JPH0988309A - Mat floor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the internal dew condensation of a mat floor while reducing weight and prevent defectiveness such as the expansion of sewing holes. SOLUTION: An upper plate layer 3 is laminated on the upper face side of a core material layer 2 formed of polystyrene resin foam plate, a lower plate layer 4 is laminated on the lower face side of the core material layer 2, and the whole is integrated by sewing. The density of the polystyrene resin foam body of the core material layer 2 is 0.025g/cm<3> -0.045g/cm<3> , and a polystyrene resin foam plate of 0.05g/cm<3> -0. l5g/cm<3> in density is used for the lower plate layer 4.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a tatami floor using a polystyrene resin foam plate as a core material.

[0002]

2. Description of the Related Art A conventional chemical tatami mat has a density of 0.025 to 0.045 g / cm ³ (foaming ratio 23 to
It is widely used that a polystyrene resin foam plate of about 42 times) is used as a core material layer, soft fiber boards are laminated on both surfaces of the core material layer, and the entire laminated body is sewn and integrated.
The soft fiber board laminated on the upper and lower surfaces of the core layer is a porous board made by intertwining wood fibers, and the inside of the board is formed with voids between the intertwined fibers, The air in this gap has a heat insulating property. Soft fiberboard is J
According to IS A 5905, and according to this standard, the soft fiberboard for tatami floor is called T-class insulation board.

The T-class insulation board is produced by steam-defibrating chipped wood, adding a water-proofing agent, making paper, and then drying it in a continuous dryer, and having a density of 0.25 g.
/ Cm ³ and bending strength of 10 kgf / cm ² or more are specified. It is said that the tatami floor using the above-mentioned insulation board is superior in heat insulating property to the straw mat.

[0004]

However, the tatami floor using the T-class insulation board as the lower plate layer of the conventional core material layer is apt to absorb moisture by the insulation board itself and is inferior in moisture resistance, and at the same time, The insulation board itself absorbs the moisture that moves from below, causing dew condensation in the insulation board, which tends to cause mold and mites on the tatami mat.

Further, the T-class insulation board is not preferable since it has a heavier weight than the polystyrene resin foam used as the core material and leads to an increase in the weight of the tatami floor.

In order to solve the above problems, the inventors of the present invention did not stack a T-class insulation board on the lower side of the core material layer in the conventional tatami floor, but instead made a polystyrene foam plate of the core material layer. We tried to improve the hygroscopicity and reduce the weight by increasing the thickness. However, when the tatami floor with the thickness of the polystyrene foam plate of the core material layer is increased, when the insulation board is laminated on the core material layer and sewn integrally, the foamed material on the lower surface side of the core material layer is used. It was found that there is a problem that the thread hole formed in the thread greatly expands in the traveling direction of the thread. If the thread hole is widened during sewing, the heat insulation of the tatami floor will decrease,
Tatami floor is not practical as a tatami floor because it causes the displacement of each layer.

The present invention is intended to solve the above-mentioned drawbacks of the prior art, and to provide a tatami floor which prevents internal dew condensation on the tatami floor, is light in weight, and has no problem that the sewing holes are widened. With the goal.

[0008]

Means for Solving the Problems That is, according to the present invention, (1) an upper plate layer is laminated on the upper surface side of a core material layer made of a polystyrene resin foam plate, and a lower plate layer is formed on the lower surface side of the core material layer. Stacked,
It is a tatami mat that is entirely sewn and integrated, and the density of the polystyrene resin foam plate of the core material layer is 0.025 g / cm ³
~ 0.045 g / cm ³ , the lower plate layer has a density of 0.05
g / cm ³ Tatamiyuka, characterized in that the polystyrene type resin foamed plate ~0.15g / cm ^3, (2) the upper plate layer of density 0.05g / cm ³ ~0.15g / cm ³ polystyrene A tatami floor according to (1) above, which is a resin foam board, (3)
The above-mentioned (2), wherein the polystyrene-based resin foam plate of the upper plate layer is a foam plate in which a foam extruded in an annular shape from a circular die is pressed while the foam is in a softened state and the inner surface is fused. Tatami floor, (4) A foamed board formed by pressing the polystyrene-based resin foamed board of the lower board layer while the foamed body extruded in an annular shape from a circular die is in a softened state and fused to the inner surface. The tatami floor according to any one of (1) to (3) above, and (5) the polystyrene resin foam plate of the core material layer is a foam plate extruded and foamed from a flat die (1) to (). The tatami floor according to any one of 4),
(6) The protective material is laminated on the upper surface side of the upper plate layer, the backing material is laminated on the lower surface side of the lower plate layer, and the protective material, the upper plate layer, the core material layer, the lower plate layer, and the backing material are laminated in this order. , The tatami floor according to any one of the above (1) to (5), which is integrally sewn integrally.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. As shown in FIGS. 1 (a) and 1 (b), the tatami floor 1 of the present invention has a density of 0.025 g / cm ^{3 to} 0.045 g / 0.03 g / cm ³ .
The upper plate layer 3 is laminated on the upper surface side of the core material layer 2 made of a polystyrene resin foam plate of cm ³ , and the lower plate layer 4 is laminated on the lower surface side of the core material layer 2. The plate layer 3 and the lower plate layer 4 are sewn with a sewing thread 7 to be integrated, and the lower plate layer 4 has a density of 0.05 g / cm ^{3 to} 0.1.
A polystyrene resin foam plate of 5 g / cm ³ is used.

