JPS639724Y2 - - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to a tatami floor made of synthetic resin foam.

In recent years, with the shortage and rising prices of straw, the raw material for tatami mats, various tatami mats using materials other than straw, such as synthetic resin foam, have been proposed in part or in whole. The base material is a styrene resin foam such as polystyrene, on which natural straw material is laminated, or instead of the straw material, a fiberboard (insulation board, etc.) made of aggregated fibrous materials is laminated. Something is appearing.

However, the upper layer of tatami flooring, such as the straw material and fiberboard, easily absorbs moisture, so the moisture causes the tatami floor to become weak, and when heavy objects are placed on it, the tatami floor tends to dent or sag, resulting in deterioration. It has disadvantages such as being easy to clean and attracting pests.

Note that polystyrene resin foam is inferior to straw material in terms of elasticity, restorability, impact resistance, feel, etc., and cannot be used alone as a suitable product for tatami flooring.

In view of the above, the present invention exhibits almost the same elasticity and texture as straw tatami flooring without using any straw material, etc.
Moreover, it was devised to provide a tatami floor that is resistant to moisture, has good elasticity, has good resilience, is highly durable, and is free from the risk of pests.

Next, embodiments of the present invention will be described based on the drawings.
A shows a tatami floor with an upper and lower two-layer structure according to the present invention, in which upper and lower layers 1 and 2 made of different types of foam are superposed. The upper layer 1 of the tatami floor A is made of a thermoplastic resin foam mainly made of olefin resin such as polypropylene, and has a large number of parallel resin foam strips 11 having a high density on the surface and a low density on the inside. It is made of a foam plate made by arranging and converging the strips and fusing adjacent strips to each other. The resin foam strips 11, 11 are fused together by simultaneously extruding thermoplastic resin in a large number of strips from a die at the tip of the extruder to foam them, and immediately after extrusion, passing through a predetermined mold to restrict foaming and mutually This is done by bringing them into close contact. Therefore, a high-density skin layer 12 is formed on the surface of the foam.
are formed, and the fused portions 13 between the strips 11, 11 are also high in density. The thermoplastic resins mainly composed of olefin resins mentioned above include:
Olefin resins such as polypropylene and polyethylene may be used alone, but examples include mixed resins of these olefin resins and styrene resins such as polystyrene, and other olefin-based copolymers. Among them, olefin resins such as polypropylene and styrene resins are examples. Mixed resin with resin, olefin resin
Those containing 50% or more, preferably about 60 to 80% are suitably used. The expansion ratio of the foam varies depending on the mixing ratio of the resin, but is on average 5 to 30 times, preferably 10 to 20 times.

On the other hand, the lower layer 2 of the tatami floor A is made of a styrene resin foam such as polystyrene and a copolymer mainly composed of styrene, and is usually foam-molded to about 15 to 50 times the size.

In addition, the thickness of the above upper layer 1 and lower layer 2 is tatami floor A
It can be set as appropriate depending on the total thickness of the tatami floor and the physical properties of each layer, but usually, for example, the thickness of the tatami floor A is about 50 mm.
, the upper layer 1 of thermoplastic foam is 10 to 20
mm, and the lower layer 2 of the styrene resin foam is set to 40 to 30 mm.

3 is a backing material, and in the case of the figure, it is a synthetic resin cloth 3 made by cross-linking flat narrow sheets of synthetic resin.
It consists of a paper 3b pasted on kraft paper 3b. While overlapping the above-mentioned upper layer 1 and lower layer 2,
It is also possible to manufacture a tatami floor by laminating the backing material 3 on the back side and sewing them together using a tatami machine, but in the case of the illustrated embodiment, asphalt, etc. The superimposed upper and lower layers 1 and 2 are wrapped in an impregnated fibrous sheet 4, and the above-mentioned backing material 3 is laminated on the back side of the fibrous sheet 4, and the whole is sewn together to form a tatami floor A. 5 indicates the sewing thread. The fibrous sheet 4 and the backing material 3 can protect the thermoplastic resin foam of the upper layer 1 and the styrene resin foam of the lower layer 2, and can prevent damage from the seams. Especially backing material 3
When it is made of the synthetic resin cloth 3a as described above, it is strong against tearing and has an excellent effect of preventing damage from seams.

In the figure, 6 is a tatami mat cover, which is attached to the tatami floor A by conventionally known means.

As mentioned above, the tatami floor A of the present invention has an upper layer 1 of thermoplastic resin foam mainly composed of olefin resin.
It has a two-layer structure with a lower layer 2 of styrene resin foam, and does not use any hygroscopic materials such as straw or fiberboard, so it has excellent moisture resistance and antiseptic properties, and the tatami surface will not get scratched. First, tatami mats can last a long time, prevent the growth of pests such as mites, and are hygienic as they do not generate dust.

In particular, in the tatami floor A of the present invention, as the constituent material of the upper layer 1, a large number of resin foam strips 11 having a high density on the surface and a low density on the inside are arranged in parallel and bundled, and adjacent strips are stacked together. In other words, a foam with a unique internal structure in which the skin layer 12 and the fused parts 13 between the strips are high in density is used as a manufacturing feature. Since the thermoplastic resin of the material is mainly composed of olefin resin such as polypropylene, the upper layer 1 has better elasticity and toughness than the styrene resin foam of the lower layer. The fused parts 13 between the strips have high toughness, so the upper layer 1 compensates for the weaknesses of the lower layer 2 made of styrene resin foam, and the tatami floor as a whole has a firm body and excellent pressure and impact resistance. It exhibits almost the same elasticity, resilience, and feel as straw tatami flooring, and is resistant to moisture, so unlike straw materials, there is no risk of weakening due to moisture or inhibiting resilience. It is extremely durable, with little denting or sagging when heavy items such as chests of drawers are placed on it. In addition, the high-density portion of the upper layer 1 can prevent the needle hole from expanding excessively during sewing and damage from the hole portion.
The sewn condition can be maintained well. Of course, since both the upper and lower layers 1 and 2 are made of foam, they can be sewn using a tatami machine.

Furthermore, since the present invention uses foam as a constituent material, it is extremely lightweight and easy to handle, making it possible to increase the efficiency of tatami production and transportation, as well as having excellent heat insulation and heat retention properties.

[Brief explanation of drawings]

Figure 1 is a partially cutaway perspective view showing the tatami floor of the present invention;
FIG. 2 is an enlarged sectional view taken along the line - front figure. A... Tatami floor, 1... Upper layer, 2... Lower layer, 3...
Backing material, 4... Fibrous sheet, 5... Sewing thread, 6...
...Tatami Omote.

Claims (1)

[Claims for Utility Model Registration] 1. A thermoplastic resin foam mainly composed of olefin resin such as polypropylene, which has many resin foam strips arranged in parallel with high density on the surface and low density on the inside. The upper layer is made of a foam plate made by converging the strips together and fusing adjacent strips to each other.
A tatami floor comprising a styrene resin foam as a lower layer and both layers stacked on top of each other. 2. The tatami mat according to claim 1, wherein the thermoplastic resin is a mixed resin of an olefin resin such as polypropylene and polyethylene and a styrene resin such as polystyrene, and the olefin resin accounts for 50% or more. floor.