JPH0960259A - Nonflammable lightweight artificial tatami mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lightweight artificial tatami mat excellent in nonflammability and durability. SOLUTION: The upper face section of a tatami padding 2 is covered with an aluminum foil 3, then it is covered with a tatami facing 4 made of artificial rush to form an artificial tatami mat. Both upper and lower faces of a hard cotton layer 5 are pinched by soft fiber sheets 6a, 6b to form the tatami padding 2, and a hard fiber sheet 7 is laminated on the upper soft fiber sheet 6a. Polyester fibers are three-dimensionally entangled and compression-molded to the 25%-compressive hardness 0.2-0.8kgf/cm<2> and the impact resilience 30-60% to form the hard cotton layer 5. Nonlammability treatment is applied to the soft fiber sheets 6a, 6b, hard fiber sheet 7, and tatami facing 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flame-retardant lightweight artificial tatami mat, and more particularly to a flame-retardant lightweight artificial tatami mat suitable for use in transportation such as vehicles and ships.

[0002]

2. Description of the Related Art Tatami mats are deeply rooted in the Japanese habits and are widely used not only in houses but also in Japanese-style rooms for cars and ships called "zashiki trains".

The tatami mat used in such a transportation system has to have a flame retardant standard, and the railway car must have passed the flame retardant test for materials for railway cars of the Ministry of Transport. As a tatami mat that has passed the above test and is currently used, it consists of a tatami mat floor with villous felt as a cushioning material and a hard board or insulation board laminated on it, and a tatami mat table of natural grass that has been made flame-retardant by chemical treatment. There is a tatami mat.

[0004]

However, the above-mentioned tatami mat has various problems.

That is, since natural rush is used as the material for the tatami mat, there is yellowing due to the treatment with the flame retardant agent and yellowing over time, and the abrasion resistance and the tensile strength are weak. In addition, it has poor antifouling performance and is prone to mite and mold. Furthermore, since the water content of spilled food and drink is easily absorbed, not only the tatami mat but also the tatami mat may swell. For these reasons, tatami mats made from the natural tatami mats have a short service life.

Further, since the villous felt is used as the material for the tatami floor, the weight is large and it takes time to put in and take it out, and the load on the vehicle is also heavy.

The present invention has been made in order to solve the above problems, and an object thereof is to provide a lightweight artificial tatami mat having excellent durability in addition to excellent flame retardancy. Is.

[0008]

In order to achieve the above object, the flame-retardant lightweight artificial tatami of the present invention has an upper surface of a tatami floor (2) covered with an aluminum foil (3), and an artificial grass. An artificial tatami mat covered with a tatami mat (4) consisting of the tatami mat (2), wherein the tatami mat (5) is sandwiched between soft fiber boards (6a) and (6b) on both upper and lower sides, and the upper soft part is further softened. The hard fiber layer (7) is laminated on the fiber board (6a), and the hard cotton layer (5)
Is three-dimensionally entangled with polyester fibers to give a 25% compression hardness of 0.2 to 0.8 kgf / cm ² and a impact resilience of 3
The soft fiberboard (6a) (6b), the hard fiberboard (7) and the tatami mat (4), which are compression molded to 0 to 60%.
Is characterized by being subjected to flame retardant treatment.

In the flame-retardant lightweight artificial tatami according to the present invention, the hard cotton layer (5) as the core of the tatami floor (2) is
The cushioning property of the tatami mat, such as the feel of the foot, is guaranteed, and polyester fibers are three-dimensionally entangled and heat compression molded together with binder fibers. As the binder fiber, polyester, polypropylene or the like having a melting point lower than that of the main fiber by 50 to 60 ° C. or high adhesiveness is preferably used. Such a hard cotton layer (5) has a 25% compression hardness of 0.2 to 0.8 kgf / cm ² based on JIS K-6767 in order to secure appropriate cushioning properties and light weight. There is a need to. If the compression hardness is lower than this lower limit, the tatami mat will be liable to be weakened and durability will be lost, and if it is higher than the upper limit, cushioning will be poor. The preferred lower limit value of 25% compression hardness is 0.4 kgf / cm ² , and the preferred upper limit value is 0.6 kgf / cm ² . Further, not only the mere hardness but also an appropriate restoring force when stepped on is required, so that the impact resilience based on JIS K-6401 is 30 to 6
It is necessary to use 0%. If the impact resilience is less than this lower limit, the feel is like sinking, and if it is greater than the upper limit, the resilience is too strong and the pedal feel becomes poor. The preferred lower limit of impact resilience is 40%,
A preferable upper limit value is 50%. Further, the density is preferably 0.08 to 0.12 g / cm ³ in order to ensure lightness.

