JPH06288063A - Thin tatami - Google Patents

Abstract

PURPOSE:To form an irregular shape finally, and to produce a tatami covering which uses structural rushes which form a melting film on the surface by allowing thermoplastic resin-made tape extending in the longitudinal direction to pass through a heating member which forms a small clearance. CONSTITUTION:A thermoplastic resin-made tape is adapted to pass through a first heating device while the tape is extended with a roll so that the tape may be introduced into a second heating device where the tape terminates its irregular shaping. The tape is pulled up with a roll and cut to a specified length. The structural rushes are woven, thereby producing a tatami or mat facing. Then, the front and rear surface of a sheet of plywood are covered with an aluminum sheet 19. Felt 21 is pasted on the sheet as a cushion material where the tatami facing 17 is bonded thereon. The whole thickness is arranged to no exceed 25mm. This construction makes it possible to increase a heat transfer coefficient and reduce a heat source temperature.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thin tatami mat having a smaller thickness as compared with a tatami mat using a normal natural rush.

[0002]

2. Description of the Related Art There are various conventional room heating methods. These include gas stoves, electric stoves, electric carpets, etc. However, floor heating is the best when considering indoor air cleaning and room temperature distribution. This is an electric heater or a tube of hot water that passes under the floor, the air does not get dirty, and it also works for head and foot heat.

Most of the floor heating is used in the western space (the floor is not tatami mat). However, in our country,
There is also a strong demand for floor heating in Japanese-style rooms due to the attachment to tatami mats.

Despite the high demand, floor heating in tatami rooms is low for the following three reasons. The igusa on the surface deteriorates depending on the heating temperature. This is because in order to raise the surface temperature to some extent, it is necessary to considerably heat the back surface. Since the thickness is large (55 mm), the heat transfer coefficient is small and the heating loss is large. Most of the heat that is heated is not introduced into the room, but only under the floor and inside the tatami. Due to humidity, the tatami mat expands and contracts significantly, creating gaps.

In order to solve such drawbacks, it is conceivable to make the tatami thin and to use a core material having a small expansion coefficient due to humidity and temperature. For example, a cushion material such as plywood or felt is used for the core material. This is because the expansion coefficient due to temperature is large for plastic etc.
This is because it cannot be used very much.

[0006]

However, although the conventional thin tatami mats have been solved, the tatami mats on the surface of all tatami mats use natural igusa, so the igsa itself is deteriorated by heat and its lifespan is shortened. Was significantly shortened, and the aesthetics were also spoiled. That is, the above is not solved.

Further, in the case of a wood chip plate or plywood, expansion and contraction due to temperature are very small, but expansion due to moisture is large. That is, when heated, the wood loses its equilibrium water content and dries and contracts. When the heating is stopped, it will be restored, but over time, a gap of 3 to 5 mm will be formed on the side wall of the tatami mat. Furthermore, warping due to humidity occurs, and the edges and four corners of the tatami mat rise. Of course, such a thing cannot be used. That is, the above is not solved. Therefore, in the industry, a tatami mat, which does not have the above-mentioned disadvantages, has been long-awaited for heating.

[0008]

In view of the above-mentioned circumstances, the present inventor has completed the thin tatami of the present invention as a result of earnest research, and is characterized in that the heat stretched in the longitudinal direction is used. By passing a tape-shaped body made of a plastic resin into a heating member that forms a narrow void, irregularly convergently formed, and a tatami mat formed by weaving an imitation igusa having a fused coating formed on the surface, Secured to a plywood board that covers both the front and back sides with an aluminum sheet to a total thickness of 25
It is in the point of being less than mm.

The imitation rush according to the present invention will be described. As an example of the method for manufacturing the imitation rush, the raw material tape from the inflation device is drawn by the first pinch roll while passing through the first heating device, and is introduced into the second heating device. Irregularly converged by the second heating device. This is pulled by the second pinch roll and sent to the subsequent cutting step. If it is cut into a predetermined length in the cutting step, it is completed. This imitation rush is a woven tatami mat like the natural rush.

