JPH09296591A - Straw mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide effective adsorbing action of porous carbon powder/grain such as activated charcoal by disposing the porous carbon powder/grain close to matting, make the plane of the matting flat and produce mats in large quantity easily and efficiently at a low cost. SOLUTION: A straw mat contains porous carbon powder/grain 1 such as activated charcoal therein. In this straw mat, a permeable cushioning layer 3 with fiber aggregated solidly without directionality is laminated under the lower face of matting 2, and a carbon layer 4 with the porous carbon powder/ grain 1 accommodated in a thin sheet-like bag 6 is laminated under the lower face of the cushioning layer 3. The bag 6 of the carbon layer 4 is formed by connecting a surface sheet and a back face sheet in a partially linear state, then partitioning the interior into a plurality of areas and filling the porous carbon powder/grain 1 in each of a plurality of partition chambers 6A.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tatami mat containing porous carbon powder particles such as activated carbon.

[0002]

2. Description of the Related Art Tatami mats containing porous carbon particles such as activated carbon have already been developed. Porous carbon particles, such as activated carbon, have a feature of absorbing odor and moisture to make tatami a comfortable environment. Therefore, the tatami mat containing activated carbon and the like can effectively prevent the surface from being damp and mold and microorganisms to be generated. In addition, there is a feature that a bad smell in a room can be adsorbed in a wide area. Furthermore, there is a feature that the heat retention is also improved, and the tatami surface can be made an ideal environment.

[0003] In order to realize this feature, tatami mats containing activated carbon have been developed. Tatami with built-in activated carbon,
It is described in the following publications. (1) Japanese Utility Model Publication No. 57-27867 (2) Japanese Utility Model Publication No. Sho 61-28834 (3) Japanese Utility Model Publication No. 60-72837 (4) Japanese Utility Model Publication No. 60-122247 (5) Japanese Utility Model Publication No. 2-68864 (6) JP-A-2-103440 (7) JP-A-5-22753 (8) JP-A-6-12633 (9) JP-A-7-43935

[0004] In the tatami described in these publications, it is important to stack activated carbon close to the tatami mat in order to effectively use the action of activated carbon. Activated carbon that is stacked close to the tatami surface can pass through the thin and air-permeable tatami surface and can effectively absorb odor and moisture. However, activated carbon is
Since it is not flat but granular, if it is arranged close to the tatami surface, there is a disadvantage that it is difficult to make the surface of the tatami surface clean and flat. This disadvantage is due to (6), (7),
As described in the official gazette of (8), the activated carbon can be eliminated by being separated from the tatami mat surface and built into the tatami mat floor. However, in the tatami where activated carbon is stored on the tatami floor, the activated carbon is separated from the tatami surface, and it is difficult to effectively use the excellent adsorption action of activated carbon. This is because a member interposed between the activated carbon and the tatami mat prevents free permeation of air.

[0005] Such an adverse effect can be solved by forming the activated carbon layer into a plate shape. Since the plate-shaped activated carbon layer can have a flat upper surface, it can be stacked close to the tatami mat and the surface of the tatami mat can be made flat. In order to make the activated carbon layer flat, tatami mats using carbonized cork as a core material have been developed. Further, tatami mats in which activated carbon is made into a fiber sheet and laminated on the inner surface of a tatami mat surface have been developed (Japanese Utility Model Publication No. 63-32).
255).

[0006]

A tatami mat using carbonized cork as a core material can arrange carbon close to the tatami mat with a flat surface of the tatami mat. However, since the tatami mat of this structure uses carbonized cork instead of activated carbon, there is a disadvantage that the manufacturing cost is considerably increased. In addition, the tatami mat containing the activated carbon fiber sheet also has a disadvantage that the manufacturing cost is increased because a special fiber sheet is used. Furthermore, when a tatami with a built-in carbonized cork is stacked close to the tatami surface, when a strong load is applied to the local part of the tatami, the carbonized cork is crushed thinly, and a recess is formed on the surface of the tatami. There are disadvantages that cannot be restored. In addition, the activated carbon fiber sheet also has a disadvantage that it is difficult to increase the filling amount of activated carbon to increase the adsorption capacity.

