TWI725122B - 異向性榻榻米表層 - Google Patents

異向性榻榻米表層 Download PDF

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Publication number
TWI725122B
TWI725122B TW106105407A TW106105407A TWI725122B TW I725122 B TWI725122 B TW I725122B TW 106105407 A TW106105407 A TW 106105407A TW 106105407 A TW106105407 A TW 106105407A TW I725122 B TWI725122 B TW I725122B
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Taiwan
Prior art keywords
surface layer
tatami
anisotropic
resin
rush
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TW106105407A
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English (en)
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TW201732133A (zh
Inventor
青谷博
橫田裕次
島田隼人
稻津明
上乾智
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日商積水成型工業股份公司
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Publication of TW201732133A publication Critical patent/TW201732133A/zh
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Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Floor Finish (AREA)
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  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)

Abstract

[課題]本發明提供一種色相根據視角而有所不同，設計性優異的異向性榻榻米表層。 [解決手段]本發明之異向性榻榻米表層，其係由藺草或人工藺草的横線與縱線所構成，且以縱線在表面露出的方式織成的榻榻米表層，其特徵為：横線與縱線的色差ΔE為6.0以上

Description

異向性榻榻米表層
本發明係關於一種設計性優異的異向性榻榻米表層，其色相根據視角而有所不同。
被廣泛使用為日本家中地板材料的榻榻米，係藉由在榻榻米基材的表面積層榻榻米表層的方式所構成。榻榻米表層，一般係由「引目織」所織成。引目織，如圖8所示，係以2條横線(藺草)200、200相對於2條縱線300、300交叉的方式依序編織而成的方法(例如，參照專利文獻1、2)，根據縱線的數目，而具有諸目、目積、大目等。
上述榻榻米表層中，縱線被横線(藺草)所包入，因為縱線可見的是低強度劣品，而以「横線(藺草)緊密連接」的方式編織，故只有横線(藺草)呈現在表面上。因此，無論從哪個方向看都是相同的色相，沒有變化，設計性也不佳。
[先前技術文獻]
[專利文獻]                           [專利文獻1]日本特開平10-183957號公報                           [專利文獻2]日本特開2002-188276號公報
