JP3434204B2 - Tatami floor component for thin tatami mat and thin tatami mat using the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tatami mat component used for constructing a tatami mat having a small thickness, and a tatami mat having a small thickness obtained by using the tatami mat component. .

[0002]

2. Description of the Related Art In recent years, in the field of housing design, as a Japanese-Western eclectic house, a house without a step between a western room and a Japanese-style room has attracted attention as a barrier-free house. In the case of using a traditional tatami mat, in order to eliminate the step between the Japanese-style room and the Western-style room, it is necessary to lower the size of the Japanese-style room or raise the floor of the Western-style room. Therefore, if a thin tatami mat having a thickness of about 7 to 25 mm is used in place of the conventional tatami mat having a thickness of about 55 mm, the construction is easy, and the Western-style room and the Japanese-style room can be easily changed.

As a material for a tatami mat floor, for example, Japanese Unexamined Patent Publication No. Hei 7
As described in JP-A-217163, JP-A-8-284381 and the like, there is known a laminate formed by laminating a veneer plate on a foam in order to disperse the pressure applied to the tatami mat. A thin tatami mat is formed by laminating a cushioning material and the like on the tatami floor constituent material and then covering the surface with a tatami mat surface.

[0004]

However, the above-mentioned conventional tatami mat material for thin tatami mats is formed from foamed plates and veneer, etc. When sewn on the tatami floor while making the tension,
There is a problem that the tatami mat tends to warp due to its low flexural modulus. When the tatami mat is warped, the end of the tatami mat warps upward on the surface side of the tatami mat and a recess is likely to be formed on the tatami mat surface. Such a tatami mat is not preferable because it causes a squeak noise and causes the user to stumble.

It is an object of the present invention to provide a tatami floor component for producing a tatami mat and a tatami mat for the purpose of improving the above problems.

[0006]

The present invention provides (1) total thickness 7
In a tatami mat constituent material used for a thin tatami mat of up to 25 mm, the tatami mat constituent material is provided on both surfaces of a plate-like body (excluding synthetic resin foam) having a density of 0.02 to 0.5 g / cm ³ . A sheet impregnated with a thermoplastic resin, in which a plurality of continuous reinforcing fibers composed of long glass fibers having a fiber diameter of 5 to 36 μm are converged and arranged in one direction, and the glass fiber content in the sheet is 40 to 80 A thickness of 4 to 20 m obtained by adhering and integrating a fiber-reinforced resin sheet having a weight% of 0.1 to 1.0 mm.
and has a flexural modulus of 6000 kgf / c
a tatami mat material for thin tatami mats, characterized by having a size of at least m ² .
( 2 ) The fiber-reinforced resin sheet is a fiber-reinforced resin sheet obtained by arranging continuous reinforcing fibers in one direction and laminating and integrating at least two sheets impregnated with a thermoplastic resin so that the fiber directions are orthogonal to each other. A certain tatami floor constituent material for thin tatami according to the above (1), ( 3 ) A cushion layer is arranged on the upper surface of the tatami floor constituent material according to the above (1) or (2), and a backing material is provided on the lower surface as necessary. A thin tatami having a total thickness of 7 to 25 mm, in which a tatami mat is arranged to sew the tatami mat on the tatami mat so that tension is applied to the tatami mat.
( 4 ) The gist of the thin tatami described in ( 3 ) above, which has a thermal resistance value of 0.5 (m ² · h · ° C / kcal) or less.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below with reference to the drawings. As shown in FIG. 1, the tatami mat component 1 of the present invention is
It is used as one material for forming a tatami mat having a total thickness of 7 to 25 mm and has a density of 0.02.
~ 0.5 g / cm ³ of plate-like body 2 and fiber reinforced resin sheet 3
Are integrally bonded and are formed to have a thickness of 4 to 20 mm.

The tatami mat material 1 has a flexural modulus of 6 in both directions when the flexural moduli of the tatami are measured in the longitudinal and transverse directions.
000 kgf / cm ² or more. When the bending elastic modulus is less than 6000 kgf / cm ^{2, when} it is attempted to sew a tatami mat without slack, a concave warp is likely to be formed on the tatami surface side, and the object of the present invention cannot be achieved. To prevent more reliably the warpage, the flexural modulus is preferably 8000kgf / cm ² or more, further preferably 10000 kgf / cm ² or more.

