JPH07180328A - Tatami mat floor - Google Patents

Abstract

PURPOSE:To provide a tatami mat floor which is light and excellent in the compressive strength and further facilitates the disposal treatment after use. CONSTITUTION:A core material 2 of a tatami mat floor body 1 is made of a paper core which can be easily incinerated. And a frame 3 made of a foamig synthetic resin having at least 20mm in the width is provided as a unit at the four peripheral sides to reinforce the core material 2 composed of the paper core. And the frame is desired so that insulation bards 4, 5 superposed at both upper and lower faces, a tatami mat superficial material, and a mat edge can be securely and easily sewed on.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improved tatami floor which is lightweight, has excellent compressive strength, and is easy to dispose of waste materials.

[0002]

2. Description of the Related Art A tatami mat made of natural rice straw has been known for a long time, but the tatami mat made from rice straw is difficult to be stably supplied and has a large weight, which causes a problem in handleability. Moreover, since it is poor in workability, in recent years, building material tatami floors made of industrial products such as insulation boats and polystyrene foam boards have been widely used. Among them, a tatami floor made of a composite material in which a polystyrene foam plate is adopted as a core material and an insulation board is arranged on the front surface or the back surface thereof is widely used because it is excellent in lightweight and sitting comfort.

[0003]

However, the polystyrene foam plate generates a large amount of combustion heat and black smoke during the incineration process, which may damage the incinerator due to the combustion heat, and the black smoke harms the environment. There are problems,
In addition, it is difficult to dispose in the ground because it is difficult to decompose, and it is difficult to process. Therefore, there are tatami floors that are made up of insulation boards only, but insulation boards have a specific gravity that is about 10 times that of polystyrene foam, which makes them heavier and difficult to handle and handle. .

The above-mentioned problems can be solved by adopting a paper core as a core material, but the paper core is composed of a large number of cells whose peripheral walls are made of paper material having a constant height. Since the porosity of the cavity that penetrates the cell in the up-down direction reaches 90% or more, not only is it easily prone to dents and damage when an impact force is applied from the lateral direction, but the cell is also cut during cutting. However, there is a problem in that the tatami mat is difficult to be sewn, and the tatami mat is difficult to sew, and the peripheral portion, which is particularly inferior in strength, is liable to be depressed due to long-term use.

The present invention has been made in view of the above problems, and a tatami floor made of a paper core used as a core material is reinforced with synthetic resin at four sides to maintain stable strength and shape. It is intended to be provided.

[0006]

In order to achieve the above object, the tatami floor according to claim 1 of the present invention is a composite of a suitable width having the same thickness as the core material around the four sides of the core material comprising a paper core. A resin frame material is integrally provided to form a tatami floor main body,
This tatami-bed mainly has insulation boards integrally laminated on one or both sides.

In the tatami floor according to claim 2 of the present invention, a tatami floor main body is formed by providing reinforcing frame portions by impregnation and hardening of synthetic resin in appropriate width portions around four sides of a core material made of a paper core. This tatami floor has a structure in which an insulation board is integrally laminated on one side or both sides.

[0008]

[Function] Since the paper core is used as the core material and the insulation boards are laminated and integrated on one or both sides of the core, not only a lightweight and inexpensive tatami floor is obtained, but also the combustion heat generated during incineration after use. Since it is low, there is no risk of damaging the incinerator, and a large amount of black smoke is not generated, and it can be easily treated.

Further, the synthetic resin frame material is integrally provided around the four sides of the core material made of a paper core, or the reinforcing frame portion is formed by impregnation and hardening of the synthetic resin, whereby the four end portions of the core material are reinforced, Fatigue and damage can be almost eliminated. Further, the synthetic resin frame material and the frame portion improve cutting workability and are excellent in sewing workability of tatami mats, tatami helicopters and the like.

[0010]

EXAMPLES Next, an example of the present invention will be described in detail. In FIGS. 1 and 2, reference numeral 1 is a tatami-bed main body, and a core material 2 composed of a paper core has four sides with the same thickness and width as the core material 2. The frame member 3 made of a synthetic resin having at least 20 mm or more is constantly provided. As the paper core on which the core material 2 is formed, those specified in JIS A6931 are used. That is, a paper material having a constant width and thickness is formed by forming a large number of continuous cells 2a having a honeycomb shape, a corrugated cardboard shape, a rectangular shape, a circular shape, etc., having through holes vertically with the width direction being vertical. Is. Then, as the core 2, density of 20-30 kg / cm ^3, compressive strength 2 kgf / cm ² = more, bending strength it is preferred to use 2.5 kgf / cm ² or more paper core.

