JP5399049B2 - Tatami core and tatami - Google Patents

Description

  The present invention relates to a tatami mat core material using a synthetic resin foam as a heat insulating base material, and a tatami mat covering the core material with a tatami mat surface material.

  With the shortage of tatami mat materials such as natural grass and changes in the living environment, tatami mats using a synthetic resin foam such as polystyrene foam as a heat insulating base material are frequently used. The tatami mat using the synthetic resin foam as a heat-insulating base material has the advantages that not only the heat-insulating property of the tatami floor is improved, but also the tatami mat itself can be reduced in weight, and insect-proofing and mold-proofing can be easily performed. On the other hand, since the synthetic resin foam is inferior in rigidity, various structural devices for reinforcing the heat insulating base material made of the synthetic resin foam with a material having rigidity have been made.

  For example, as a technique using veneer plywood as a reinforcing material, a lightweight tatami mat with a heat-insulating base material in which hard polystyrene foam and soft polystyrene foam are alternately stacked, on which thin veneer plywood is stacked and sewn. A floor has been proposed (see Patent Document 1).

  Moreover, it is set as the heat insulation base material which inserted the synthetic resin foam board which has elasticity in the intermediate part of a synthetic resin foam board, and arrange | positions a veneer plywood on the upper surface of a heat insulation base material, and the upper side surface and heat insulation of a veneer plywood There has also been proposed a tatami mat in which a plate-like cotton body is disposed on the lower surface of the base material and covered with a tatami mat (see Patent Document 2).

  Furthermore, a tatami floor using a synthetic resin molded board as a reinforcing material for a synthetic resin foam used as a heat insulating base material has also been proposed (see Patent Document 3).

Japanese Utility Model Publication No. 49-4419 Japanese Utility Model Publication No. 62-94231 JP 2003-307024 A

  By the way, in the technique using a veneer plywood as a reinforcing material of patent documents 1 and 2, since the veneer plywood which is wood is heavy, there is a problem that the weight of the tatami mat cannot be sufficiently reduced and the cushioning property of the tatami surface is poor. is there.

  Further, in the technique using a synthetic resin molded board as a reinforcing material of Patent Document 3, there is a problem that the synthetic resin molded board is easily changed in size due to the influence of temperature change. That is, since the synthetic resin molded board contracts in the winter, there is a problem that a gap is easily formed between the tatami mats, and in the summer, the synthetic resin molded board expands, so that the tatami mat is difficult to enter.

  The present invention was devised in view of the above circumstances, and can reduce the weight of a tatami mat while having rigidity capable of reinforcing a heat insulating base material made of a synthetic resin foam. An object of the present invention is to provide a tatami core and a tatami mat that have little change in dimensions and have a cushioning property on the upper surface side.

For the above purpose, the first aspect of the present invention is that two non-woven fabric plates having different fiber densities formed by three-dimensionally entangled synthetic fibers are stacked on the upper surface of a heat insulating substrate made of a synthetic resin foam. The fiber density of the lower nonwoven fabric plate in contact with the heat insulating substrate is 0.15 g / cm ³ or more and 0.5 g / cm ³ or less, and the fiber density of the upper nonwoven fabric plate is 0.05 g / cm ³ or more. Less than 0.15 g / cm ³ , the fiber density of the lower nonwoven fabric plate is higher than that of the upper nonwoven fabric plate, and the synthetic fibers constituting the lower and upper nonwoven fabric plates are straight synthetic fibers. There is provided a core material for tatami mats characterized by being.

In the first aspect of the present invention, both the lower and upper nonwoven fabric plates are compressed in a state where the fibers are entangled using fibers having wet heat adhesion alone or fibers having wet heat adhesion and other fibers. And plate-like bodies adhered to each other by contacting with heated steam,
The fiber having wet heat adhesion is a core-sheath type composite staple fiber in which the surface of the polyethylene terephthalate core layer is covered with a sheath layer of ethylene-vinyl alcohol copolymer, and the other fibers are polyethylene terephthalate fibers,
Is included as a preferred embodiment.