Regarding the flame-retardant performance of the hard cotton layer (5), the polyester fiber itself satisfies the flame-retardant performance, for example, the "A-A standard" of the flame-retardant test for materials for railway vehicles by the Ministry of Transport. Therefore, it is not necessary to separately perform the flame-retardant treatment for the soft fiber boards (6a) (6b) and the hard fiber board (7) described later.
Also, no toxic gas is generated during combustion.

The soft fiberboards (6a) (6b) sandwiching the upper and lower surfaces of the hard cotton layer (5) are used for maintaining the shape of the tatami floor (2) and protecting the hard cotton layer (5). Such soft fiber boards (6a) (6b) use fibers such as pulp as an adhesive, waterproofing agent,
An insulation board, which is compression-molded into a plate shape by a wet process with an additive such as a fireproofing agent and has a density defined by JIS A5905 of less than 0.35 g / cm ^3, can be exemplified. With the density of this level, the above object is achieved, the weight is light, and the needle passage when sewing the tatami floor (2) is easy. It is also easy to cut out the thickness of the tatami mat (4) in order to flatten the back surface of the tatami mat (see FIG. 1). Further, the soft fiber board (6a) (6b),
A product that has been subjected to a flame retardant treatment with a flame retardant to ensure flame retardancy is used. Examples of the flame retardant include known ones such as phosphoric acid type, boric acid type, sulfur type, ammonium salt and metal chloride, and are not particularly limited as long as a predetermined flame retardant performance is obtained. The treatment method may also be a known method such as dipping or spraying, and is not particularly limited as long as a predetermined flame retardant performance can be obtained.

The hard fiber board (7) laminated on the upper soft fiber board (6a) of the above-mentioned two soft fiber boards (6a) (6b) prevents partial dent due to concentration of load. The shape maintenance of the tatami mat (2) is further ensured. Further, even though it is hard, it is a fiber board, so that the feel of the foot is not impaired. Such a hard fiber board (7) is obtained by compression-molding fibers such as pulp into a plate shape in the same manner as the soft fiber boards (6a) and (6b) described above, and has a density defined by JIS A5905. Can be exemplified by a hard board having a value of 0.80 g / cm ³ or more. In addition, flame retardant treatment is also applied to the soft fiberboard (7) described above.
You can do the same as.

Each layer (7) (6a) in the tatami floor (2)
The thickness ratios of (5) and (6b) are, in order from the top, in consideration of the balance of cushioning properties, shape retention, lightness, durability, etc. as a tatami mat. %, Upper soft fiber board (6a); 25-40%, hard cotton layer (5); 15
.About.35%, lower soft fiber board (6b); preferably 25 to 40%. If the hard cotton layer (5) becomes too thick outside this range, the cushioning property will increase, but the fiber boards (7), (6a), and (6b) will become relatively thin, making it difficult to maintain the shape and lowering the durability. . On the other hand, if the hard cotton layer (5) becomes too thin, the fiberboards (7), (6a) and (6b) become relatively thick, and durability is improved, but the cushioning property is poor and the usability is poor. Also, of the two types of fiberboard, hard and soft,
If the uppermost hard fiberboard (7) is thinner than the above, the effect of promoting shape retention is poor, and if it is thicker, it becomes heavier and counteracts weight reduction, and the feel to the touch becomes worse. Particularly preferable ratios of the thicknesses of the respective layers are the hard fiber board (7); 6 to 10%, the upper soft fiber board (6a); 30 to 35%, and the hard cotton layer (5); 2
0 to 30%, lower soft fiber board (6b); 30 to 35%. In addition, the thickness of a typical tatami floor (2) is 25 to 35 mm.
Taking the tatami floor (2) having a thickness of 30 mm as an example, the preferred specific thickness of each layer is a hard fiber board (7); 1.5 to 4.5 mm, an upper soft fiber board ( 6a);
7.5-12 mm, hard cotton layer (5); 7.5-10.5 m
m, lower soft fiber board (6b); 7.5 to 12 mm.

The formation of the tatami floor (2), that is, the integration of the hard fiber board (7), the soft fiber board (6a) (6b) and the hard cotton layer (5), is carried out by these (7) (6a) (6b). ) (5) is piled up and sewn with the thread (8). At this time, an adhesive may be appropriately used in combination in order to prevent displacement between the layers and facilitate the sewing operation.