The synthetic resin frame member 3 integrally provided on the four sides of the core member 2 is preferably made of a self-adhesive synthetic resin such as foamed phenol, foamed urethane or foamed urea. In order to provide such synthetic resin frame material 3 around the four sides of the core material 2, the paper core is cut to form the core material 2 having a length of 1800 mm × width of 800 mm × thickness of 25 mm, and the core material 2 is put into the mold material. It can be obtained, for example, by injecting an appropriate amount of foamed phenolic resin around it, then foaming (30 times) and curing it. In this way, the width of the four-sided frame material is 100 mm, that is, length 2000 mm × width 1000 mm. × Thickness
A 25 mm tatami mat main body 1 is formed.

As the size of the tatami mat main body 1 is large, there is a length of 2000 mm × width of 1000 mm × thickness of 25 mm, and as a small size, length of 1400 mm × width of 700 mm × thickness.
Since there is 25 mm, the size of the core material 2 consisting of a paper core is cut and formed in advance according to the size of the tatami floor to be manufactured, and the core material 2 is reinforced around the core material 2 and sewing of an insulation board or the like described later is performed. At least for the purpose of success
The foamed synthetic resin frame material 3 of 20 mm or more is formed.

The specific gravity of the tatami mat main body 1 varies depending on the amount of foam synthetic resin used, the cell shape of the paper core, and the porosity. For example, as shown in FIGS. 1 and 2, the cells 2a are formed in a rectangular shape. Tatami mat main body 1 with a core material
The specific gravity of 0.025 is obtained, and the corrugated cardboard-shaped core material 2 as shown in FIG. 3 has a specific gravity of about 0.032.

On the upper and lower surfaces of the tatami floor main body 1 thus formed, the same length and width as the tatami floor main body 1 and the thicknesses of 15 mm and 10 mm, respectively.
The insulation boards 4 and 5 are stacked and sewn to the synthetic resin frame material 3 of the tatami mat main body 1 to form a tatami mat (see FIG. 4). Furthermore, a tatami mat is manufactured by fitting a tatami mat, a tatami helicopter, etc., according to the usual tatami mat production specifications.

FIG. 5 shows another embodiment of the tatami floor of the present invention. In the above-mentioned tatami floor main body 1, a frame material 3 made of foamed synthetic resin is provided around the core material 2 on four sides. In the tatami floor main body 11, a core material 12 made of a paper core is used, which is cut to the size of the tatami floor main body 11, and a reinforcing frame portion 13 is formed by impregnating and curing synthetic resin in an appropriate width portion around the four sides of the core material. It will be done.

The core 12 of the tatami mat main body 11 is composed of a paper core defined by JIS A6931 as in the tatami mat main body 1, and the paper core is permeated into a suitable width portion around the four sides of the core mat 12. The reinforced frame portion 13 is formed by infiltrating and curing an excellent synthetic resin, for example, a synthetic resin liquid such as phenol, epoxy, urethane, urea and melamine.

The width dimension of the reinforcing frame portion 13 is set so as to have at least 20 mm or more when the dimension adjustment is performed to obtain a final product. Specifically, a paper core having a length of 2000 mm × a width of 1000 mm × a thickness of 25 mm cut into the largest size is used as the core material 12, and the core material 12 extends inward in the length direction from its short side edge. A reinforcing frame portion 13 is formed by permeation and curing of the synthetic resin liquid in the peripheral portion of the core material 12 in a width portion of 320 mm and 170 mm inward from the long side edge.

If the reinforcing frame portion 13 having such a width is formed, the tatami floor of the smallest size (length 1400 mm × width 700 mm × thickness 25 mm) is obtained by cutting and removing the outer peripheral portions of the reinforcing frame portion 13 on all sides. Even when the main body 11 is manufactured, the four-sided peripheral portion thereof,
A reinforcing frame portion 13 having a width of at least 20 mm or more can be provided.

The reinforcing frame portion 13 is, for example, dipped in a methanol solution of a phenol resin containing a polymerization initiator and having a solid content of 10 to 25%, and successively dipping a predetermined width portion of the peripheral edge portion of the core material 12 made of a paper core. And let it soak for 30 minutes in air, then 150
It can be formed by drying and curing for about 2 hours in a dryer at ℃. Thus impregnation of the resin, by forming the reinforcing frame part 13 due to the curing process, its density before treatment 33 kg / cm ^3, compressive strength 2.1kgf / cm ^2, bending strength of 2.6 kgf / cm ² Paper After the core is processed, the density is 45kg / c
m ^3, a compressive strength of 7.0 kgf / cm ^2, the flexural strength has been reinforced with 8.0 kgf / cm ^2.