Generally, there are two types of tatami mats, one having a thickness of 55 mm for general houses and the other having a thickness of 50 mm for condominiums. Regarding the thickness of each layer of the tatami floor 1 of the present invention, in the tatami floor for a general house, the core material 2 is about 30 mm and the upper plate layer 3 is about 15 mm.
mm, it is desirable to form the lower plate layer 4 to about 10 mm, and in the tatami floor for condominium, the core material 2 is about 25 mm,
It is preferable to form the upper plate layer 3 with a thickness of about 15 mm and the lower plate layer 4 with a thickness of about 10 mm. Further, the size (length and width) of the tatami floor 1 is appropriately formed according to the size of the tatami mat according to the standard.

The polystyrene resin foam plate used in the core layer 2 of the tatami floor 1 of the present invention has a density of 0.025 g / cm ³ to.
Those having a range of 0.045 g / cm ³ (foaming ratio 23 times to 42 times) are used. The density of the foam plate of the core material layer 2 is 0.
If it is less than 025 g / cm ³ , the foaming ratio is too high and the settling tends to occur when the tatami mat is used. On the other hand, if the density of the foam plate of the core material layer 2 exceeds 0.045 g / cm ³ , the weight of the tatami floor itself increases, and the weight increase when forming the tatami is not practical.

The polystyrene resin foam plate of the core layer 2 is
Compressive strength of 1.0kgf / cm ² or more, especially 2.0kg
It is preferably f / cm ² or more. Compressive strength is 1.
If it is less than 0 kgf / cm ² , the foamed plate is easily crushed, which causes a settling of the tatami floor.

The polystyrene resin used as the base resin of the polystyrene resin foam plate of the core material layer 2 is a homopolymer containing styrene monomer as the main component of the constituent monomer,
Or, a copolymer is used, and specifically, for example, polystyrene, a styrene homopolymer such as polyparamethylstyrene, a styrene-maleic anhydride copolymer, a styrene-acrylonitrile copolymer, a styrene-butadiene copolymer. , Styrene-butadiene-acrylonitrile copolymer, (ABS resin), styrene-acrylic acid copolymer,
Examples thereof include a styrene-based copolymer such as a styrene-methacrylic acid copolymer, a mixture of the above homopolymer and a copolymer, a mixture of the above copolymers, and the like. Further, other vinyl resin may be added to the base resin.

The polystyrene resin foam plate of the core layer 2 is
When it is formed to have a thickness of 25 mm and a width dimension of 910 mm, it is obtained by the following manufacturing method, for example. A foaming agent and a flame retardant were added to the polystyrene resin as needed, and the mixture was heated and melted in an extruder, and a foaming agent composed of methyl chloride and dichlorofluoromethane was placed in the extruder. Press-in from the foaming agent injection port, and then heat, melt, and knead them to form a uniform flow composition. Atmosphere at an extrusion temperature of 95 to 120 ° C from a die orifice with a width of 440 mm at a flat die tip and a lip interval of 1 mm. By extruding into the inside (discharging amount: 200 to 400 kg / hr) and immediately thereafter passing it through a shaping device called a guider, a plate-like foam having a cross-sectional shape with a thickness of about 25 mm and a width of about 910 mm is obtained. You can At this time, the above-mentioned guider is maintained at a temperature lower than the extrusion temperature by 15 to 25 ° C, and the foam inside the guider is formed into a plate shape according to the shape inside the guider frame, and is installed behind the guider. It is taken out in the extrusion direction by the conveyor, rolls, etc.