  The second aspect of the present invention is that the back surface material is assigned to the lower surface of the core material for tatami mats according to the first aspect of the present invention, and the surface material, the side surface and the peripheral edge of the back surface are wrapped together with the back surface material. The tatami mat is characterized by being covered and integrated.

  The second aspect of the present invention includes as a preferable aspect that the back material is a sheet material having a waterproof surface at least on the exposed surface side.

  According to the present invention, the fiber density of the lower nonwoven fabric plate in contact with the heat insulating substrate is the upper nonwoven fabric plate out of the two nonwoven fabric plates superimposed on the upper surface of the heat insulating substrate made of synthetic resin foam. It is set higher than the fiber density. These non-woven boards are compressed structures that are formed into a plate shape with three-dimensionally entangled fibers, so if the fiber density is increased, the rigidity that can reinforce the synthetic resin foam despite its light weight Have Therefore, the necessary reinforcing effect of the heat insulating substrate can be obtained.

  In addition, the nonwoven fabric board is intertwined with fibers and forms fine voids inside, so it has heat insulation and the expansion and contraction associated with the temperature change of each fiber is absorbed, thus suppressing dimensional changes due to temperature changes. can do.

  Furthermore, since the fiber density of the upper nonwoven fabric plate is set low, an appropriate cushioning property can be imparted to the upper surface side.

  Hereinafter, an example of the present invention will be described with reference to the drawings.

  FIG. 1 is a cross-sectional view schematically showing the structure of a tatami mat according to an example of the present invention, and FIG. 2 is a cross-sectional view schematically showing the structure of a tatami mat core used in the tatami mat shown in FIG. In addition, in FIG.1 and FIG.2, in order to clarify the cross-sectional structure of the tatami mat and tatami mat core material according to the present invention, the ratio of the thickness to the length dimension or the width dimension of each component member is expressed thicker than actual. Yes.

  As shown in FIG. 1 and FIG. 2, the tatami mat 1 according to this example includes a tatami core material 10, a back material 20 addressed to the lower surface of the tatami core material 10, and the back material 20 together with the tatami mat. It is comprised with the tatami surface material 30 which covers the periphery of the surface of the core material 10, a side surface, and a back surface. The total thickness of the tatami mat 1 is usually about 20 to 60 mm.

  The core material 10 for tatami is made by superimposing 12 and 13 non-woven fabric plates on the upper surface of a heat insulating base material 11 made of a synthetic resin foam.

As the synthetic resin foam constituting the heat insulating substrate 11, for example, a polystyrene resin foam, a polyethylene resin foam, a polypropylene resin foam, a polyurethane resin foam, a phenol resin foam, or the like is used. However, a polystyrene foam is preferred because of its low water absorption and excellent heat insulation. Moreover, although a bead foam molded body or an extrusion foam molded body may be sufficient, since it is excellent in pressure resistance, an extrusion foam molded body is preferable. The synthetic resin foam constituting the heat insulating base material 11 preferably has a density of 20 to 50 kg / m ³ and a foaming ratio of 20 to 50 times in order to obtain appropriate rigidity and heat insulating properties. The heat-insulating base material 11 has a thickness of about 10 to 50 mm and has a flat plate shape that is cut into a tatami mat plane (for example, 900 mm × 1800 mm).

  The two nonwoven fabric plates 12 and 13 to be superposed on the upper surface of the base material 11 are formed by three-dimensionally intermingling synthetic fibers, and the fiber density of the lower nonwoven fabric plate 12 in contact with the heat insulating base material 11 is higher. It is higher than the fiber density of the nonwoven fabric plate 13.

  Since the lower nonwoven fabric plate 12 has a structure in which synthetic fibers are entangled three-dimensionally and has a structure capable of absorbing thermal expansion and contraction of each fiber, the overall dimensional change due to temperature change is suppressed. Moreover, since the fiber density is relatively high, the rigidity is increased, and it serves as a reinforcing material for the heat insulating base material 11.