[發明所欲解決之課題]
鑒於上述問題點，本發明之目的係提供一種設計性優異的異向性榻榻米表層，其色相根據視角而不同。
[解決課題之手段]
亦即，本發明係關於： [1]一種異向性榻榻米表層，其係由藺草或人工藺草的横線與縱線所構成，且以縱線露出表面的方式所織成的榻榻米表層，其特徵為：横線與縱線的色差ΔE為6.0以上； [2]如上述[1]記載之異向性榻榻米表層，其中，横線的直徑為0.5~2mm，縱線的直徑為横線直徑的5~80%； [3]如上述[1]記載之異向性榻榻米表層，其中，横線的顏色為1種或2種以上； [4]如上述[1]記載之異向性榻榻米表層，其中，縱線為麻線、綿線、聚酯線或綿與聚酯的混合線； [5]如上述[1]記載之異向性榻榻米表層，其中，縱線的顏色為1種或2種以上； [6]如上述[1]記載之異向性榻榻米表層，其係藉由平織或斜紋織所織成； [7]如上述[1]記載之異向性榻榻米表層，其中，相鄰的横線係以彼此緊密連接的方式織成；相鄰的縱線係以間隔5~30mm的方式織成；及 [8]如上述[1]~[7]任一項記載之異向性榻榻米表層，其背面更接合有底墊。
[發明效果]
本發明之異向性榻榻米表層的構成，如上所述，其色相根據視角而不同，且設計性優異。又，將積層有此榻榻米表層的榻榻米配置於室內等，藉此，在室內等，可根據視角使其色相不同，進而提升室內等的裝飾性。
本發明之異向性榻榻米表層，係以藺草或人工藺草的横線與縱線所構成，以縱線在表面露出的方式織成的榻榻米表層，其特徵為：横線與縱線的色差ΔE為6.0以上。
本發明中所使用的横線為藺草或人工藺草。人工藺草，係指從烯烴系樹脂等的合成樹脂所製造的藺草以及捻紙藺草等，可使用過去習知的任何人工藺草。
作為上述人工藺草，例如，可列舉下述的人工藺草：將烯烴系樹脂、無機填充劑、著色劑等所構成的樹脂膜單軸延伸而得到帶狀體，再將該帶狀體纏繞為繩狀，接著使經纏繞的繩狀體通過具有狹窄空隙部之加熱構件的空隙部中，藉此使該繩狀體彼此不規則熔黏成束且表面形成熔黏被膜。
作為上述烯烴系樹脂，例如，可列舉：高密度聚乙烯樹脂、中密度聚乙烯樹脂、低密度聚乙烯樹脂、直鏈狀低密度聚乙烯樹脂、聚丙烯樹脂、乙烯―丙烯共聚物、乙烯―1-丁烯共聚物、乙烯―1-戊烯共聚物、乙烯―1-己烯共聚物等。
作為上述無機填充劑，例如，可列舉：碳酸鈣、碳酸鎂、氧化鋁、氧化鎂、氧化鈦、氫氧化鎂、滑石、雲母、黏土(clay)等。
若在樹脂膜中添加無機填充劑，則在將樹脂膜單軸延伸時，所含之無機填充劑作為核，而在帶狀體中形成空隙，進而減輕重量，且提升隔熱性、緩衝性等，故較佳係相對於烯烴系樹脂100重量份，添加10~50重量份的無機填充劑。
作為上述著色劑，例如，可列舉：偶氮系、酞菁系、士林(Threne)系、染料色澱(lake pigment)系等的有機顔料；氧化物系、鉻酸鉬系、硫化物･硒化物系、亞鐵氰化物系等的無機顔料等。著色劑的添加量，可因應需求適當決定，但一般而言，相對於烯烴系樹脂100重量份，較佳為0.1~10重量份，更佳為1~5重量份。
再者，可因應需求含有：酚系抗氧化劑、芳香族胺系抗氧化劑等的抗氧化劑，柳酸酯系、二苯甲酮系、苯並三唑系、氰基丙烯酸酯系等的紫外線吸收劑，受阻胺(hindered amine)系的光穩定劑，陽離子系、非離子系等的抗靜電劑、衝撃改良劑、抗混濁劑、阻燃劑等。
上述樹脂膜，係由烯烴系樹脂、無機填充劑、著色劑等所構成，可藉由擠製法、T字模法、鑄造法、壓延(calender)法、充氣(inflation)法、噴塗法等的過去習知的製膜法製造。
上述帶狀體係將上述樹脂膜單軸延伸者，而單軸延伸方法，只要使用過去習知的任何方法即可，例如，可列舉：滾軸單軸延伸法、區域單軸延伸法等。
若單軸延伸溫度變低則無法均勻延伸，變高則導致樹脂膜熔融而切斷，故較佳係在延伸之樹脂膜的烯烴系樹脂的「融點-60℃」~融點的範圍，更佳為烯烴系樹脂的「融點-50℃」~「融點-5℃」。
若單軸延伸的倍率變低則機械強度降低，若變高則變硬，導致作為榻榻米表層的品味降低，故較佳為2~10倍。又，上述帶狀體的厚度較佳為5~20μm。