On the upper and lower surfaces of the tatami mat main body 11 formed in this way, the tatami mat main body 11 has the same length, the same width and the thickness of 15 mm and 10 mm, respectively.
By superimposing the insulation boards 14 and 15 of the above and superposing the protective sheet 16 on the upper surface of the upper insulation board 14 and the moisture-proof paper 17 on the lower surface of the lower insulation board 15 and sewing them to the core material 12, respectively. A tatami mat was manufactured by forming a tatami mat (see FIG. 6) and further attaching a tatami mat, a tatami helicopter and the like based on the usual tatami mat production specifications.

The tatami mat obtained in each of the above-mentioned inventions has the same weight as that of the conventional tatami mat made of a composite of insulation board and polystyrene foam. There was no problem in the sewing workability and cutting property of a helicopter, etc., and neither the peripheral edge of the four directions nor the settling was found. In each of the above embodiments, the insulation boards are integrally laminated on both upper and lower surfaces of the tatami floor, but the structure may be provided only on one surface,
For other configurations, the conventional tatami mat structure can be adopted.

[0022]

As described above, according to the tatami floor of the present invention, a synthetic resin frame material having an appropriate width and having the same thickness as the core material is integrally provided around the four sides of the core material composed of a paper core. Since a tatami floor main body is formed by providing a reinforced frame portion by impregnation and hardening of a synthetic resin in an appropriate width portion of the four side edges, an insulation board is integrally laminated on one or both sides of the tatami floor main body. In addition to being lightweight and excellent in handling such as transportation, it is possible to provide an inexpensive tatami floor, and the combustion heat generated during incineration after use is also low, which may damage the incinerator. Moreover, it can be easily treated without generating a large amount of black smoke.

Further, the four end portions of the core material can be firmly reinforced by a synthetic resin frame material provided around the four sides of the core material made of a paper core, or a reinforced frame portion of synthetic resin impregnated and hardened in the four peripheral portions. Therefore, it is possible to prevent the core material from being worn out or damaged, and further improve the cutting workability of the four-sided peripheral edge portion of the core material. The sewing can be performed reliably and easily and has excellent workability.

[Brief description of drawings]

FIG. 1 is a simplified plan view showing an embodiment of the invention described in claim 1 of the present invention,

FIG. 2 is an enlarged perspective view of a part thereof,

FIG. 3 is a simplified perspective view showing a modification example thereof.

FIG. 4 is a partial vertical sectional view of a tatami floor,

FIG. 5 is a partially simplified perspective view showing an embodiment of the invention described in claim 3 of the present invention,

FIG. 6 is a partial vertical sectional view of the tatami floor.

[Explanation of symbols]

 1, 11 Mainly tatami mat floor 2, 12 Core material 3 Synthetic resin frame material 13 Reinforcement frame part 4, 5, 14, 15 Insulation board

[Procedure amendment]

[Submission date] March 28, 1994

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] 0003

[Correction method] Change

[Correction content]

[0003]

However, since the polystyrene foam plate generates a large amount of combustion heat and black smoke during incineration, it may damage the incinerator due to the combustion heat, and the black smoke harms the environment. There are problems, and besides, it is difficult to disassemble, so it is not preferable to dispose in the ground, and the treatment is difficult. Therefore, there are tatami floors that are made up of only insulation boards, but insulation boards have a specific gravity that is higher than polystyrene foam.
Since it reaches eight times the weight, it becomes heavy and there is a problem in handling and other handling.

[Procedure Amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0007

[Correction method] Change

[Correction content]

Further, in the tatami floor according to claim 3 of the present invention, a tatami floor main body is formed by providing a reinforcing frame portion by impregnation and hardening of a synthetic resin in an appropriate width portion around four sides of a core material made of a paper core, This tatami floor has a structure in which an insulation board is integrally laminated on one side or both sides.

Claims (4)

[Claims] 1. A tatami-bed main body is formed by integrally providing a synthetic resin frame material having an appropriate width and having the same thickness as the core material around the four sides of the core material consisting of a paper core to form a tatami-bed main body. A tatami floor that is made by laminating a ration board together. 2. The tatami floor according to claim 1, wherein the frame member is made of foamed resin having self-adhesiveness such as foamed phenol resin or foamed urethane resin. 3. A tatami-bed main body is formed by providing reinforcing frames by impregnation and hardening of a synthetic resin in appropriate width portions around four sides of a core material made of paper core, and an insulation board is formed on one or both sides of the tatami-bed main body. A tatami floor that is made by stacking together. 4. The tatami floor according to claim 3, wherein the impregnated synthetic resin is a synthetic resin having permeability such as phenol, epoxy and urethane.