JPS639963B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a hygienic, lightweight, and inexpensive breathable rice husk tatami floor.

Traditionally, tatami flooring was made by stacking ina straw alternately vertically and horizontally, pressed and then pierced with hemp thread.
In recent years, with the tightening of the rural labor force, it has become difficult to collect ina straw, and prices have soared, leading to an increase in the production cost of tatami flooring, and the current situation is that the selling price has become relatively high, and demand is declining year by year.

For this reason, efforts have been made to develop cheaper alternatives to this, but there are few to be found.

That is, there are chemical products using various foamed resins, and products made by bonding long woody fibers such as wood wool with resin, but none of them have reached the point where they can fully perform the functions of conventional products. Tatami flooring is required to have a certain degree of hardness and elasticity that is suitable for the daily life of Japanese people, and to be breathable. Especially,
The ability to adjust heat absorption, humidity, heat radiation, humidity, heat retention, and insulation through breathability enhances health benefits. In the case of foamed resin products, it is generally difficult to adjust the hardness and elasticity and to create capillary ventilation pores, and in the case of adhesives such as wood wool, even if air permeability can be maintained, it is highly hygroscopic and can become wet. Therefore, it is not good for health.

As mentioned above, conventional substitutes do not fully demonstrate the functionality of tatami flooring, but the product price is not necessarily cheaper than inawara tatami flooring due to high raw material and processing costs. Not yet.

The present invention aims to fundamentally solve these problems.

That is, in the present invention, rice husks are used as a raw material instead of straw, which accounts for most of the material cost of tatami flooring. Due to the recent mechanization of agricultural management, rice husks are collected annually from shared facilities such as country elevators or rice centers.
More than 3.5 million tons of waste have been intensively emitted, but until now some of it has been used for compost and other things have been disposed of or incinerated, so it is hoped that it can be put to better use.

Rice husk contains a large amount of crude fiber, lignin, and silica, has few water-soluble components, and is granular, hollow, and hydrophobic, so it has heat absorption, heat dissipation, heat retention, and heat insulation properties that are better than rice straw. Strengths are utilized,
Since ancient times, it has been used as a stuffing for sleeping pillows, along with buckwheat, and the important requirement in this case is breathability. If it were possible to use rice husk as a raw material to compress and mold rice husk to a degree that has the hardness and elasticity required for tatami flooring while maintaining its breathability, it would be even better in terms of health and hygiene than traditional straw flooring. It can even be said that it is an excellent product, but in terms of manufacturing costs, rice husk can be obtained almost free of charge, making it extremely inexpensive compared to inawara flooring.

However, there is a contradictory relationship between compression molding and air permeability, so there has been no suitable manufacturing method. However, the present invention involves squeezing rice husks mixed with adhesive in advance, or melting the adhesive while squeezing. Hot air at a temperature that is pressurized enough to blow through the pressed rice husks is forcibly passed through the rice husks to melt the adhesive, and then switched to similarly pressurized cold air to blow through the rice husks. This makes it possible to solidify and form a lightweight tatami floor with numerous mesh-like ventilation pores. in this case,
By using hot air, it is possible to avoid moisture absorption and swelling caused by steaming the rice husks.

Furthermore, the tatami floor made using this manufacturing method has a sterilization effect due to the passage of hot air, and the use of an adhesive that has a pest extermination effect prevents the growth of pests such as mites, making it extremely hygienic. It can be made into something. In this case, a conventionally known synthetic resin having bactericidal properties, such as a polyurethane resin or a thermoplastic resin containing a polyurethane resin, is used as the adhesive having a pest control effect.

In addition, one example of application is to cover the rice hulls with mesh-like fibers or the like in order to reinforce the molded product.

Next, an explanation will be given using drawings showing examples.
Adhesive was mixed in advance in a hollow part in a box-like formwork 6 having a double bottom part 5 with a hot air and air intake port 4 having a switching valve 3 that enabled switching between the hot air port 1 and the air port 2. The rice husks are enclosed, and the top lid 7 is compressed using the compressor 8. At the same time, hot air taken in from the hot air intake port is injected into the rice husks in the hollow part through the pores 9 in the double bottom, and the pores in the top lid are compressed. The adhesive is melted while being blown through the air intake port 10, and the air-permeable rice husk tatami floor 11 can be formed by operating the switching valve to switch to pressurized cold air from the air intake port and solidifying it.

[Brief explanation of the drawing]

FIG. 1 is an overall view and a partial perspective view of the manufacturing equipment with the top cover removed. FIG. 2 is an overall view and a partial perspective view of the manufacturing equipment showing the state of rice husk molding. 1...Hot air port, 2...Air port, 3...Switching valve,
4...hot air, air intake, 5...double bottom, 6...
...Box-shaped formwork, 7...Top lid, 8...Press machine, 9...
Pore in double bottom, 10...Pore in top lid, 11...
Breathable rice husk tatami floor.

Claims (1)

[Claims] 1 The bottom of the box-shaped formwork is double-bottomed, many pores are evenly placed on the top facing the hollow inside the box, hot air and air intakes are provided on the sides, and the other sides are sealed. It has a mechanism consisting of a box-shaped formwork with a heavy bottom and an upper lid that can slide up and down within the formwork and has many pores evenly attached.The hollow part of the formwork has a pest control effect. "Rice husks" mixed with an adhesive having a The adhesive is injected into the hollow part through the pores and blows through the pores of the top lid, melting the adhesive and
By switching to pressurized cold air to solidify and tighten the aggregate, a hygienic, lightweight, and inexpensive tatami floor with numerous congested, mesh-like ventilation pores is formed. Manufacturing method for rice husk tatami flooring.