According to the above method, the extrudate that starts foaming after extrusion and fills the inside of the guider passes through the regulated frame of the guider while being pressed, and is cooled. The surface layer portion in which the foam having a shape stretched in the width direction and / or the longitudinal direction exists is formed on the front surface and the back surface of the foam plate, while the cooling effect hardly reaches the center portion and the foaming is in a continuous state, The polystyrene-based resin foam plate obtained by the above method is excellent in compressive strength because a central layer in which bubbles having a shape stretched in the thickness direction is present is formed.

Generally, the core material layer of the tatami floor is desired to have a low density from the viewpoint of enhancing the heat insulating property and reducing the weight. However, the lower the density, the lower the compressive strength and the tatami mat. In this case, it becomes easy to get tired. Therefore, as the foam plate of the core material layer, one having a low density to some extent and having a compressive strength to the extent that settling does not occur is used. From this point, it is preferable to use a polystyrene-based resin foam plate extruded and foamed from the above flat die for the core layer, and has a high compressive strength at the same density when compared with foam plates obtained by other methods. Therefore, the weight can be further reduced. In the polystyrene resin foam plate, in the above method, the discharge amount, the temperature of the guider, and the foam take-up speed are appropriately set to determine the bubble diameter in the thickness direction and width direction and / or longitudinal direction of the upper and lower surface layer portions and the central layer. By adjusting the ratio, an arbitrary compressive strength can be obtained.

The lower plate layer 4 has a density of 0.05 g / cm ³ to
A polystyrene resin foam plate of 0.15 g / cm ³ (expansion ratio 7 to 21 times) is used. The tatami floor 1 of the present invention,
A major feature is that the conventional T-class insulation board of the lower plate layer of the tatami floor is replaced with a polystyrene resin foam plate having a specific density. The polystyrene resin foam plate has a closed cell structure, has a lower hygroscopicity than the T-class insulation board, and does not cause a problem that moisture is absorbed inside the lower plate layer 4 to cause dew condensation when used as a tatami mat. Moreover, since the polystyrene resin foam plate of the specific density of the lower plate layer 4 has a higher density than the foam plate of the core material layer 2, when the thickness of the core material layer is increased without laminating the lower plate layer. It is possible to prevent the thread hole from spreading at the time of sewing, which has occurred in Moreover, if the foam has the above-mentioned density, the weight can be sufficiently reduced as compared with the T-class insulation board, and the foam has substantially the same physical properties as the T-class insulation board, so that it can be used as a tatami floor. The physical properties are almost the same.

The polystyrene resin foam plate of the lower plate layer 4 is
When the density is less than 0.05 g / cm ³ , the sewing holes tend to spread in the thread advancing direction, while the density is 0.15 g / cm ³
When it exceeds, the difference in weight is less than that of the T-class insulation board, and the effect of reducing the weight of the tatami floor cannot be sufficiently obtained. Further, the polystyrene resin foam plate of the lower plate layer 4 preferably has a compressive strength of 1.5 to 3.0 kgf / cm ² .

Generally, when a tatami mat is sewn on a tatami mat, a bending load is applied to the tatami mat, but if the bending strength of the lower plate layer is high, cracking in this case can be satisfactorily prevented. In addition, when the bent tatami floor returns to its original shape, the higher the bending strength, the better the restoration.
Therefore, the bending strength of the polystyrene resin foam plate of the lower plate layer 4 is preferably 15 kgf / cm ² or more.

As the polystyrene-based resin used for the polystyrene-based resin foam plate of the lower plate layer 4, the resins exemplified as the polystyrene-based resin of the core material layer 2 can be used. Further, the polystyrene resin foam plate of the lower plate layer 4 can be manufactured by the method described below. After melt-kneading the styrene-based resin and the foaming agent in the extruder, a circular foam is extruded from a circular die at the tip of the extruder to obtain a tubular foam, and then this tubular foam is rolled between rolls while it is in a softened state. Or squeezing (pressing) through and then pressing the inner surface side of the tubular foam body into a plate shape, or
The tubular foam is cut open along the extrusion direction to form a plate.

The polystyrene-based resin foam plate of the lower plate layer 4 is particularly preferably pressed while the foam extruded in an annular shape from the circular die is in a softened state, and the inner surface side is pressure-bonded and fused. It will be. The polystyrene-based resin foam plate described above has good bending strength, and can favorably prevent cracks and the like when the tatami mat is sewn and integrated.

In order to obtain a polystyrene resin foam plate having a predetermined density, thickness and physical properties of the lower plate layer 4, a method of adjusting the amount of the foaming agent or a melt-kneaded product of the resin and the foaming agent from the inside of the extruder is used. When extruding and foaming into a tubular form, the gap of the circular die is adjusted wider than usual, the discharge amount per unit time of the extruder is not changed, and the discharge amount per unit area is delayed, and the foamed sheet A method of increasing the cooling amount and cooling efficiency of the outer surface and the inner surface of the resin and further cooling the resin inside the extruder die to adjust the resin temperature during extrusion foaming is used.