Nonwoven sheet 12 and the lower, suppresses the thermal expansion and contraction, in order to impart the necessary rigidity as the reinforcing material, fiber density Ru der 0.15 or 0.5 g / cm ³ or less. When the density of the lower nonwoven fabric plate 12 is larger than 0.5 g / cm ³ , it becomes difficult to absorb the expansion and contraction of each constituent fiber accompanying the temperature change, and the dimensional change accompanying the temperature change becomes large. Moreover, when the density of the lower nonwoven fabric plate 12 is smaller than 0.15 g / cm ³ , the rigidity is lowered and the heat insulating base material 11 is easily deformed. More specifically, the lower nonwoven fabric plate 12 has a linear expansion coefficient of 1 to 3 × 10 ⁻⁵ (K ⁻¹ ), a compression modulus of 100 to 400 N / cm ² , and a bending strength of 100 to 300 N / mm. It is preferably ² , and these physical properties can be satisfied by adjusting the fiber density. The thickness of the lower nonwoven fabric plate 12 is usually 2 to 6 mm.

  Since the upper nonwoven fabric plate 13 has a fiber density smaller than that of the lower nonwoven fabric plate 12, the linear expansion coefficient is smaller than that of the lower nonwoven fabric plate 12, and mainly serves to impart cushioning properties.

Upper nonwoven plate 13, in order to obtain a moderate cushioning property, fiber density Ru der less than 0.05 g / cm ³ or more ~0.15g / cm ^3. Even if the fiber density of the upper non-woven fabric sheet 13 is smaller than even 0.05 g / cm ³ becomes 0.15 g / cm ³ or more, cushioning tends to lack. Further, the upper nonwoven fabric sheet 13, the compression modulus 30~200N / cm ^2, bending 50 to 200 / cm ² intensity in the longitudinal direction, is preferably in 30~100N / cm ² in the width direction, the fiber density These physical properties can be satisfied by adjusting. The thickness of the upper nonwoven fabric plate 13 is usually 2 to 4 mm.

Lower and upper nonwoven plates 12 and 13, in order to obtain the physical properties, and is obtained by configuration are entangled in a three dimensional straight synthetic fibers. A straight synthetic fiber means a synthetic fiber without a crimp. In the case of a crimped synthetic fiber, it is flexible even if the fiber density is increased, and it is difficult to satisfy the compressive strength and bending strength.

  Since the lower and upper nonwoven fabric plates 12 and 13 are easy to obtain the above-mentioned physical properties, fibers using wet heat adhesiveness alone or mixed fibers of fibers having wet heat adhesiveness and other fibers are used, and the fibers are separated from each other. It is preferably a plate-like body that is compressed in an entangled state and is bonded to each other by contacting with heated steam. The wet heat adhesive fiber is a fiber that exhibits adhesiveness by contact with heated steam, and is preferably a core-sheath type composite staple fiber in which the surface of the polyethylene terephthalate core layer is covered with a sheath layer of an ethylene-vinyl alcohol copolymer. . The core-sheath mass ratio is preferably about 40-60: 60-40. Other fibers are preferably polyethylene terephthalate (PET) fibers. The mixing ratio between the two is preferably 5 to 30% by weight of PET fiber with respect to 70 to 95% by weight of the core-sheath type composite staple fiber.

  The lower and upper nonwoven fabric plates 12 and 13 are transferred to a belt conveyor equipped with a polycarbonate endless net using the wet heat adhesive fiber alone or a mixed fiber of the wet heat adhesive fiber and other fibers. It can be obtained by forming a plate-like body in which entangled fibers are bonded to each other by subjecting the front and back surfaces to heat steam treatment.

  The lower and upper nonwoven fabric plates 12 and 13 may be simply superimposed on the upper surface of the heat-insulating substrate 11, but it is preferable that they are previously stacked and brought into contact with each other by heating steam. By doing in this way, the workability | operativity at the time of manufacture of the tatami 1 can be improved.