將帶狀體纏繞成繩狀，再使經纏繞的繩狀體通過具有狹窄空隙部之加熱構件的空隙部中，藉此使彼此不規則熔黏成束且表面形成熔黏被膜，因此，在使繩狀體通過加熱構件之空隙部時，較佳係藉由沿著單軸延伸方向折疊帶狀體而纏繞的方法、將細的帶狀體互相捻合成捻線狀的方法、將細的帶狀體互相組合成組合繩狀的方法等，而成為繩狀體，再使其通過加熱構件之空隙部。
上述加熱構件，只要是可加熱且具有可使繩狀體通過之狹窄空隙部的構件即可，藉由使繩狀體通過狹窄空隙，可使帶狀體彼此不規則熔黏成束且於表面形成熔黏被膜，因此，空隙部的直徑較佳為繩狀體的直徑的50~90%。又，空隙部的剖面形狀，只要與欲得之人工藺草剖面形狀約略相同即可，例如，較佳為圓形、橢圓形等。又，亦可在空隙部的出口附近形成突起，而能夠形成「於所形成之熔黏被膜上形成皺摺或貫通孔」的態樣。
因為係藉由使繩狀體通過加熱構件之空隙部中，而使帶狀體彼此不規則熔黏成束且同時於表面形成熔黏被膜，故上述加熱構件的加熱溫度較佳係在帶狀體之烯烴系樹脂的融點以上，更佳為烯烴系樹脂的「融點+100℃」~「融點+150℃」。
使繩狀體通過加熱構件之空隙部中的速度，若太慢則帶狀體的熔黏率變高、空隙率減少，導致其變重且變硬，反之，若太快則表面難以形成熔黏被膜，故該速度雖亦與加熱溫度相關，但一般較佳為15~75m/分。
又，上述人工藺草的空隙率若變小，則變重且變硬，導致緩衝性、隔熱性、耐衝撃性等降低，反之，若空隙率變大，則機械強度降低，故較佳為15~50%。
上述方法所製造的人工藺草，因為經單軸延伸的帶狀體部分地熔黏且表面形成熔黏被膜，故空隙率高而輕量，且隔熱性、緩衝性、耐衝撃性、機械強度、衛生性、耐候性等優良。
上述横線的粗細，因為是榻榻米表層的横線，故直徑較佳為0.5~2mm，更佳為0.8~1.5mm。又，横線的重量較佳為3000~10000丹尼，更佳為4000~6000丹尼。
上述横線的顏色可任意決定，例如，可列舉：紅色、朱紅色、粉紅色、紫色、深藍色、群青色、青色、藍色、綠色、深綠色、淺綠色、褐色、土黄色、黄色、皮膚色、米色、黑色、灰色、白色等。
上述縱線，只要使用以往用於製造榻榻米表層的縱線即可，例如，可列舉：麻線，綿線，聚酯線，綿與聚酯的混合線等，較佳係藉由著色劑等著色為紅色、青色、綠色、褐色等。
本發明之異向性榻榻米表層，因為係以縱線在表面露出的方式織成的榻榻米表層，故較佳係藉由平織或斜紋織所織成。又，為了提升機械強度，相鄰的横線係以彼此緊密連接的方式織成；與以往榻榻米表層相同地彼此相鄰的縱線，較佳係以間隔3~30mm的方式織成。
上述横線的顏色可為1種，亦可併用2種以上不同顏色的横線。又，縱線的顏色亦可為1種，亦可併用2種以上不同顏色的縱線。
接下來，參照圖式說明本發明之異向性榻榻米表層。圖1係顯示本發明之異向性榻榻米表層之一例的俯視圖；圖2係圖1中A-A的剖面圖。異向性榻榻米表層1係藉由平織所織成，横線2、2…以與相對於縱線3、3…交叉」的方式依序織入。又，横線2在位於縱線3下方之處被壓縮，若從上方觀察，其寬度變狹窄，而形成狹小部21，其之間則形成寬幅部22。因此，横線2，在縱線3方向上，形成狹小部21與寬幅部22交互的態樣，縱線3在狹小部21處通過横線2的上部，而在寬幅部22處則通過横線2的下方。結果，縱線3在狹小部21處，露出於榻榻米表層的表面。
本發明之異向性榻榻米表層，因為雙方面露出横線2與縱線3，故為了呈現異向性，横線2與縱線3的色差ΔE為6.0以上，較佳為13.0以上。
又，色差係在兩種顏色之間可感受到的差別或是經數値化的値，其係依據JIS Z8722，以色差式計算「使用色彩色差計並藉由分光色差方法所測定的顏色」。
以下詳細說明。對於測定樣品1與樣品2之色差，首先，藉由色彩色差計測定樣品1的L1 (明度)及a1 、b1 (色度)。接著，同樣地藉由色彩色差計測定樣品2的L2 (明度)及a2 、b2 (色度)。最後，藉由下式計算所得之L1 、a1 、b1 及L2 、a2 、b2 的値。接著，ΔE的値為色差。 ΔE=[(L1 -L2 )2 +(a1 -a2 )2 +(b1 -b2 )2 ]1/2