Here, the thermoplastic resin means a resin whose viscosity is lowered by heating and becomes moldable, and a polyolefin such as polypropylene is a representative thereof, but is not particularly limited. Of course, a mixture of various thermoplastic resins may be used. To this, a weathering agent, a pigment, a matting agent, etc., which are usually mixed, may be mixed. Stretching may be performed by an ordinary method, and the magnification is about 2 to 7 times.

The tape-shaped body may be manufactured by any method, but it is preferable that a tubular shape obtained by inflation processing is folded as it is into two pieces, and the pieces are cut into an appropriate width. . A plurality of tapes of this appropriate width are combined and passed through the heating section to form a single imitation rush. The thickness of the tape-shaped body is about 0.005 to 0.05 mm, and the cutting width is about several mm to 20 to 50 mm.

[0012] Although not essential, this tape-shaped body is preferably provided with a large number of uneven wrinkles. The uneven wrinkles are wrinkles such as waves existing in parallel to the longitudinal direction of the tape-shaped body, and do not need to be regular. With such wrinkles, the imitation rush can absorb water because it has a so-called strength and can absorb water and the like therebetween.

The narrow gap means that it is narrower than a state in which the tape-like bodies are simply converged, and is usually about 1.0 to 1.5 mm. This value is determined by the diameter of the finished imitation rush, and is about 1 mm when manufacturing a product close to a natural rush.

The heating member may be one in which the narrow space itself is electrically heated like a heater, or a heating member may exist around the narrow space. The irregular convergence means that the tape-shaped body is not folded or rolled up regularly, but is wrinkled at random to form a tubular body having the tape-shaped body inside. Processes other than the above essential processes may be added or other control equipment may be used. Further, the above steps may be carried out in series, but may be carried out in two steps or the like. That is, it is a method of winding and storing once in an intermediate stage and introducing the stored one to the next step.

As an example of steps other than the above essential steps,
There are a cooling step and a heating step after the convergence. The cooling step is usually air cooling, which only sends cooling air, but may be water cooling. Alternatively, a method of simply leaving it alone may be used. The next heating step is 80 to 100 ° C.
Is preferable, and a method of passing through hot water or sprinkling hot water is suitable. Of course, you may heat with steam.

As a method of making the surface of the finished imitation rush impressed, it is easy to pass it through a roller having a groove. Then, a large number of small protrusions are provided inside the groove. When passing through this groove, a small hole is formed by the protrusion. This may be carried out continuously with the production before the imitation igusa is cooled, or may be carried out as a separate step with heating again after being completely cooled. Of course, if the protrusion is as sharp as a needle, it is possible without heating.

The method of imparting unevenness is not limited to this, and any method may be used. For example, the igusa is pressed and rotated on a flat plate having many irregularities. In addition, one line may be performed or multiple lines may be performed at the same time. That is, the projections and depressions are simultaneously provided by passing through a roll having a large number of grooves.

In order to approximate the imitation rush, that is, to approximate the natural rush (of course, it is not necessary to do so, the following numerical values are important). Product diameter,
The filling rate, the thickness of the film, and the width of each tape-shaped body. Here, the filling rate is obtained by dividing the cross-sectional area of the film itself by the cross-sectional area of the finished rush, and is the ratio of the film to the cross-section of the rush.

According to experiments conducted by the inventors, it has been found that the following numerical values are preferable in order to bring the imitation rush closer to a natural product. The diameter of the product is 1.0mm to 3.0mm, the filling factor is 50 to 90%, the thickness of the film is 5 to 50μ. Yes, and if it is not particular about its similarity to natural products, it does not need to be included in this range.

The tatami mat is made by weaving the above imitation rush, and the weaving may be done in any manner.
Not only the method currently woven with natural rush, but also a completely new weave.