[0007] The present invention has been developed for the purpose of further solving this drawback. An important object of the present invention is to arrange the porous carbon powder particles such as activated carbon close to the tatami mat so that the adsorption effect of the porous carbon powder particles can be effectively exerted, and further, simply and easily, It is to provide a tatami that can be mass-produced efficiently and inexpensively, and further, the tatami mat can be made flat.

[0008]

The tatami mat of the present invention has the following constitution in order to achieve the above-mentioned object. The tatami mat of the present invention is an improved tatami mat having porous carbon powder particles 1 such as activated carbon contained therein, and is characterized by having the following unique structure. (A) On the lower surface of the tatami mat 2, a breathable buffer layer 3 in which fibers are collected in a three-dimensionally non-directional manner is laminated. The buffer layer 3 is most preferably a collection of palm fibers. (B) The carbon layer 4 containing the porous carbon powder particles 1 in a thin sheet-shaped bag 6 is laminated between the tatami floor 5 and the lower surface of the buffer layer 3. (C) The bag 6 of the carbon layer 4 has air permeability at least on its upper surface so that it can permeate the tatami mat 2 and adsorb odors and moisture contained in the indoor air. (D) In the bag 6 of the carbon layer 4, the topsheet and the backsheet are partially linear in order to evenly disperse the porous carbon powder particles 1 to be housed therein to have a substantially uniform thickness. The interior is divided into a plurality of regions by being connected, and each of the plurality of divided chambers 6A is filled with the porous carbon powder particles 1.

[0009]

Embodiments of the present invention will be described below with reference to the drawings. However, the following examples illustrate tatami mats for embodying the technical idea of the present invention, and the present invention does not specify tatami mats as follows.

Further, in this specification, in order to make it easier to understand the claims, the numbers corresponding to the members shown in the embodiments will be referred to as “claims” and “ In the column of “means”. However, the members shown in the claims are not limited to the members of the embodiment.

The tatami mat shown in FIG. 1 includes a tatami mat table 2, a buffer layer 3 and
The carbon layer 4 and the tatami floor 5 are sequentially laminated.

The tatami mat 2 is conventionally used as a tatami mat,
Or everything that will be developed as a tatami table,
For example, a woven grass that is arranged in parallel and braided into a sheet is used.

The buffer layer 3 is a breathable layer in which fibers are assembled in a three-dimensionally non-directional manner. The buffer layer 3 is disposed between the carbon layer 4 and the tatami mat 2 and absorbs irregularities formed on the surface of the carbon layer 4. Palm fibers are the most suitable for the fibers of the buffer layer 3. However, plastic fibers such as nylon fibers and polypropylene fibers can be used instead of or together with the coconut husk fibers. The thickness of the buffer layer 3 is designed to be, for example, 1 to 5 mm, preferably 2 to 3 mm in a state of being stacked on the tatami mat. The fibers of the buffer layer 3 can also be bonded at their intersections so that they do not fall apart. However, the intersections of the fibers do not necessarily need to be bonded.
The fibers are gathered in no direction and then pressed to form a sheet, which is laminated between the carbon layer 4 and the tatami mat 2.

The carbon layer 4 is below the buffer layer 3,
It is laminated on the tatami floor 5, that is, between the buffer layer 3 and the tatami floor 5. The buffer layer 3 and the carbon layer 4 are laminated on the entire surface of the tatami floor 5. However, the carbon layer 4 can be laminated on almost the entire surface of the tatami floor 5 except for the peripheral portion. The carbon layer 4 is
The porous carbon powder particles 1 are stored in a thin sheet-shaped bag 6. Activated carbon is most suitable for the porous carbon powder particles 1. This is because the suction power is excellent. As the activated carbon, for example, coconut shell activated carbon or activated carbon produced from wood or bamboo can be used. However, instead of activated carbon, porous carbon can be used for the porous carbon powder particles 1. As charcoal, charcoal of coconut, wood, bamboo and the like can be used. Porous charcoal has an inexpensive feature compared to activated carbon.

As the porous carbon powder particles 1, for example, those having an average particle size of 0.5 to 4 mm, preferably 1 to 3 mm are used. When the porous carbon powder particles 1 having a small average particle diameter are used, the amount of air passing through the carbon layer 4 becomes small, and the substantial adsorption capacity becomes low. On the contrary, if the average particle diameter of the porous carbon powder particles 1 is too large, the irregularities on the surface of the carbon layer 4 become large.