又，因為縱線3係在比寬幅部22更低之位置的狹小部21之處，露出於榻榻米表層的表面，故若縱線3的直徑變小，則根據角度而被横線2所遮蔽導致無法目視，進而增加異向性。因此，縱線3的粗細，較佳係小於横線2的直徑，較佳為横線直徑的2~80%，更佳為5~50%。
本發明之異向性榻榻米表層，為了提升機械強度，較佳係以下述方式所織成：相鄰的横線2、2以彼此緊密連接的方式織成，與以往的榻榻米表層相同地彼此相鄰的縱線3、3則以間隔5~30mm的方式織成。
本發明之異向性榻榻米表層，亦可在背面接合底墊。底墊係如下所述的墊材：可補強異向性榻榻米表層，且在對於構成異向性榻榻米表層之藺草施加載重時可防止藺草移動，並可防止端部的藺草脫線。
作為上述底墊，例如，可列舉：紙；麻纖維、綿纖維、聚乙烯纖維、聚丙烯纖維、胺甲酸酯纖維、聚丙烯酸纖維、聚酯纖維等的纖維的不織布及織布；聚苯乙烯樹脂、聚氯乙烯樹脂、聚乙烯樹脂、聚丙烯樹脂等的烯烴系樹脂；聚胺甲酸酯樹脂；橡膠等的樹脂墊及發泡樹脂墊。
該等之中，合成樹脂墊為防水性，故即使水潑到異向性榻榻米表層，亦可防止水滲透到背面側(在與榻榻米基材積層而作為榻榻米的情況，則為榻榻米基材)，因而較佳；特佳為機械強度、耐候性、柔軟性等優異的聚氯乙烯樹脂墊、聚乙烯樹脂墊、聚丙烯樹脂墊。
又，將烯烴系樹脂與無機填充材所構成的墊材延伸的延伸墊、在上述熱塑性樹脂中混合透濕性樹脂的樹脂墊等亦為防水性，且具有透氣性，因而適用。
作為上述烯烴系樹脂，例如，可列舉：高密度聚乙烯樹脂、中密度聚乙烯樹脂、低密度聚乙烯樹脂、直鏈狀低密度聚乙烯樹脂、聚丙烯樹脂、乙烯―丙烯共聚物、乙烯―1-丁烯共聚物、乙烯―1-戊烯共聚物、乙烯―1-己烯共聚物等。
作為上述無機填充劑，例如，可列舉：碳酸鈣、碳酸鎂、氧化鋁、氧化鎂、氧化鈦、氫氧化鎂、滑石、雲母、黏土等。
若添加無機填充劑，則在延伸烯烴系樹脂墊時，將所含之無機填充劑作為核，而在墊中形成空隙進而賦予通氣性，但若大量包含，則導致機械強度降低，且賦予透水性，故一般而言相對於烯烴系樹脂100重量份，較佳為添加5~20重量份。
烯烴系樹脂與無機填充材料所構成之墊材的延伸方法，可為單軸延伸，亦可為雙軸延伸。延伸倍率一般為2~10倍，延伸溫度若變低則無法均勻延伸，若變高則烯烴系樹脂墊熔融切斷，故較佳係在延伸之烯烴系樹脂墊的烯烴系樹脂的「融點-60℃」~融點的範圍，更佳為烯烴系樹脂的「融點-50℃」~「融點-5℃」。
作為上述透濕性樹脂，並未特別限定，可使用以往習知的任何透濕性樹脂，例如，可列舉：聚酯系彈性體。又，作為主原料使用的樹脂與具有透濕性的樹脂相溶性優良，因而較佳，一般而言，相對於烯烴系樹脂100重量份，較佳係添加具有透濕性之聚酯系彈性體樹脂0.3~20重量份，更佳為0.5~10重量份。
又，發泡樹脂墊，即使施加載重而產生凹陷亦可輕易復原，因而較佳，特別是發泡倍率10~50倍、較佳為20~40倍的獨立氣泡性聚乙烯發泡樹脂墊，因為柔軟性、緩衝性、復原性等優良，且為防水性，因而較佳。
又，獨立氣泡性發泡樹脂墊，係指具有未與墊材外部連通之氣泡的發泡樹脂墊，若獨立氣泡率降低，則導致隔熱性、復原性、彈力性、機械強度等降低，故較佳為30%以上，更佳為50%以上。例如，可藉由將發泡樹脂墊浸漬於水中，再測定水增加的體積，而可輕易測定獨立氣泡率。
上述底墊材的厚度並未特別限定，但若太薄，則機械強度降低，補強效果亦降低，且防止藺草偏移的效果降低，反之，若太厚則導致變重，且柔軟性降低而難以摺疊，故較佳為0.005~5mm，更佳為0.01~2mm。
上述異向性榻榻米表層背面接合有底墊的情況下，較佳係至端部為止全面性穩固地接合於異向性榻榻米表層。又，異向性榻榻米表層的端部以外的中心部，只要為細條、點狀程度，則即使存在未接合部分亦無妨。