The tatami mat of this imitation rush is resistant to temperature and hardly deteriorates or discolors at a temperature of about heating. By using this, the above-mentioned drawbacks can be almost completely eliminated.

Next, the thickness of the aluminum sheet is not particularly limited, but a thickness of 0.1 to 0.5 mm is preferable, and the surface may be subjected to rust prevention processing such as painting. This aluminum sheet plays a role of preventing moisture and humidity from entering the base material portion. The inventor also conducted experiments on a plastic sheet, but it could not be used because of its large expansion coefficient due to temperature. Also, other metals were not preferable because of problems such as weight and cost. Aluminum sheet
It does not require any particular purity or precision as long as it is commercially available.

The aluminum sheet prevents moisture and humidity from entering the veneer plate, which will be described later, which is a base material.

The veneer plate means a thin plate made of lumber, and a plurality of the timbers are laminated with their fiber directions at right angles.
The thickness is not particularly limited, but is preferably about 1 to 10 mm. This veneer board is a portion that serves as a base material of the tatami mat. The fibers in the veneer plate are present at right angles, so the expansion and contraction due to humidity and temperature is very small. Since the veneer plate having a small expansion and contraction is used and the entry of moisture into the veneer plate is prevented by the aluminum sheet, the above-mentioned drawbacks are almost completely eliminated.

Further, since the total thickness is 25 mm or less, the above-mentioned drawbacks are eliminated. The 25 mm is a number obtained from heat transmission and shape retention during handling. If it is thicker than this, the heat transfer rate is inevitably small and the thermal efficiency is deteriorated.

The above three layers (tatami table, aluminum, plywood) can be laminated by any method, but the adhesive bonding is the simplest. Of course, you may sew it like a normal tatami mat.

In order to improve the cushioning property,
A cushion material such as a non-woven fabric may be inserted between the tatami mat and the aluminum, or between the aluminum and the plywood or both. The thickness is preferably about 2 to 10 mm. The aluminum sheet may also be attached to the back surface of the veneer plate. This is to block moisture and water from below.

Furthermore, as a prevention of misalignment when spread,
A rubber plate resistant to heat may be partially or wholly attached to the back surface.

The thin tatami mat of the present invention is most suitable for floor heating as described above, but it is not limited to heating, and various usages are conceivable, for example, it can be easily spread in a Japanese room by spreading it between the plates. In particular, if the room is not a room where tatami mats are always laid, the tatami mats can be easily stored and the effect of humidity is extremely small even during long-term storage.

[0030]

The present invention will be described in more detail with reference to the embodiments shown in the drawings. FIG. 1 is an apparatus 1 showing a manufacturing process of a plastic rush (imitation rush) used for the thin tatami of the present invention.
Here is an example: In this example, two steps are performed separately. FIG. 1 shows the steps up to the irregular convergent formation, and FIG. 2 shows the subsequent steps.

In the tape-shaped body manufacturing process, a thermoplastic resin (polypropylene or polyethylene) as a raw material is introduced into a feeder 2 of an inflation device 1, heated and extruded from a mold 3, and expanded in a hollow state through a cooling device 4. Let out. In this example, the hollow state has a diameter of about 400 to 800 mm and a thickness of about 0.03 to 0.07 mm. After passing this between the rolls 5 to make a double film, it is cut by a cutter 6 in the longitudinal direction to have a slit width of about 30 to 80 mm. Then, it is stretched 2 to 7 times. Stretching is 100-150 with the heating device 7.
It suffices to heat it to around ℃ and pull it with the roll 8. In order to anneal this, the heating device 9 is passed again.
Then, it is wound around the winding roll 10.

In the converging molding step, the tape-shaped body (cut) is introduced from the winding roll 10 into the space of the heating and converging device 11. The diameter of this void is about 1.0 mm. The heating temperature is about 300-400 ℃, and the passing speed is 40-
About 100m / min is enough. After passing, the film expands more than the diameter of the voids, and the diameter becomes about 1.5 mm.