The flexural modulus in the present invention refers to JIS
Based on the measurement of "bending strength" (loading speed 10 mm / min.) In Section 4.8 of A9511-1989, JIS K
It is calculated by the calculation method of “bending elastic modulus” in Section 7.2 of 7221-1984. In the bending test, in the case of a tatami mat, in a normal tatami mat, the bending load is applied in the longitudinal direction of the tatami mat floor forming material that is rectangular and in the transverse direction that is the lateral direction of the tatami mat. , A test piece is prepared and the flexural modulus in both the longitudinal direction and the transverse direction is obtained. When using it for a tatami mat for half-mats, a bending test is performed in each of the directions of two sides of the square tatami mat component that intersect at right angles,
Determine both flexural moduli. In the tatami floor constituent material of the present invention, the bending elastic modulus in both the longitudinal direction and the transverse direction is 60.
It has 00 kgf / cm ² or more.

The tatami mat component 1 has a compressive strength of 1.0 kgf.
/ Cm ² or more is preferable, and 1.3 kgf / cm ² or more is more preferable. The above compression strength is JIS K 7220.
-Test speed 10 according to the method of measuring compressive strength in 1983.
It means what was tested at mm / min. In the present invention, the load at 10% strain is adopted as F (yield strain, specified strain or load at proportional limit) of the JIS formula (2). In the case where the maximum value of the load is shown up to 10% strain, the maximum load during that period is adopted. The compressive strength of the tatami mat component 1 is 1.0 kgf /
cm ² or more (preferably 1.3 kgf / cm ² or more) and, it is desirable to the compressive strength of the plate-like body 1.0 kgf / cm ² or more (preferably 1.3 kgf / cm ² or higher) .

The plate-like body 2 is made of a wood board, an inorganic board, a honeycomb core, or a composite laminated body thereof having a density of 0.02 g / cm ³ or more and 0.5 g / cm ³ or less.

Examples of the wood board include particle board, plywood, hard board, medium density fiber board, insulation board and the like. Examples of the inorganic board include glass wool, ceramic fiber, rock wool, lightweight cement board, wood wool cement board, wood chip cement board, pulp cement board, gypsum board, calcium silicate board, and other inorganic material lightweight boards.

As shown in FIG. 2, in the honeycomb core 21, for example, a large number of tubular portions 23 each having a hexagonal cross section are formed adjacent to each other in the outer peripheral direction in the direction T penetrating the front and back of the plate surface and are parallel to the plate surface. It is a plate-shaped member having a honeycomb shape in which a large number of hexagons are combined with each other. In the honeycomb core 21 shown in FIG. 2, the tubular portion 23 penetrates the front and back of the plate surface, but the shape is not limited to such a shape, and the front and back 22 of the tubular portion may be closed. Further, the honeycomb core is not limited to the one having a normal hexagonal cross-section shown in FIG. 2, and although not particularly shown, all the structures formed by combining a plurality of flat plates parallel to one common axis or curved plates are used. included. That is, the cross-sectional shape parallel to the plate surface of the honeycomb core is
Any shape may be used, such as a thin hexagonal shape, a quadrangular shape, a triangular shape, a continuous shape such as a circle in a lattice pattern.

In the honeycomb core 21 used as the plate-shaped body 2, the surface forming the tubular portion 23 has the plate-shaped body 2
It suffices that it is perpendicular to the fiber-reinforced resin sheet 3 laminated on one side or both front and back sides, and it is not always necessary for the adjacent tubular portions to stick to each other, and the joint portions are separated. It may be present in or in a block form. Further, in the honeycomb core, the size and shape of each tubular portion 23 may not be all uniform and may be different, or the bent strips may be bonded to each other at any point on the strip surface. Good.

In order to obtain a high-strength tatami mat component 1, the honeycomb core 21 preferably has a size (cell size) d of each cylindrical portion shown in FIG. 2 of 3 to 30 mm, It is preferable that they have the same shape and are closely adhered to each other. Further, the cell size d may be as fine as about 3 mm or as large as about 30 mm, but the strength of the composite plate is increased and the adhesiveness with the fiber reinforced resin sheet 3 is improved. In order to achieve this, it is preferable to reduce the bottom area of each tubular portion and make the thickness of the material forming each tubular portion as thick as possible within the range of 0.1 to 1 mm.