  The back material 20 is preferably a sheet material having a waterproof surface at least on the exposed surface side. Specifically, a synthetic resin sheet, a laminated sheet of cloth and synthetic resin, a laminated sheet of paper and synthetic resin, or the like can be used, and the lower surface of the substrate 11 with the synthetic resin surface as an exposed surface side (lower surface side). Addressed to.

  In this way, the back surface material 20 is applied to the lower surface of the heat insulating base material 11, and the back surface material 20 is covered with the tatami mat surface material 30 so as to wrap around the front surface, the side surface and the periphery of the back surface of the tatami core material 10. Each of the constituent members is integrated to form the tatami mat 1 by fastening the peripheral edge thereof with a sewing thread or a fastening needle.

  In addition, the back surface reinforcement material 40 can be attached and reinforced to the heat insulation base material 11 fixation site | part.

  Thus, in the core material 10 for tatami and the tatami 1 of this invention, it functions as a reinforcing material among the lower side and upper side nonwoven fabric boards 12 and 13 superimposed on the upper surface of the heat insulating base material 11 of a synthetic resin foam. The fiber density of the lower nonwoven fabric plate 12 is set higher than the fiber density of the upper nonwoven fabric plate 13 functioning as a cushioning material. Since the lower and upper nonwoven fabric plates 12 and 13 are structures formed by three-dimensionally interlacing synthetic resin fibers and formed into a plate shape, adjusting the fiber density can reduce the weight while reducing the weight of the insulating base. Rigidity and cushioning properties that can reinforce the material 11 can be provided. Moreover, since it has a fine space | gap inside the lower side and upper side nonwoven fabric boards 12 and 13, it has heat insulation, there is little influence by a temperature change, and there are few dimensional changes of a tatami. Moreover, since the structural member of the core material 10 for tatami mat | matte of this invention is a synthetic resin foam and a nonwoven fabric board, it is easy to cut | judge. In addition, the nonwoven fabric plate has high surface friction strength, little dust generation, and good adhesion to the synthetic resin foam, so that the workability when covering with the tatami mat 30 is also good.

Hereinafter, the present invention will be described in more detail with reference to examples and comparative examples of tatami mats according to the present invention.

〔Example〕
A tatami mat 1 having the structure shown in FIG. 1 was produced.

  As the synthetic resin foam of the base material 11, an extruded expanded polystyrene foam (trade name: Styrofoam, manufactured by Dow Chemical Co., Ltd.) having a thickness of 45 mm and an expansion ratio of 33 times was used.

The lower nonwoven fabric plate 12 that is in contact with the upper surface of the heat insulating substrate 11 and functions as a reinforcing material has a thickness of 2 mm, a fiber density of 0.2 g / cm ³ , and a bending strength of about 300 N / long in the length direction. A non-woven fabric board having a cm ² width of about 150 N / cm ² and a linear expansion coefficient of 2 × 10 ⁻⁵ (k ⁻¹ ) was used.

The upper nonwoven fabric plate 13 functioning as a buffer material has a thickness of 3 mm, a fiber density of 0.1 g / cm ³ , a bending strength of about 150 N / cm ² in the length direction, and about 80 N / width in the width direction. A nonwoven fabric plate having a cm ² and a linear expansion coefficient of 2 × 10 ⁻⁵ (k ⁻¹ ) was used.

  A paper having a synthetic resin laminated on the lower surface of the heat insulating base material 11 is addressed as a back surface material 20, and the back surface material 20, the surface of the tatami mat core material 10, the side surface, and the periphery of the back surface are wrapped. The tatami mat 1 was produced by covering with a material 30 and fastening the peripheral edge of the back surface with a fastening needle.

  The total weight of the tatami mat 1 produced in this example was 6 kg. Further, the displacement measured by a local compression test specified in JIS A 5914 was 2 mm, which showed a sufficient rigidity. Furthermore, when the dimensions were measured under an atmosphere of 25 ° C./90% humidity and an atmosphere of 5 ° C./30% humidity, the dimensional change amount (the change amount of the dimension at low temperature relative to the dimension at high temperature) was The width direction was -1 mm.