Next, the imitation igusa delivered from the void is
Pass the cooling process. In this example, it is just blast cooling. That is, the blower 12 only blows the wind. When the cooling is completed, it is introduced into the heat treatment process. In this example,
Pass through hot water bath 13. Here, the outer shape of the imitation igsa that has been deformed or flattened by heat contraction is expanded and shaped by heat so that its cross section is approximately a perfect circle. Next, it passes through the cooling step 14 again, and finally is cut into a predetermined size (usually 1 to 2 m) by a cutter 15. This completes the imitation rush 16. Weave this in the usual way (like weaving with natural rushes as a tatami mat) and tatami mat 1
7 is ready.

FIG. 3 is a perspective view showing an example of the thin tatami mat 18 of the present invention (the drawing is shortened by cutting the longitudinal direction). A tatami mat 17 made by weaving the imitation igusa 16 in the same manner as a normal tatami mat is visible on the surface. The thickness is about 15 mm, which is considerably thinner than a normal tatami mat. The edges may be conventional but are also glued or sewn.

FIG. 4 is a sectional view of FIG. Veneer plate 2 whose front and back surfaces are covered with the aluminum sheet 19
A felt 21 is attached as a cushioning material to No. 0, and a tatami mat 17 is adhered on it.

Next, a comparison test of conventional thin tatami mat and heat transfer coefficient will be described. The same thickness (1
5 mm) and placed on the same heated floor to compare the surface temperature of tatami mats. The conventional thin tatami mat used here is the conventional product A
, The tatami mat is natural igusa, the core material is made of ventilation felt and the middle layer material of hemp, and the conventional product B is the natural tatami mat table and the core material is porous board and plywood. belongs to. It was placed on a room temperature of 10 ° C and a hot water panel surface temperature of 60 ° C. Surface temperature during constant time Tatami space after raising and lowering Warp in the corner Conventional product A: 22 ° C 2.5mm Slightly existing product B: 21 ° C 1.8mm Slightly working product: 28 ° C None None Everything is better than the traditional one.

[0037]

The present invention described in detail above has the following great effects. Since the thickness of the whole tatami is small (25 mm or less), the heat transfer coefficient is large, and the thermal efficiency is good when used as a tatami for floor heating. Furthermore, since a metal sheet is used, heat transfer which is more than simply thin can be obtained. Because of good heat transfer, the heat source temperature can be lowered, and the risk of low temperature burn in contact with clothes or bedding is reduced. Because the tatami mat is not a natural rush but a specially manufactured imitation rush, it does not easily become heat-resistant. Since an aluminum sheet is attached, moisture does not enter the plywood board, and it does not expand or contract due to moisture or warp.
Since there is almost no expansion and contraction, it does not crack and damage the board surface. In addition, the plastic tatami mat has effects such as generation of mites, no fading, and less clogging of dust. Of course, it retains the effect of being thin and easy to store.

[Brief description of drawings]

FIG. 1 is a schematic side view showing an example of an apparatus for producing an imitation rush used for the tatami of the present invention.

FIG. 2 is a schematic side view showing an example of an apparatus for manufacturing an imitation rush used for the tatami of the present invention.

FIG. 3 is a partial perspective view of the tatami mat of the present invention.

4 is a cross-sectional view of FIG.

[Explanation of symbols]

 16 Imitation rush 17 Tatami mat 18 Thin tatami 19 Aluminum sheet 20 Veneer 21 Felt

Claims (1)

[Claims] 1. A tape-shaped body made of a thermoplastic resin stretched in the longitudinal direction is passed through a heating member forming a narrow void to irregularly converge and form a fusion coating on the surface. A tatami mat made by weaving the imitation rushes, which is fixed to a veneer plate that covers both the front and back sides with an aluminum sheet, and has an overall thickness of 25 mm or less.