The material of the honeycomb core may be any of aluminum, fiber reinforced plastic (FRP), paper, thermoplastic resin such as polypropylene and polyethylene, and is not particularly limited as long as sufficient strength can be exhibited, but the honeycomb core made of paper (Paper honeycomb) is preferable because it is inexpensive, lightweight, and has sufficient compressive strength.

The fiber reinforced resin sheet 3 is formed by mixing a fiber material into resin and is formed into a sheet shape. Since the fiber reinforced resin sheet 3 has a high bending elastic modulus, the bending elastic modulus of the tatami mat constituent material can be greatly improved. You can

Examples of the fiber of the fiber reinforced resin sheet 3 include glass fiber, carbon fiber, boron fiber, metal fiber, ceramic fiber, polyester fiber, vinyl chloride / acrylonitrile copolymer fiber, polyvinyl alcohol fiber and the like. Glass fibers having excellent strength and dimensional stability of the fiber-reinforced resin sheet are preferable, and among them, glass long fibers are most preferable. As the resin constituting the fiber reinforced resin sheet 3, polystyrene resin, polypropylene resin, polyethylene resin, polyvinyl chloride resin,
Examples thereof include synthetic resins such as polyvinylidene chloride resin and unsaturated polyester resin.

The most preferable fiber-resin combination of the fiber-reinforced resin sheet 3 is a thermoplastic resin such as polypropylene in a fiber sheet in which a plurality of continuous fibers made of long glass fibers having a fiber diameter of 5 to 36 μm are converged and arranged in one direction. Examples include a sheet impregnated with a resin. Further, it is more preferable that the above-mentioned sheets are laminated and integrated so that the fiber directions of the respective sheets are orthogonal to each other. The fiber reinforced resin sheet 3
The content of glass fiber therein is preferably 40 to 80% by weight.

Since the fiber-reinforced resin sheet of this most preferred embodiment is particularly excellent in tensile strength, it is a thin sheet and easily imparts a high bending strength and a high bending elastic modulus to a tatami floor constituent material, and further to a tatami floor. be able to. As a result, it becomes possible to increase the thickness of the plate-shaped body within the predetermined thickness and reduce the density thereof, which can greatly contribute to the weight reduction of the tatami mat.

The fiber-reinforced resin sheet of the most preferred embodiment is known from JP-A-7-178859.
The thickness of this fiber reinforced resin sheet is 0.1 to 1.0 mm
Is preferred. The tatami mat component of the present invention may be formed by providing the fiber-reinforced resin sheet 3 on both sides of the plate-like body 2 or by laminating only one side of the plate-like body 2. In the case of only one side, it may be laminated on either side of the front side or the back side of the tatami mat.

The tatami mat component 1 is manufactured by bonding and integrating the fiber reinforced resin sheet 3 on one side, preferably both sides, of the plate-like body 2. Usually, this adhesion is performed by interposing an adhesive agent therebetween. When a resin such as a honeycomb made of resin is used as the plate-shaped body, if the resin and the resin constituting the fiber-reinforced resin sheet are of the same type, it is also possible to heat-bond the both. .

As the fiber-reinforced resin sheet 3, a single sheet or a sheet obtained by impregnating a fiber sheet in which continuous fibers made of long glass fibers as described above are bundled and arranged in one direction with a thermoplastic resin such as polypropylene When using a sheet in which the sheets are laminated and integrated so that the fiber directions of the sheets are the same, one of the plate-like bodies 2 is made to intersect with the fiber direction of the other so that the fiber directions of the plate-like bodies 2 intersect. It is desirable that the fiber-reinforced resin sheets 3 are laminated and integrated on both sides.

The tatami mat component 1 is formed to have a thickness of 4 to 20 mm. If it is less than 4 mm, sufficient strength cannot be obtained.
If it exceeds 0 mm, it is difficult to form a tatami mat having a thickness of 25 mm or less.

