JPH07292937A - Tatami mat - Google Patents

Abstract

PURPOSE:To provide a tatami mat or a sports tatami mat that is excellent in heat-retaining, sound-insulating or sound-absorbing, dustproof, mothproof, and impact-absorbing, properties. CONSTITUTION:A tatami padding 3, which is formed when bubbles or chips 1 of a fibrous material or the like are randomly arranged and bound together by a binder 2 into a plate shape with a number of holes 31 or grooves formed therein, has a back sheet 51 bonded to its bottom surface and a tatami facing 52 sewed to its top surface. A cushioning material may be laid on the top of bottom surface of the tatami padding 3, and a tatami border 53 may be sewed to the upper edge of the outer periphery of the tatami padding 3 when needed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tatami mat used as a floor material for general houses or a sports tatami mat used for sports such as judo.

[0002]

2. Description of the Related Art A sports tatami used in sports such as judo will be described below as an example. Since this sports tatami mat is more worn than a general tatami mat, a new material or its processed or laminated body is often used in addition to or in place of the old natural straw. In such a conventional tatami floor, a soft foamed resin layer, a hard foamed resin layer and a urethane chip layer which are sequentially laminated (No. 5-36903).
An elastic binder contained on the outer periphery of a wood fiberboard
No. -36027), a synthetic resin foam with which the tatami mat is closely contacted with grooves or dents (Jitsukaihei 3-92246).

[0003]

[Problems to be Solved by the Invention] For tatami mats as floor materials,
Properties such as heat retention, soundproofing or sound absorption, dustproofing, insectproofing, etc. are required.Furthermore, in terms of impact absorbability (hardness, tactile feel of tatami etc. in judo) and cost, processability etc. Is also required. In the above tatami mat, the shock absorption property is mainly improved, the deterioration over time and the deformation due to temperature are suppressed, and the property is excellent, but the increase in the manufacturing cost due to the multilayering of different materials is not preferable.

As for the above, although the manufacturing cost can be suppressed, the wood fiber board with the hardened wood chips tends to be hard,
There remains a problem in shock absorption. As for, the synthetic resin foam is liable to cause fatigue due to deterioration over time,
There are drawbacks such as partial deformation, and both have advantages and disadvantages.

The deformation of the tatami mat such as shock absorption and settling depends on the hardness of the material of the plate or face material that constitutes the tatami mat. In the tatami floor shown above, the hardness of the whole tatami floor is adjusted by singly or laminating plate materials or face materials having different hardness. However, as can be seen from the above-mentioned problems, a single layer has a poor impact absorption property and is easily deformed, and a multilayer structure causes a problem of high cost.

[0006] Therefore, in order to reduce the manufacturing cost, the tatami floor is made a single layer or a few layers, and the hardness of the plate material or face material of this tatami floor can be adjusted sufficiently, for example, by laminating plate materials or face materials of different hardness. We decided to study the tatami mat with a new tatami mat made of new material and structure.

[0007]

What has been developed as a result is that a chip 1 made of foam or fibrous material is used as a binder 2
The back sheet 51 is attached to the bottom of the tatami floor 3 and the tatami mat 52 is sewn to the upper surface of the tatami floor 3 which is solidified by the above and has a large number of holes 31 or grooves formed on the bottom surface thereof. It is a tatami made by sewing a tatami edge 53. For example, a tatami mat is not necessary for a sports tatami used for judo or the like.

Examples of the foam include a polyurethane foam. In addition to this, a natural or synthetic rubber foam, a plastic foam such as polyethylene, polypropylene, polyvinyl chloride, or the like, or an elastic material substantially equivalent to the foam. It can be used. Examples of the fibrous material include felt, non-woven fabric, carpet, and cloth. Further, as the binder, a urethane-based prepolymer which is cured by steaming with pressurized steam can be used. The back sheet, tatami mat, and tatami mat have been commonly used.

In the tatami of the present invention, if it is desired to further improve the impact absorption, the chip 1 such as foam or fibrous material is solidified with the binder 2 and a large number of holes or grooves 32 are formed on the bottom surface.
The cushioning material 4 is laid on the upper or bottom surface of the tatami floor 3 on which the sheet is formed, the back sheet 51 is attached to the bottom surface side, and the tatami mat table 52 is sewn to the upper surface side. Tatami edge 53 on the upper edge
It is preferable that the tatami is a sewn structure. For the cushioning material,
The insulation board etc. which are used as a construction material can be used.

[0010]

The tatami mat of the present invention has excellent heat retaining properties, soundproofing or sound absorbing properties, dustproofing properties, insect-proofing properties, etc. by using the tatami flooring 3 in which chips 1 such as foam or fibrous material are solidified. It can be obtained, durability is improved, and deformation such as fatigue due to deterioration over time can be eliminated. Also, by adjusting the mixing ratio of the binder 2 that binds and holds the chip 1,
The impact absorption of the tatami floor 3 having the above characteristics can be adjusted in a wide range. Moreover, the entire tatami floor 3 can be sterilized in the manufacturing process by "vaporization by pressurized steam" performed in the process of curing the binder 2.

A large number of holes 31 or grooves 32 formed on the back surface of the tatami floor 3 are formed on the back surface of the tatami floor 3 by a back sheet 51 made of a moisture absorbing / releasing paper (for example, a large number of small holes formed by punching). Space filled with air 33,
By forming 34 and automatically adjusting the amount of air held according to the humidity and the temperature of the outside world, heat retention can be improved. Further, the spaces 33, 34 have a cushioning function against impacts applied from the upper surface of the tatami mat, especially sounds, and can improve soundproofing or sound absorption and shock absorption.

The cushioning material 4 complements or enhances the strength of the tatami floor 3 having the above-mentioned characteristics which are reduced by forming the hole 31 or the groove 32. In addition, the tatami floor 3 which firstly significantly reduces the impact and sound applied to the tatami mat, and has the above-described excellent soundproofing or sound absorbing and shock absorbing properties, further reduces or almost completely reduces the impact and sound. To be able to absorb.

[0013]

Embodiments of the tatami of the present invention will be described below with reference to the drawings. FIG. 1 is a partially enlarged cross-sectional view of a tatami mat 6 configured by using a tatami floor 3 (hereinafter, referred to as a multi-hole type) having a circular truncated cone-shaped hole 31 on its bottom surface, and FIG. 6 is a partially cutaway perspective view showing FIG.

The tatami floor 3 of the tatami mat 6 of the present invention is formed by solidifying chips 1 such as foam or fibrous material with a binder 2. The chips 1 used as the material of the tatami floor 3 can be those that have been conventionally treated as waste such as scraps of automobile interior parts. In the present embodiment, the floor of the automobile, the heat insulation for the roof, etc., the felt used for the purpose of sound absorption (those processed into a plate shape with a phenol resin using cut cotton as a main material) with a diameter of about 15 mm, The tip 1 is made of polyurethane foam and seat end material, which are generated when the cushion material of the seat is molded, and have a diameter of about 6 mm.

The binder 2 is a urethane prepolymer
(Polymeric isocyanate prepolymer) is used. These are uniformly mixed in a ratio of 55% by weight of felt as chip 1, 30% by weight of foam and 15% by weight of binder 2. This mixture is put into a mold having frustoconical peaks, first pressed at an air pressure of 5 kg / cm ² , and then steamed under pressure at a temperature of 100 ° C. or higher and a vapor pressure of 3 to 4.5 kg / cm ^2. The binder 2 is reacted by irradiation to solidify it, and finally it is sufficiently dried in a drying chamber to obtain a finished product.

The multi-hole type tatami floor 3 thus obtained is
Chips 1 made of felt and foam are mixed in a block form, and both are bonded by a binder 2, so that they exhibit good elasticity, and also exhibit excellent soundproofing or sound absorbing properties and shock absorbing properties. Become. In this embodiment, as shown in FIG. 1 or 2, a multi-hole type tatami floor 3 has a bottom sheet 51 having a porous material attached thereto and a top surface having a tatami mat 52 sewn (in the figure, a sewing thread is used). Is omitted), and the tatami edge is on the long side edge of tatami 6.
53 is sewn on and completed.

As shown in FIG. 2, the tatami mat 6 of this embodiment is used.
Is a highly breathable paper back sheet with a porous bottom 51
Since the tatami mat is attached, the tatami mat 3 has good ventilation. Space 33 formed by hole 31 and back sheet 51 provided on the bottom of tatami floor 3
Has a cushioning function by allowing air to flow in and out through the back sheet 51 to mainly control the temperature of the tatami mat 6 by adjusting the temperature and absorb the impact from the upper surface of the tatami mat 6 in the space 33. The shock absorption of the tatami floor 3 due to this cushioning function is
Can be adjusted depending on the size and arrangement, and can be adjusted in a fairly wide range by changing the mixing ratio of the chips 1 and the binder 2 which are the raw materials of the tatami floor 3.

Further, the tatami floor 3 is sterilized and disinfected by steaming high-pressure steam in the manufacturing process, and the tatami floor 3 as a whole does not have a risk of invading harmful insects and dust into the interior, which is extremely hygienic. A tatami mat 6 can be used. Furthermore, since the tatami floor 3 can divert wastes to a great extent to reduce the material cost, and the manufacturing process thereof is integrally formed with the binder 2, the time and cost can be reduced. It is possible to cite the characteristic that the tatami mat 6 having the above characteristics can be provided at a low price.

As described above, the space formed on the bottom surface side of the tatami mat can adjust the degree of heat retention and shock absorption of the tatami mat. The larger the space, the greater the range of adjustment and the greater the effect. Therefore, the tatami mat using the grooved floor type tatami floor 3 shown in FIGS. 3 and 4 is obtained by replacing the holes of the above-described embodiment with a plurality of grooved grooves 32 parallel to the short direction of the tatami mat 7. Figure 3
1 corresponds to FIG. 1, and FIG. 4 corresponds to FIG. In the tatami mat 7 using the grooved type tatami mat 3, as shown in FIG. 3 or 4, the decrease in strength due to the replacement of the holes with the groove 32 causes the insulation on the upper surface and the bottom surface of the tatami mat 3. It is complemented by pinching the board.

In this grooved type tatami floor 3, the bottom area of the tatami floor 3 is smaller than that of the multi-hole type tatami floor (compare FIG. 2 and FIG. 4), so that there is a possibility that the strength against impact will be weakened as it is. is there. Therefore, for the purpose of complementing the strength and further for enhancing the shock absorbing property, the upper surface and the lower surface of the tatami floor 3 are sandwiched by the insulation board which is the cushioning material 4.
Unlike the case of the previous embodiment, since the lower surface of the tatami floor 3 is closed by the cushioning material 4, the air flow into and out of the space 34 formed by the groove 32 is as shown in FIG. This is performed by the groove end 35 which is opened on the side surface.

In addition, the cushioning material 4 having excellent shock absorbing performance
Compared to the tatami mat 7 using the multi-hole type tatami mat 3 described above, the shock absorbing property is improved and the heat retaining property is better than the space formed by the holes in the space 34 formed by the groove 32. Also, because of its large volume, its capacity is increasing. The cushioning material 4 is
It also has the function of protecting the tatami floor 3 from shocks and realizes long-term durability of the tatami floor 3. As a result, the replacement interval of the tatami mat 7 can be lengthened, and the usage cost can be reduced.

Although the tatami mats of these two embodiments have slightly different characteristics, they are all suitable for sports tatami mats that are used in situations where impact is particularly likely to occur such as judo. However, since it is excellent in heat retention, soundproofing or sound absorption, and insect repellent, it may be used in ordinary houses. In this case, as its raw materials, felt and foam produced from automobile manufacturing plants,
In addition, it is economical because it can be provided at a low price by using wastes including non-woven fabrics, carpets, and scraps of general fabrics. Reuse of this waste is also meaningful in terms of environmental protection.

[0023]

The effects of the tatami mat of the present invention are as follows. Firstly, the tatami itself has the following properties: heat retaining property, soundproofing or sound absorbing property, dustproof property, insectproof property
Further, it can be mentioned that it is excellent in shock absorption. These are raw materials with different characteristics that are made into chips, mixed while keeping their respective characteristics, integrated, that the mixing ratio of binder to chips can be adjusted in a fairly wide range, holes provided on the bottom of tatami floors or This is due to the heat retaining property of the groove, the shock absorbing property, and its adjustment in a wide range.

In addition to the above, since the foam or felt that becomes the raw material chips can use waste such as scraps produced from an automobile manufacturing plant, it is possible to reduce costs and treat waste. Therefore, it is also meaningful for environmental protection.

[0025] In terms of the binder, the sterilization by high pressure steam in the reaction process of the binder realizes a clean tatami mat, and since the tatami mat is integrated with this binder, unnecessary pests and dust are tatami matted. It does not enter the floor and reduce the durability of the tatami mat or deteriorate the characteristics of the tatami mat illustrated in steam.

As a final remark, unlike the conventional tatami floors made of new materials, it is easy to keep the tatami mat warm by changing the shape, number, and arrangement of holes or grooves provided on the bottom surface even though it is a single layer. The impact resistance and shock absorption can be adjusted, and its range is wide, so that the product can have variations. As a result, we can provide tatami mats with improved heat insulation, soundproofing, or sound absorption properties to ordinary houses at low cost, and also, taking advantage of their excellent shock absorption properties, use them as sports tatami mats. Will also be able to.

[Brief description of drawings]

FIG. 1 is a partially enlarged cross-sectional view of a tatami using a multi-hole type tatami floor.

FIG. 2 is a partially cutaway perspective view of the tatami mat of the embodiment.

FIG. 3 is a partially enlarged cross-sectional view of a tatami using a grooved tatami floor.

FIG. 4 is a partially cutaway perspective view of the tatami mat of the embodiment.

[Explanation of symbols]

 1 chip 2 binder 3 tatami floor 31 hole 32 groove 4 cushioning material 51 back sheet 52 tatami mat

Claims (2)

[Claims] 1. A backing sheet on the bottom surface of a tatami floor, which is obtained by solidifying a chip 1 such as foam or fibrous material with a binder 2 and forming a large number of holes 31 or grooves on the bottom surface. 51
A tatami mat formed by attaching a tatami mat table 52 to the upper surface of the tatami mat. 2. A cushioning material on the upper surface or the bottom surface of the tatami floor with respect to the tatami floor 3 in which chips 1 such as foam or fibrous material are solidified with a binder 2 and a large number of holes or grooves 32 are formed on the bottom surface. Four
A tatami mat made by stacking, and further attaching a back sheet 51 on the bottom side and a tatami mat table 52 on the top side.