper and lower surfaces to receive a ball of a linear slider, which will be described later. A linear slider (Misumi Group Inc., C-SV2R24-1240) is fixed to the back side of the L-shaped plate portion 532. The ball of the linear slider 53 comes into contact with the recess 542 of the protrusion. The linear slider 53 is in contact with the recess 542 via the ball. When the slider 53 is moved in the horizontal direction, the linear slider 53 slides on the protrusion 541.

The masses of the above-described fixing part 52, plate-shaped part 536, slide shaft 531, and ring-shaped retaining member 534 act on the blade of the cutter knife. The slide shaft 531 of the fixed part 52 is simply inserted into the through hole of the linear bush 533 of the slider 53, and the fixed part 52 is in a free state. Therefore, the mass of the slider 53, rail portion 54, etc. does not act on the blade 51 of the cutter knife.

In this test, a replacement blade for a cutter knife (LB10K) manufactured by Olfa Corporation was used as the cutter knife blade. The blade 51 was attached to the fixing part 52 so that the straight line at the tip of the blade 51 made an angle of 30 degrees when the horizontal line on the surface of the tatami mat 7, which was the object to be cut, was 0 degrees. The moving speed of the slider 53 was set to 1.5 m/min. The length of the tatami mat to be cut was 500 mm. The vertical load acting on the blade 51 was set to 1.0 kg.

A polycarbonate plate 6 (Takiron C.I. Co., Ltd.) with a thickness of 1 mm and smooth surfaces on both sides was placed on a workbench, and the core material of Example 1 below or the core material 7 of each comparative example was placed on it. A spring scale was fixed to the handle 535 of the apparatus, and the spring scale was pulled at the above-mentioned moving speed to cut the tatami. For Example 1 and each comparative example, six tatami mats were prepared, and the average value of the number of times the slider was moved until each tatami reached cutting, and the average value of the load of the spring scale when pulling the handle 535. are summarized in Table 1.

The configurations of the core material of Example 1 and the core materials of each comparative example are as shown in Table 1. The felts used in Example 1 and Comparative Example 1 were each a single layer, and the constituent material was polyester fiber. The insulation board and expanded polystyrene board used in the comparative example are very common materials sold as constituent materials for tatami mats. "Blank" in Table 1 is the load that acts on the blade when the slider is moved in the horizontal direction to perform so-called dry cutting without placing a tatami mat on the polycarbonate board.

As shown in Table 1, the core material according to Example 1 can be cut fewer times than the core materials according to Comparative Examples 2 and 3, which are made of insulation boards. can. When the core materials according to Example 1, Comparative Example 2, and Comparative Example 3 were cut manually using a cutter knife without using the above-mentioned cutting device, the same results were obtained in the sensory evaluation. The result was

As shown in Table 1, in the core material according to Example 1, compared to the core materials according to Comparative Examples 4 and 5, which are made of expanded polystyrene, the core material according to can be cut. When the core materials according to Example 1, Comparative Example 4, and Comparative Example 5 were cut manually using a cutter knife without using the above-mentioned cutting device, the same results were obtained in the sensory evaluation. The result was

The core material according to Comparative Example 1 has satisfactory ease of cutting, but is inferior in long-term durability. That is, the core material according to Comparative Example 1 has a low density and is easily worn down when stepped on repeatedly with the foot, and the cushioning properties of the core material are lost in a relatively short period of time. The core material according to Example 1 was superior to the core material according to Comparative Example 1 in terms of long-term durability.

1 Tatami 12 Outer material 11 Core material 13 Non-woven fabric sheet 14 Anti-slip material 51 Cutter knife blade

Claims (4)

This tatami is laid on structural floors as an alternative to flooring materials, and the core material and the surface material covering the core material are cut by hand using a cutter knife, allowing the size of the tatami to be adjusted according to the construction location. ,
The tatami includes a plate-shaped core material and a surface material that wraps the core material,
The core material is a single layer felt board with a thickness of 5 to 12 mm and a density of 110 to 180 kg/ ^m3 ,
The thickness of the surface material is 1 to 4 mm,
The overall thickness of tatami is 10 to 14 mm. Apply a load of 1 kg in the vertical direction to the blade of the cutter knife, move the blade of the cutter knife laterally at a speed of 1.5 m/min, bring the blade into contact with the core material, and cut the core material. The tatami according to claim 1, wherein the number of times the core material is cut is 1 to 2 times. Apply a load of 1 kg in the vertical direction to the blade of the cutter knife, move the blade of the cutter knife laterally at a speed of 1.5 m/min, bring the blade into contact with the core material, and cut the core material. The tatami mat according to claim 1 or 2, wherein the load required to pull the blade laterally is 2.8 to 3.7 kg. In addition to the surface material and the core material, the method further includes a nonwoven fabric sheet arranged on the back side of the core material, and an anti-slip material arranged on the back side of the nonwoven fabric sheet,
The tatami mat according to claim 1 or 2, wherein the tatami mat is composed of only four items in total: the face material, the core material, the nonwoven fabric sheet, and the anti-slip material.

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