The tatami mat component 1 of the present invention is for expressing the main mechanical strength of the tatami mat, and when it is used as a tatami mat, it may be used only by the tatami mat component 1. However, there is a case where a soft sheet such as an insect repellent sheet, a cushion sheet, a moisture absorbing / releasing sheet, a protective sheet, and a back sheet is further laminated on the tatami mat component 1. For example, tatami floor 6
3 to 5, the cushion layer 4 may be laminated on the front surface side of the tatami mat component 1, and the cardboard 10 and the backing material 5 may be laminated on the back surface side.

As shown in FIG. 4, the tatami mat 9 of the present invention can be obtained by sewing the tatami mat 7 and the tatami mat 8 to the tatami floor 6 formed as described above. The tatami mat 9 is formed to have a total thickness of 7 to 25 mm.
In this case, the tatami mat 7 is sewn and integrated with the tatami floor 6 in a tensioned state by applying tension so as not to loosen. As shown in FIG. 5, the cardboard 10 is designed to reduce a step between the tatami mat and the back surface of the tatami mat when the longitudinal end of the tatami mat 7 is wound and fixed to the back surface. It is provided.

The tatami mat 9 has a thermal resistance value of 0.5 (m ² · h · ° C).
/ Kcal) or less, when it is laid on a floor heating panel, it has excellent heat transfer properties, so that heating efficiency can be improved. Moreover, at this time, the tatami mat 9 has the effect of being less likely to warp even if it receives the heat of the floor heating panel due to the existence of the tatami mat floor constituent material 1. In addition, the measurement of the thermal resistance value is performed according to JIS.
According to the "Flat plate heat flow meter method" of A 1412-1994,
The value obtained by measuring the tatami mat of the test piece (the thickness is left unchanged and the length and width are cut according to the shape and dimensions of the hot plate of the measuring device) is used.

The tatami mat of the present invention has a thickness of 7 to 7 as described above.
Since it is a 25-mm tatami mat, it is optimally used as a tatami mat for barrier-free houses. Further, since it is lightweight and thin, it can be optimally used as a simple tatami mat to be laid on a flooring of a house or the like.

[0029]

Example 1 A single tatami-sized fiber-reinforced resin sheet (Preglon LF15N) is provided on both front and back surfaces of a single tatami-sized T-class insulation board (density: 0.24 g / cm ³ ) having a thickness of 7 mm.
/ K15: manufactured by Mitsui Chemicals, Inc. was laminated and adhered using a hot-melt adhesive (trade name: Hirodyne 7514, manufactured by Hirodyne Industry Co., Ltd.) to obtain a tatami mat material having a thickness of 7.5 mm. Further, a non-woven fabric having a thickness of 1 mm was laminated on the front side of the tatami mat constituent material, and a cardboard having a thickness of 1 mm was laminated on the back side of the tatami mat constituent material to integrally sew a tatami mat. Pregron L
F15N / K15 is formed by laminating a non-woven fabric on a laminated sheet obtained by laminating polypropylene sheets containing 70% by weight of glass long fibers having a fiber diameter of 17 μm in a direction orthogonal to each other, and a basis weight of about 320 g / m ^2. , Tensile strength is 42 kgf / mm ² , tensile elastic modulus is 1900 kg
It is a sheet having f / mm ² and a thermal expansion coefficient of 5 × 10 ⁻⁶ / ° C. Compressive strength of the obtained tatami floor material (JIS A951
According to the test of Section 4.9 of 1-189. The thickness of the test piece remains the same), bending strength (JIS A9511-1)
989, Section 4.8. Load speed is 10 mm /
min. ), Maximum load (JIS A9511-1989
According to the test in Section 4.8. ) And the flexural modulus (as described above) are shown in Table 1. Next, when the tatami mat made of igusa was sewn and integrated with the tatami mat material by using an automatic table tensioner, tension was applied to the tatami mat, and no warpage was observed. . Moreover, when the thermal resistance value of this tatami was measured according to the "flat plate heat flow meter method" of JIS A 1412-194, it was 0.16.
It was m ² · h · ° C / kcal.

Comparative Example 1 A polystyrene sheet resin foam (density: 0.095 g / cm ³ ) having a thickness of 10 mm and having a size of one tatami mat was used on both front and back surfaces.
A high-strength PET non-woven fabric (Valcompo: trade name of Toyobo Co., Ltd.) of about 300 g / m ² for a tatami mat size was laminated and adhered to each other to obtain a tatami mat constituent material having a thickness of 10.5 mm. The results of measuring the physical properties of the obtained tatami mat constituent material in the same manner as in Example 1 are shown in Table 1. Next, when a tatami mat was integrally sewn on the tatami mat material in the same manner as in Example 1, a large warp occurred.