In the tatami floor 1 of the present invention, the upper plate layer 3 is T
Although a grade insulation board may be used, the density is 0.05 g / cm ^{3 to} 0.15 g / cm ³ (foaming ratio 7
It is preferable to use a polystyrene-based resin foam plate having a size of up to 21 times. Further, it is more preferable to use, as the upper plate layer 3, a polystyrene resin foam plate in which a foam extruded and expanded into an annular shape from a circular die is pressed and the inner surface is fused. This polystyrene resin foam plate is specifically a polystyrene resin foam plate obtained by the same method as the lower plate layer 4 described above. In this case, the polystyrene resin foam plate of the upper plate layer 3 may be a foam plate having exactly the same density as the lower plate layer 4, or a polystyrene resin foam plate having a different density from that of the lower plate layer 4. Either or both may be used.

The upper plate layer 3 has a density of 0.05 g / cm ³
When a polystyrene resin foam plate of 0.15 g / cm ³ is used, the foam plate is lighter than the T-class insulation board, so that the tatami floor 1 can be further reduced in weight.
Moreover, similar to the effect of using the polystyrene-based resin foam plate for the lower plate layer 4, the core hole layer 2 is thickened without stacking the T-class insulation board to reduce the weight of the thread hole. However, the sewing work is easy even in the upper plate layer. When a material other than the polystyrene resin foam plate is used for the upper plate layer 3, it is required to use JIS A 5
905, density less than 0.25 g / cm ³ , bending strength 10 kg / cm ² or more, water content 6-10.
%, Water absorption 0.20 g / cm ³ or less, it is preferable to use a T-class insulation board which is a soft fiberboard for tatami floors.

After the upper plate layer 3 and the lower plate layer 4 are laminated on the core material layer 2 and these laminated bodies are sewn together with sewing threads to integrate them, the conventional tatami mating device is used as it is. It can be done using.

FIG. 2 shows another example of the tatami floor of the present invention. As shown in FIG. 2, in the tatami floor 1 of the present invention, the protective material 5 is further laminated on the upper surface side of the upper plate layer 3, and the backing material 6 is further laminated on the lower surface of the lower plate layer 4 to form the protective material 5 It is preferable to sew a laminated body in which the upper plate layer 3, the core material layer 2, the lower plate layer 4, and the backing material 6 are laminated in this order so as to be integrated as a whole. Protective material 5
Is a synthetic fiber nonwoven fabric having a thickness of 0.5 to 2.0 mm, a mildewproof sheet, or the like. The backing material 6 may be, for example, a knitted polyethylene tape having a thickness of 0.1 to 1.0 mm, or a polyethylene tape adhered to each other.

When the protective material 5 and the backing material 6 are provided in this way, in addition to the protective function such as mold prevention on the upper surface of the tatami floor and the general protective effect on the lower surface of the tatami floor, the upper plate layer 3 or It is possible to better prevent the sewn holes of the polystyrene resin foam of the lower plate layer 4 from expanding. The thickness of each layer (core material layer 2, upper board layer 3, lower board layer 4) of the tatami floor of the embodiment shown in FIG. 2 is so small that the thickness of the protective material 5 and the backing material 6 is negligible. It is formed to a thickness similar to that of the tatami floor.

Although not particularly shown, the tatami floor 1 of the present invention is used as a tatami by covering the surface of the tatami mat with a tatami mat made of igusa or the like.

[0029]

EXAMPLES Specific examples of the tatami floor of the present invention will be described below. Example 1 Density 0.029 g / cm ³ (foaming ratio 36 times), thickness 3
A 0 mm polystyrene foam plate (extruded and foamed from a flat die and made into a plate shape by a guider) as a core material layer,
A T-class insulation board having a thickness of 15 mm is laminated on the upper surface of the core material layer, a nonwoven fabric is further laminated on the upper surface of the insulation board, and a density of 0.066 g / cm ³ ( Foaming ratio 16 times), thickness 10
mm polystyrene foam board (extruded and foamed from a circular die and pinched while being in a softened state to form a plate), and a polyethylene split cloth as a backing material is laminated on the lower surface of the foam board The body was sewn together with a tatami machine to make a tatami floor. On the lower surface of the tatami floor, no problem was found in that the needle holes widened significantly. Example 2 Density 0.035 g / cm ³ (foaming ratio 30 times), thickness 3
A 0 mm polystyrene foam plate (extruded and foamed from a flat die and made into a plate shape by a guider) as a core material layer,
0.066 g on each of the upper surface and the lower surface of the core material layer
/ Cm ³ (expansion ratio 16 times), thickness 15 mm (top surface),
A 10 mm (bottom) polystyrene foam plate (which was extruded and foamed from a circular die and pressed into a plate shape while being in a softened state) was laminated, and a mildew-proof sheet was laminated on the upper surface of the foam plate on the upper surface side as a protective material. A polyethylene split cloth was laminated as a backing material on the lower surface of the foam on the lower surface side, and the laminated body was sewn and integrated with a tatami machine to form a tatami floor. On the upper surface portion and the lower surface portion of this tatami floor, no problem that the needle hole greatly expanded was observed.