Thus, by using the hard and soft fiberboards (7) (6a) (6b) and the polyester hard cotton layer (5) as materials for the tatami floor (2), the tatami (1) is lightweight. The shape of the tatami mat is stable and the tatami mat (1) is less likely to become tired while maintaining the cushioning property of the tatami mat.

The aluminum foil (3) is placed between the tatami floor (2) and the tatami mat (4) to enhance flame retardancy and
It is used to enhance waterproofness and can prevent fire spread and liquid penetration to the tatami floor (2) even if cigarette fire or food or drink is dropped. Since the aluminum foil (3) is a metal foil, it naturally has excellent flame retardancy and waterproofness.

The tatami mat (4) is made of artificial rush, but if it has the advantages peculiar to artificial rush, such as less discoloration than natural rush and excellent abrasion resistance,
It can be used regardless of the material and manufacturing method. As an example of a tatami mat made of artificial rush, as a weft, an artificial rush made of colored paper impregnated with a synthetic resin such as acrylic resin or fluorocarbon resin is used as hemp or cotton. Some warp yarns are woven with a tatami loom. Further, the flame retardant treatment may be carried out either before or after weaving, and the flame retardant used and the treating method are the same as in the case of the hard and soft fiber boards (7) (6a) (6b) described above. There is no particular limitation as long as a predetermined flame retardant performance can be obtained. The tatami-mat table (4) using such artificial rush has not only excellent flame-retardant performance due to flame-retardant treatment, but also impregnated with a synthetic resin during the production of artificial rush to improve water repellency. Also, it is less likely to become dirty, has excellent abrasion resistance and tensile strength, and suppresses the occurrence of mites and molds. Further, even if the flame-retardant treatment does not cause yellowing, and the discoloration over time is extremely small, the texture of the new tatami mat can be maintained for a long time.

The flame-retardant lightweight artificial tatami mat according to the present invention is excellent in flame retardancy as a whole tatami because each part has excellent flame retardancy.

[0019]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, one embodiment of the flame-retardant lightweight artificial tatami mat according to the present invention will be described with reference to the drawings.

FIG. 1 is a partial longitudinal sectional view of a flame-retardant lightweight artificial tatami mat (1) suitably used for vehicles. This flame-retardant lightweight artificial tatami mat (1) is formed from a tatami mat (2), an aluminum foil (3) covering the tatami mat (2), and a tatami mat (4). The size of one tatami mat is 70
It is 0 mm × 1800 m.

In the tatami mat (2), the upper and lower surfaces of the hard cotton layer (5) are sandwiched between two insulation boards (6a) and (6b), and the hard board (7) is placed on the upper insulation board (6a). ) Are laminated and these are sewn together with a thread (8).

The hard cotton layer (5) is formed by three-dimensionally entwining polyester fibers with a low-melting point polyester fiber as a binder, and heat-compressing and molding into a plate shape.
The compression hardness is 0.49 kgf / cm ² , and the impact resilience is 44.
9%, the density is 0.1 g / cm ³ , and the thickness is 8 mm. Also, the insulation board (6a)
(6b) has a density of 0.25 g / cm ³ and a thickness of 10 mm, and the hardboard (7) has a density of 1.0.
The thickness is g / cm ³ and the thickness is 2.5 mm.

The insulation board (6a) (6
b) and the hard board (7) were subjected to a flame-retardant treatment by immersing them in a flame-retardant treatment liquid of the following composition for 24 hours, and the flame-retardant test according to the Ministry of Transport's railroad vehicle material flame-retardant test “AA standard” Has flammability.

(Flame Retardant Treatment Liquid) Ammonium phosphate 6% Boric acid 9% Isopropyl alcohol (penetrant) 3% Water 82% The aluminum foil (3) has a thickness of 100 μm.

The tatami mat (4) is obtained by weaving an artificial grass as a weft and a hemp as a warp in a tatami loom, and after the weaving, a flame-retardant treatment is applied, and the thickness is 3 mm. The artificial grass is
This is prepared by making a twist of light green paper that imitates a blue tatami mat and immersing it in a mixed resin of 80% acrylic resin and 20% waxy fluororesin. Impregnation with this resin improves water repellency, stain resistance, wear resistance, and tensile strength,
It has the effect of suppressing the generation of mites and molds. The flame-retardant treatment is carried out by immersing the tatami-mat in the flame-retardant treatment liquid for 24 hours as in the case of the boards (6a) (6b) (7), and as a result, the material flame-retardant test “A- It has flame-retardant performance based on "A standard". Furthermore, by the impregnation of the mixed resin and the flame retardant, the effect of non-slip is added,
It is also suitable as a tatami mat for vehicles from the viewpoint of safety.