  The tatami mat 1 produced in this example was measured based on the “method for evaluating the floor from the viewpoint of pain when pressing against the body” established by the Floor Performance Study Group, and found to be −0.95 and had sufficient cushioning properties. It was a result. Here, it shows that it is so hard that it is tatami mat, so that the-(minus) numerical value of a measured value becomes large.

[Comparative Example 1]
A tatami mat was prepared in the same manner as in the example except that a 2.3 mm thick veneer plywood and a 2 mm foamed polyethylene cushion material functioning as a reinforcing material were disposed on the upper surface of the heat insulating base material 11.

  The total weight of the tatami mat produced in this comparative example was 7 kg. The displacement measured by the local compression test specified in JIS A 5914 was 2 mm. Furthermore, when the dimensions were measured in an atmosphere of 25 ° C./90% humidity and an atmosphere of 5 ° C./30% humidity, the dimensional change was −1.5 mm in the length direction and −1 mm in the width direction.

  The tatami mat produced in this comparative example was measured on the basis of the “method of evaluating the floor from the pain when pressing against the body” established by the Floor Performance Study Group, and it was −2.41, and the cushioning property was slightly inferior. became.

[Comparative Example 2]
A tatami mat 1 was produced with the same configuration as in the example except that a polyolefin recycled resin plate (synthetic resin board) having a thickness of 10 mm functioning as a reinforcing material was disposed on the upper surface of the heat insulating substrate 11.

  The total weight of the tatami mat produced in this comparative example was 9 kg. The displacement measured by the local compression test specified in JIS A 5914 was 2 mm. Furthermore, when the dimensions were measured under an atmosphere of 25 ° C./90% humidity and an atmosphere of 5 ° C./30% humidity, the dimensional change was −3 mm in the length direction and the width direction.

  The tatami mat produced in this comparative example was measured based on the “method for evaluating the floor from the viewpoint of pain when pressing the body” established by the Floor Performance Study Group, and was found to be −3.11, resulting in poor cushioning properties. It was.

It is sectional drawing which shows typically the structure of the tatami concerning an example of this invention. It is sectional drawing which shows typically the structure of the core material for tatami mats concerning an example of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Tatami 10 Tatami core 11 Base material 12 Lower nonwoven fabric board 13 Upper nonwoven fabric board 20 Back surface material 30 Tatami surface material

Claims (5)

Two nonwoven fabric plates having different fiber densities formed by three-dimensionally entangled synthetic fibers are vertically stacked on the upper surface of a heat insulating base material made of a synthetic resin foam, and are in contact with the heat insulating base material. fiber density of the side of the nonwoven fabric sheet is 0.15 g / cm ³ or more 0.5 g / cm ³ or less, the fiber density of the upper nonwoven fabric sheet is less than 0.05 g / cm ³ or more 0.15 g / cm ^3, the lower A core material for tatami mats, wherein the nonwoven fabric plate has a fiber density higher than that of the upper nonwoven fabric plate, and the synthetic fibers constituting the lower and upper nonwoven fabric plates are straight synthetic fibers . Both the lower and upper nonwoven fabric plates use wet fibers alone or a mixed fiber of wet fibers and other fibers, compressed in a state where the fibers are entangled, and heated steam The core material for tatami mats according to claim 1 , wherein the tatami mat core materials are plate-like bodies that are brought into contact with each other and bonded to each other. The fiber having wet heat adhesion is a core-sheath type composite staple fiber in which the surface of the polyethylene terephthalate core layer is covered with a sheath layer of ethylene-vinyl alcohol copolymer, and the other fibers are polyethylene terephthalate fibers. The core material for tatami mats according to claim 2 . A back surface material is applied to the lower surface of the core material for tatami mats according to any one of claims 1 to 3 , and the front surface, side surfaces, and peripheral edges of the back surface of the core material are wrapped together and covered with a tatami surface material. A tatami mat characterized by that. The tatami mat according to claim 4 , wherein the back material is a sheet material having a waterproof surface at least on the exposed surface side.

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