[0030]

As described above, in the tatami floor of the present invention, the lower plate layer has a density of 0.050 g / cm ^{3 to} 0.15 g / cm ^3.
By using the polystyrene-based resin foam plate of, compared with the conventional tatami floor using a T-class insulation board in the lower plate layer, moisture from under the floor does not condense inside the lower plate layer, It can prevent mold and mites from forming on the tatami floor. Further, the polystyrene-based resin foam plate does not have a strength decrease due to moisture absorption unlike an insulation board, and can exhibit stable performance as a tatami floor.

Furthermore, the tatami floor of the present invention is a conventional tatami floor using an insulation board for the lower plate layer because the polystyrene resin foam plate of the lower plate layer is lighter than the T-class insulation board. On the other hand, the weight can be reduced.

In addition, it is lightweight, and there is no problem that the needle hole greatly expands on the surface of the foam plate, and workability during tatami mat production is excellent. That is, in the tatami floor of the present invention, as compared with the case where the thickness of the polystyrene resin foam of the core material layer is increased,
Since the foam of the lower plate layer has a higher density than that of the core material layer, a sufficient resistance is exerted against the force of the sewing thread tearing through the foam during sewing, and the expansion of the thread hole is prevented. .

[Brief description of drawings]

1 shows a first embodiment of a tatami floor of the present invention, (a) is a perspective view showing the appearance, (b) is a vertical cross-sectional view taken along the line BB of (a) (note that ( The sewing thread is omitted in b)].

FIG. 2 is a longitudinal sectional view of essential parts showing a second aspect of the tatami floor of the present invention (the sewing thread is omitted).

[Explanation of symbols]

 1 tatami floor 2 core layer 3 upper board layer 4 lower board layer 7 sewing thread

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yuichiro Hashizume 3-13-7 Nishisako, Odawara City, Kanagawa Prefecture 6th Maison Hoshizaki 201 (72) Inventor Hirofumi Goto 1-1-56 Misumi Town, Higashimurayama City, Tokyo ( 72) Inventor Atsuo Uemura 4-16-17 Ikenohata, Taito-ku, Tokyo Solitaire U401

Claims (6)

[Claims] 1. An upper plate layer is laminated on an upper surface side of a core material layer made of a polystyrene resin foam plate, a lower plate layer is laminated on a lower surface side of the core material layer, and the whole is integrally sewn. It is a tatami mat and the density of the polystyrene resin foam plate of the core material layer is 0.
A tatami floor, which is 025 g / cm ^{3 to} 0.045 g / cm ³ and the lower plate layer is a polystyrene resin foam plate having a density of 0.05 g / cm ^{3 to} 0.15 g / cm ³ . 2. The upper plate layer has a density of 0.05 g / cm ^{3 to} 0.
The tatami floor according to claim 1, which is a polystyrene resin foam plate having a weight of 15 g / cm ³ . 3. The polystyrene resin foam plate of the upper plate layer,
3. The tatami floor according to claim 2, which is a foam plate in which a foam extruded in an annular shape from a circular die is pressed while the foam is in a softened state and the inner surface is fused. 4. The polystyrene resin foam plate of the lower plate layer,
The tatami floor according to any one of claims 1 to 3, which is a foam plate in which a foam extruded in an annular shape from a circular die is pressed while being in a softened state and the inner surface is fused. 5. The polystyrene-based resin foam plate of the core material layer,
A foam plate extruded and foamed from a flat die.
The tatami floor according to any one of 4 to 4. 6. A protective material is laminated on the upper surface side of the upper plate layer, and a backing material is laminated on the lower surface side of the lower plate layer. The protective material, the upper plate layer, the core material layer, the lower plate layer, and the backing material are arranged in this order. The tatami floor according to any one of claims 1 to 5, which is laminated and integrally sewn.