The tatami mat processing is performed in the same manner as the tatami mats for houses and conventional tatami mats for vehicles. In addition, in this embodiment, a cutout portion (9) corresponding to the thickness of the tatami mat (4) is formed at the peripheral edge of the insulation board (6b) on the lower surface side of the tatami mat (2) to form the tatami mat (4). The end of the tatami is housed in the notch (9) so that the back surface of the tatami (1) is not uneven.

The weight of the flame-retardant lightweight artificial tatami mat (1) manufactured in this example is about 12 kg. On the other hand, the conventional tatami mat for vehicles having the same size and using villous felt as the tatami mat weighs about 15 kg, and the weight can be reduced by about 20%.

In the tatami (1) of this embodiment, the tatami floor (2) consisting of the hard fiber board (7), the soft fiber boards (6a) (6b) and the hard cotton layer (5) is used as it is. However,
A protective sheet may be added to the back side of the tatami floor (2) to protect the lower soft fiber board (6b). The material of the protective sheet is preferably flame-retardant or subjected to flame-retardant treatment, and polypropylene, polyester, etc. can be recommended. The form of the sheet can be arbitrarily selected from a film, a woven fabric, a knitted fabric, a non-woven fabric and the like.

[0029]

Industrial Applicability As described above, the present invention is an artificial tatami in which the upper surface of the tatami floor is covered with aluminum foil and further covered with a tatami mat made of artificial grass. The upper and lower surfaces of the cotton layer are sandwiched by soft fiber boards, and the hard fiber board is further laminated on the upper soft fiber board. The hard cotton layer has three-dimensionally entangled polyester fibers to give a compression hardness of 25%. 0.2-0.8 kgf / cm ² , impact resilience 30-60
%, The soft fiber board, the hard fiber board and the tatami mat have been flame-retarded, and thus have excellent flame-retardant performance that passes the flame-retardant standard of vehicles and the like. It has excellent durability in terms of discoloration resistance, stain resistance, abrasion resistance, tensile strength, settling resistance, and water repellency. Further, by using the above-mentioned material as the material of the tatami floor, it is possible to reduce the weight while maintaining the cushioning property of the tatami mat.

Further, by using artificial grass as a tatami mat and subjecting it to a flame retardant treatment, an effect as a non-slip can be obtained, and it becomes more suitable as a tatami used for vehicles, ships and the like.

Further, in the flame-retardant lightweight artificial tatami of the present invention, by setting the thickness of each layer of the tatami floor to a predetermined ratio,
It is particularly well-balanced in terms of cushioning properties, shape retention, lightweight properties, durability, and the like.

[Brief description of drawings]

FIG. 1 is a partial vertical cross-sectional view of a flame-retardant lightweight artificial tatami mat according to an embodiment of the present invention.

[Explanation of symbols]

 1 ... Flame-retardant lightweight artificial tatami 2 ... Tatami floor 3 ... Aluminum foil 4 ... Tatami table 5 ... Hard cotton layer 6a, 6b ... Soft fiber board (insulation board) 7 ... Hard fiber board (hard board)

Claims (2)

[Claims] 1. An artificial tatami mat comprising an upper surface of a tatami mat (2) covered with an aluminum foil (3) and a tatami mat (4) made of artificial grass, which is the tatami mat (2). Is made by sandwiching the upper and lower surfaces of a hard cotton layer (5) with soft fiber boards (6a) (6b) and further laminating a hard fiber board (7) on the upper soft fiber board (6a). (5) is three-dimensionally entangled with polyester fibers and has a 25% compression hardness of 0.2 to 0.8 kgf / cm.
^{2. The} impact resilience is compression molded to 30 to 60%, and the soft fiber boards (6a) (6b), the hard fiber board (7) and the tatami mat (4) are flame-retarded. A flame-retardant lightweight artificial tatami mat. 2. The ratio of the thickness of each layer in the tatami floor (2) is 5 to 15% for the hard fiber board (7), 25 to 40% for the upper soft fiber board (6a), and the hard cotton layer (5). ); 15-35%,
The lower flame-retardant lightweight artificial tatami according to claim 1, wherein the lower soft fiberboard (6b) is 25 to 40%.