[0031]

[Table 1] MD: Longitudinal (longitudinal) direction of tatami mat constituents TD: Horizontal (short) direction of tatami mat constituents

[0032]

As described above, the tatami mat constituent material for a thin tatami mat of the present invention is a plate-like material and a long glass fiber having a fiber diameter of 5 to 36 μm.
Multiple continuous reinforcing fibers consisting of
Sheets lined and impregnated with thermoplastic resin
By adopting a constitution in which the glass fiber content in the resin is 40-80% by weight and the fiber-reinforced resin sheet is bonded and integrated, the bending elastic modulus of the plate can be remarkably improved. Furthermore, since the tatami mat flooring material for thin tatami mats has a flexural modulus of 6000 kgf / cm ² or more, it is possible to form thin tatami mats with a total thickness of 7 to 25 mm without warping without using plywood. Is. The thin tatami of the present invention is the thin
Since the tatami mat flooring material is used, a thin tatami mat having an overall thickness of 7 to 25 mm can be obtained without forming recesses on the tatami mat surface and without causing squeaking noises or tripping .

[Brief description of drawings]

FIG. 1 is a cross-sectional view of essential parts showing an example of a tatami mat constituent material of the present invention.

FIG. 2 is an explanatory diagram of a honeycomb core.

FIG. 3 is a perspective view showing an example of a tatami mat of the present invention, in a partially cutaway state.

FIG. 4 is a longitudinal sectional view in the width direction showing one example of the tatami of the present invention.

FIG. 5 is a longitudinal sectional view in the longitudinal direction showing an example of the tatami of the present invention.

[Explanation of symbols]

1 Tatami floor material 2 plates 3 fiber reinforced resin sheet 4 cushion layer 5 Lining material 6 tatami floor 7 tatami mats 8 tatami mats 9 tatami mats 10 cardboard

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Kiyotaka Nanama 2-1-1 Uchisaiwaicho, Chiyoda-ku, Tokyo JSP Inc. (72) Yuichiro Hashizume 2-1-1 1-1 Uchisaiwaicho, Chiyoda-ku, Tokyo Stocks (56) References JP-A-5-10018 (JP, A) JP-A-7-178859 (JP, A) JP-A-7-97465 (JP, A) JP-A-6-193281 (JP , A) JP 7-109814 (JP, A) JP 7-217163 (JP, A) JP 8-284381 (JP, A) JP 56-54207 (JP, B1) JP 43-9579 (JP, Y1) (58) Fields investigated (Int.Cl. ⁷ , DB name) E04F 15/02

Claims (4)

(57) [Claims] 1. A tatami mat component used for thin tatami mats having a total thickness of 7 to 25 mm, wherein the tatami mat component has a density of 0.02 to 0.02.
Plural continuous reinforcing fibers composed of long glass fibers having a fiber diameter of 5 to 36 μm are converged and arranged in one direction on both sides of a 0.5 g / cm ³ plate-shaped body (excluding synthetic resin foam). it is, a sheet impregnated with a thermoplastic resin, the thickness of the glass fiber content in the sheet is 40 to 80% by weight
A tatami mat for a thin tatami mat, which has a thickness of 4 to 20 mm obtained by bonding and integrating a fiber-reinforced resin sheet of 0.1 to 1.0 mm , and has a bending elastic modulus of 6000 kgf / cm ² or more. Component material. 2. A fiber-reinforced resin sheet in which continuous reinforcing fibers are arranged in one direction and at least two sheets impregnated with a thermoplastic resin are laminated and integrated so that the fiber directions are orthogonal to each other. The tatami mat material for thin tatami mats according to claim 1, which is a sheet. 3. A cushion layer is arranged on the upper surface of the tatami mat component according to claim 1 or 2, and a lining material is arranged on the lower surface if necessary to form a tatami mat. The tatami mat is sewn together so that tension is applied to the
A thin tatami mat characterized by being ~ 25 mm. 4. A thermal resistance value of 0.5 (m ² · h · ° C./kc
a) The thin tatami mat according to claim 3, wherein: