JPH0882076A - Thin tatami mat - Google Patents

Abstract

PURPOSE: To fabricate a thin tatami mat by heat rolling tape serving as raw material made from a thermoplastic resin, and forming a tatami cover by the weaving of artificial rush which is irregularly contracted and cut into predetermined lengths. CONSTITUTION: A tape-shaped body made from an inflation molded thermoplastic resin is passed through a heating member having a small cavity and is irregularly contracted, and a fused coating is formed and artificial rush is woven into a tatami cover. A sheet of plywood with aluminum foil bonded thereto is used, for example, as a core for a tatami itself. First the core 20 and the tatami cover 17 broader than the core are prepared with the tatami cover placed facing down and the core 20 placed on the cover. Then the four corners of the tatami cover 17 are cut by a small amount to allow for the thickness of the core. Then the portion of the tatami core projecting from the core is folded back and fused to the four corners, so that the tatami cover using plastic rush can be easily secured to the core.

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 using an imitation rush.

[0002]

2. Description of the Related Art Recently, there is an increasing demand for so-called thin tatami mats having no thickness as compared with conventional tatami mats. This is because floor heating and tatami mats are laid in a part of the room. The first floor heating is to lay a heating element (heating wire, hot water or steam pipe) on the floor. Therefore, in order to improve thermal efficiency,
The upper part of the heating element must have a large heat transfer. A conventional tatami mat is too thick to carry enough heat and requires more heat. Therefore, a thin tatami mat that allows heat to pass through is used.

Most of recent apartments and the like are between the boards (rooms in which flooring such as flooring is laid), and there are few tatami rooms. This is because furniture such as beds and tatami rooms have limited uses. However, elderly people are still not familiar with the life of chairs and often request tatami mats. In such a case, a thin tatami mat is often laid on a part or all of the boards to form a simple tatami room.

Although the demand for thin tatami mats has been increasing for the above reasons, the conventional thin tatami mats are manufactured by sewing a tatami mat table using natural rush on a thin plate or plastic as a core material. It was done. Conventional tatami mats have a thickness of about 55 mm, but these are about 10 to 20 mm.

[0005]

However, in the conventional thin tatami mats, since the tatami mats on the surface of all tatami mats are made of natural igusa, the core material and tatami mats are fixed to each other only by sewing, which is very troublesome. It was such work.

It is also conceivable for the present applicant to use a plastic tatami mat, which has been developed by himself and has also applied for a patent, and to bond it to the core material. However, adhesion requires an adhesive material, and the adhesive strength varies depending on the type of the core material, so that selection is difficult. Further, depending on the core material, the surface thereof may peel off together with the adhesive material and come off.

[0007]

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-like 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 igsa having a fused coating formed on the surface, A rectangular plate-shaped core material was made wider than the core material by a specified width in both length and width, cut so that the four corners were almost equal to the corners of the core material, folded four sides so as to wrap the core material, and joined the tatami mats to each other. The point is that it is covered by fusing the parts.

The imitation rush referred to in 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 refers to a resin whose viscosity is reduced 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-like body may be manufactured by any method, but it is preferable that a tubular product obtained by inflation processing is folded as it is into two pieces and cut into an appropriate width for use. . 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.

Although not essential, this tape-shaped body may be 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-shaped body is 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 such that the narrow space itself is electrically heated like a heater, or the 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 for 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 rate is 50 to 90%, the thickness of the film is 5 to 50μ. Of course, it is not an essential requirement that it falls within this range, and it means that a product close to a natural product can be manufactured. 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 strong in temperature and hardly deteriorates or discolors at a temperature of heating. Therefore, it is most suitable for floor heating.

The core material is a portion which becomes the core of the tatami itself,
In a natural tatami mat, it is called a floor made of straw. Here, since it is a thin tatami mat, the thickness is 5 to 20 mm. The material may be a veneer plate, a plastic plate, or any other material. It may be a plastic foam or a plastic honeycomb shape. The shape is rectangular, square or rectangular.

As the core material, a material obtained by sticking an aluminum foil (sheet) to a veneer plate is also suitable. The aluminum sheet preferably has a thickness of 0.1 to 0.5 mm, and its surface may be subjected to rustproofing such as painting. The aluminum sheet serves to prevent moisture and humidity from entering the base material portion. This sheet need only be commercially available and does not require any particular purity or precision.

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 5 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. It is excellent for floor heating because it uses this plywood with small expansion and contraction, and the entry of water into it is prevented by the aluminum sheet. Aluminum is usually attached to both sides of the veneer. This is to block water from both sides.

Further, in order to improve the cushioning property,
A cushion material such as a non-woven fabric may be fitted between the core material and the tatami mat. The thickness is preferably about 2 to 10 mm. Further, rubber or the like may be attached to the back surface as a slip stopper.

As for the method of fixing the tatami mat and the core material of the present invention, it is sufficient to lightly press with a heating member (iron or the like) at the melting temperature of the plastic igusa (usually about 180 to 190 ° C.). Therefore, you can easily do it on site or in a small tatami store. In addition, since the core material is wrapped in the tatami mat and the core material and the tatami mat do not have to be directly fixed (adhesive, sewn, etc.), the surface adhesive force of the core material and the internal structure are not affected at all. Of course, in addition to this, a stacker, a stapler or the like may be used together for reinforcement.

[0026]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The process for producing the thin tatami mat of the present invention will be described with reference to the embodiments shown in the drawings. FIG. 1 shows an example of an apparatus showing a manufacturing process of a plastic rush (imitation rush) used for the thin tatami of the present invention. 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 convergent molding step, the tape-shaped body (cut) is introduced from the take-up roll 10 into the gap of the heat 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 plan view of the back surface of an example of the thin tatami mat 18 of the present invention. Thermal fusion bonding 19 is carried out at the four corners.

4 to 6 show a method of manufacturing the thin tatami mat 18 of the present invention. First, the core material 20 (in this example, with a thickness of 6 mm,
81.5 cm square) and wider (in this example,
A tatami mat 17 of 90 cm square) is prepared, the tatami mat is placed face down, and the core material 20 is placed thereon (FIG. 5). next,
The four corners of the tatami mat 17 are cut as shown by the broken lines in FIG. 6 (actually, they are folded back and lifted up and cut). At this time, considering the thickness of the core material, the material is cut into a little smaller size. And
The portion protruding from the core material may be folded back and the four corners may be fused (FIG. 3). The fusion can be surely fixed by overlapping the contacting portions a little and thermocompression bonding.

In order to prevent the tatami mat from sagging, a square bar 21 having a cross section of 4 cm is inserted between the core material 20 and the tatami mat 17 as shown in FIG. 7, and the tatami mat is pulled with a stapler 22 while pulling the tatami mat. Fix the folded part of the tatami mat (only on three sides), then fuse the two corners. Then remove the timber,
The remaining two corners may be fused. In this way, when working in combination with a stapler or the like, the work can be fastened without sagging.

[0033]

The thin mat of the present invention described in detail above has the following great effects. Easy and secure to fix. Does not damage the core material. It also prevents the tatami mat itself from fraying. Since there is no overlapping part of the bent material (imitation rush), the thickness variation can be reduced.

[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 plan view of the back surface of the thin tatami of the present invention.

FIG. 4 is a plan view showing a part of the steps of the method for manufacturing a thin tatami mat of the present invention.

FIG. 5 is a plan view showing a part of the steps of the method for manufacturing a thin tatami mat of the present invention.

FIG. 6 is a plan view showing a part of the steps of the method for manufacturing a thin tatami mat of the present invention.

FIG. 7 is a cross-sectional view showing a part of the process showing another method for manufacturing the thin tatami mat of the present invention.

[Explanation of symbols]

 16 Imitation rush 17 Tatami table 18 Thin tatami 19 Fused part 20 Core material 21 Square wood 22 Stapler

Claims (3)

[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 rush made into a rectangular plate-shaped core material, the width of the core material is made wider than the core material by a predetermined width, and the four corners are cut to be approximately equal to the corners of the core material. A thin tatami mat that is covered by folding the four sides so as to wrap it and fusing the portions where the tatami mats are in contact with each other. 2. The thin tatami mat according to claim 1, wherein the tatami mat is a twill weave. 3. The thin tatami mat according to claim 1, wherein the core material is an aluminum veneer in which an aluminum foil is attached to a veneer plate.