A bag 6 containing the porous carbon powder particles 1
Has air permeability on the upper surface or both surfaces. The most suitable sheet material for making the bag 6 is a non-woven fabric made of plastic fibers. As the non-woven fabric, one that can be melted and fused by heating a part of the fibers is used. This non-woven fabric contains
A material made of thermoplastic plastic fiber or a material made by coating the surface of the fiber with a low melting point plastic is used. Since the non-woven fabric that can be heated and welded can bond the top sheet and the back sheet without using an adhesive, the top sheet can be pressed linearly and bonded to the back sheet.

Instead of the non-woven fabric, the bag 6 can be made of breathable paper such as filter paper. The paper used to make the bag can be made extremely strong by adding synthetic fibers to pulp fibers or by making only synthetic resin fibers. In particular, the strength in a wet state can be remarkably strong.
In the paper bag, a linear adhesive is applied to the surface of the top sheet or the back sheet, the adhesive is passed through the top plate or the back sheet, and the double-sided sheets are glued in a line.

The back sheet of the bag 6 does not necessarily have to be a breathable sheet material. It is also possible to manufacture a bag by using a sheet material such as a non-breathable plastic sheet or a non-breathable plate material for the back sheet and using the breathable sheet material for the top sheet.

The top sheet and the back sheet of the bag 6 of the carbon layer 4 are partially adhered linearly to divide the inside into a plurality of regions by the porous carbon powder particles 1 of the carbon layer 4.
For evenly dispersing and preventing the dispersed porous carbon powder particles 1 from moving and causing local unevenness.

As shown in the cross-sectional view of the tatami shown in FIG. 1 and the plan view of the bag 6 shown in FIG. 2, the bag 6 of the carbon layer 4 connects the top sheet and the back sheet with a linear dividing line 6B. Then, the inside is divided into a plurality of regions, and the divided compartments 6A are filled with the porous carbon powder particles 1. In the bag 6 shown in FIG. 2, a plurality of division lines 6B are arranged in parallel at regular intervals, and further parallel division lines 6B are arranged so as to be orthogonal to each other, and the inside is divided into a rectangular division chamber 6A. There is. The interval between the adjacent dividing lines 6B is, for example, 2 to 30 cm, preferably 5
~ 20 cm, optimally about 10 cm. If the partition line 6B is approached and the partition chamber 6A is made smaller, the porous carbon powder particles 1 can be dispersed more uniformly. However, compartment 6A
If the value is reduced, the number of lane markings 6B increases, and it takes time to manufacture. Furthermore, since the part of the dividing line 6B cannot be filled with the porous carbon powder particles 1, the amount of the porous carbon powder particles 1 that can be filled is reduced. On the contrary, when the compartment 6A is too large, it becomes difficult to uniformly disperse the porous carbon powder particles 1.

The bag 6 has a carbon layer 4 having a thickness of 2 to 3 mm.
The filling amount of the porous carbon powder particles 1 is adjusted so that When the filling amount of the porous carbon powder particles 1 is increased, the adsorption amount of odor and moisture increases, but the cost increases. Since the carbon layer 4 is provided on the entire surface of the tatami mat, even if the carbon layer 4 is thin, the filling amount of the porous carbon powder particles 1 is considerably large as a whole. Furthermore, the tatami mat having the carbon layer 4 as thin as 2 to 3 mm can reduce the irregularities formed on the surface of the tatami mat 2. The reason is that the movement of the porous carbon powder particles 1 is prevented by the partition line 6B, and even if the porous carbon powder particles 1 move in the partition chamber 6A, the carbon layer 4 has few irregularities, and This is because it is absorbed by the buffer layer 3.

The tatami floor 5 is the same as the current tatami mat, or all that will be developed as the tatami mat 5 from now on, for example, straw pressed into a plate shape, and a plastic foam.

The tatami mat having the above structure is manufactured as follows. [Manufacturing Process of Carbon Layer 4] (1) The bag 6 having a part thereof opened is filled with the porous carbon powder particles 1. (2) The opening of the bag 6 is closed by adhering or welding. (3) The top sheet and the back sheet of the bag 6 are adhered to each other by the dividing line 6B to separate into a plurality of dividing chambers 6A. The compartment 6A is uniformly filled with the porous carbon powder particles 1. When the bag 6 is separated into the compartments 6A along the partition lines 6B, the top sheet and the back sheet are pressed and welded while heating, excluding the porous carbon powder particles 1 in the welded portion. Further, an adhesive is linearly applied from the surface to either the surface sheet or the back sheet, and the adhesive is permeated from the surface sheet or the back sheet to the inside and bonded.

[Step of manufacturing tatami mat] (1) Carbon layer 4, buffer layer 3 and tatami mat 2 on tatami floor 5
And are stacked. The carbon layer 4 and the buffer layer 3 are laminated on the entire surface of the tatami floor 5. Therefore, the outer shapes of the carbon layer 4 and the buffer layer 3 are formed to be the same as the tatami floor 5. (2) Like the conventional tatami mat, both edges of the tatami mat 2 are connected to the bottom of the folded tatami mat, and further, the both sides of the tatami mat 2 are sewn together to form the tatami mat 5, the carbon layer 4, and the buffer layer 3. Tatami Table 2 is a stacked tatami mat.

[0025]

INDUSTRIAL APPLICABILITY In the tatami of the present invention, the porous carbon powder particles such as activated carbon are arranged close to the tatami table so that the adsorption effect of the porous carbon powder particles can be effectively exerted. It has the feature that the plane can be made flat. That is, the tatami of the present invention has a carbon layer in which porous carbon powder particles are put in a bag, and a top sheet and a back sheet of this bag are partially linearly connected to divide the inside into a plurality of regions. The reason is that each of the plurality of compartments is filled with the porous carbon powder particles. Furthermore, on this carbon layer, between the tatami mat and the tatami mat, a breathable buffer layer, which is a collection of fibers in a three-dimensionally non-directional manner, is laminated, so irregularities such as boundaries of compartments that divide the bag are formed. Is absorbed by this buffer layer, and the surface of the tatami mat becomes a beautiful smooth surface.

Further, in the tatami of the present invention, the bag is divided into a plurality of compartments and filled with the porous carbon powder particles, so that the movement of the porous carbon powder particles can be prevented even in the use state. Therefore, for example, when the local portion of the tatami mat is strongly pressed, the porous carbon powder particles can be prevented from moving to prevent the pressed portion from becoming a recess.

Further, in the tatami of the present invention, a bag in which porous carbon powder particles are filled in a plurality of compartments is stacked between the tatami floor and the buffer layer, and the tatami mat is placed on the buffer layer. It is possible to effectively prevent the porous carbon powder particles from moving during manufacturing to have an uneven thickness. Therefore, there is a feature that the tatami having the porous carbon powder particles filled therein can be produced simply and easily and efficiently and in large quantities so that the surface of the tatami mat is not uneven.

[Brief description of drawings]

FIG. 1 is a sectional view showing a tatami mat according to an embodiment of the present invention.

FIG. 2 is a plan view of carbon layers stacked on the tatami mat shown in FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Porous carbon powder 2 ... Tatami table 3 ... Buffer layer 4 ... Carbon layer 5 ... Tatami floor 6 ... Bag 6A ... Compartment room 6B ... Compartment line

Claims (1)

[Claims] 1. Porous carbon powder particles such as activated carbon inside
A tatami having (1) built therein, characterized by having all of the following configurations. (A) On the lower surface of the tatami mat (2), there is laminated a breathable buffer layer (3) in which fibers are gathered in a three-dimensionally non-directional manner. (B) On the lower surface of the buffer layer (3), between the tatami floor (5) and the tatami floor (5), the carbon layer (4) formed by storing the porous carbon powder particles (1) in a thin sheet-like bag (6) is formed. They are stacked. (C) At least the upper surface of the bag (6) of the carbon layer (4) has air permeability. (D) The bag (6) of the carbon layer (4) has a top sheet and a back sheet partially linearly connected to each other to divide the inside into a plurality of regions, and the plurality of divided chambers. (6A) is filled with porous carbon powder particles (1).