上述接合方法，可採用習知的任何方法，例如，以橡膠系、丙烯酸系、胺甲酸酯系、矽系等的接合劑或黏著劑接合的方法、以兩面黏接片接合的方法，以乙烯-乙酸乙烯酯共聚物、線狀低密度聚乙烯樹脂等的聚烯烴系熱融型接合劑接合的方法、藉由焊接加工熔黏的方法等。
接合有底墊的異向性榻榻米表層，因為係防水性，故可以水清洗。又，輕量且不易凹陷，特別是底墊為發泡樹脂墊的情況，緩衝性優良。因此，可作為坐墊而在室內外使用，又，亦可在櫃子、桌子、椅子等施加載重的情況下，較佳地作為緩衝墊使用。
本發明之異向性榻榻米表層，較佳係與榻榻米基材積層而作為榻榻米使用。作為上述榻榻米基材，並未特別限定，例如，可列舉：稻草榻榻米基材，具有芯材的人工榻榻米基材等，使用稻草榻榻米基材的榻榻米為厚榻榻米，而使用具有芯材之人工榻榻米基材的榻榻米則具有薄榻榻米及厚榻榻米。
上述稻草榻榻米基材，耐久性、柔軟性、隔熱性、保溫性、濕氣的吸濕･放出性優良，係過去即被廣使用的厚度約55mm的厚榻榻米用的榻榻米基材，可舉例如，將平坦地堆疊多層的約400mm之稻草壓縮至約50mm的榻榻米基材。
圖6係顯示厚榻榻米之一例的剖面圖，圖中，4為異向性榻榻米表層，背面接合有底墊5。異向性榻榻米表層4中，底墊5以與稻草榻榻米基材6相接的方式被積層，且端部被捲入稻草榻榻米基材6的端部內側，經縫合而形成厚榻榻米。
上述具有芯材的人工榻榻米基材，係厚度約7~55mm的薄榻榻米及厚榻榻米用的榻榻米基材，一般係由芯材與緩衝墊所構成。
上述芯材賦予榻榻米機械強度，可列舉以往已被使用於榻榻米的芯材，例如，木質纖維板、獨立氣泡性合成樹脂發泡板等。
上述木質纖維板，係將木材其他的植物纖維漿化，藉由黏結樹脂結合再熱壓成板的建材，例如，可列舉：粒片板、合板、絕緣纖維板(絕緣板)、中密度纖維板(MDF；medium density fiberboard)、硬纖維板(硬板)等。
上述獨立氣泡性合成樹脂發泡板，例如，可列舉：聚乙烯苯乙烯、聚乙烯、聚丙烯等的合成樹脂發泡板，其發泡倍率為5~30倍。
薄榻榻米，一般而言，整體的厚度薄至8~35mm，故作為芯材，較佳為機械強度高的木質纖維板，更佳為中密度纖維板(MDF)，該厚度較佳為3~7mm，更佳為3.5~4.5mm。
上述緩衝墊，係積層於芯材表面(榻榻米表層側)而賦予薄榻榻米緩衝性、隔音性者，例如，可列舉：麻纖維、綿纖維、聚乙烯纖維、聚丙烯纖維、胺甲酸酯纖維、聚丙烯酸纖維、聚酯纖維等的纖維的不織布、織布、墊子、毛毯、聚苯乙烯樹脂發泡墊、聚乙烯樹脂發泡墊、聚丙烯樹脂發泡墊、胺甲酸酯發泡墊、橡膠發泡墊等的發泡墊；牛皮紙、板紙、厚紙、紙箱等。
緩衝墊的每單位面積重量，一般為100~700g/m2 ，厚度為3~6mm。又，緩衝墊亦可積層多片薄緩衝墊。又，亦可將緩衝墊積層於芯材的兩面。
圖7係顯示薄榻榻米之一例的剖面圖，圖中，4為異向性榻榻米表層，其背面接合有底墊5。9為人工榻榻米基材，芯材8的一面上積層有緩衝墊7。異向性榻榻米表層4中，底墊5係以與緩衝墊7相接的方式積層於人工榻榻米基材9，再者，芯材8的另一面上積層有段差調整墊10及內側緩衝墊11。異向性榻榻米表層4的端部，沿著人工榻榻米基材9(芯材8及緩衝墊7)的側面彎折，而折入芯材8與內側緩衝墊11之間，段差調整墊10則積層於芯材8、異向性榻榻米表層4與內側緩衝墊11所形成的空間之中，異向性榻榻米表層4與內側緩衝墊11接合，形成薄榻榻米。
上述段差調整墊10，例如，可列舉：麻纖維、綿纖維、聚乙烯纖維、聚丙烯纖維、胺甲酸酯纖維、聚丙烯酸纖維、聚酯纖維等的纖維的不織布、織布、墊子、毛毯；聚苯乙烯樹脂發泡墊、聚乙烯樹脂發泡墊、聚丙烯樹脂發泡墊、胺甲酸酯發泡墊、橡膠發泡墊等的發泡墊；牛皮紙、板紙、厚紙、紙箱、粗紙板(chipboard)等。
上述內側緩衝墊11，係積層於芯材背面(薄榻榻米下側)，而賦予薄榻榻米緩衝性、隔音性者，例如，可列舉：麻纖維、綿纖維、聚乙烯纖維、聚丙烯纖維、胺甲酸酯纖維、聚丙烯酸纖維、聚酯纖維等的纖維的不織布、織布、墊子、毛毯；聚苯乙烯樹脂發泡墊、聚乙烯樹脂發泡墊、聚丙烯樹脂發泡墊、胺甲酸酯發泡墊、橡膠發泡墊等的發泡墊；牛皮紙、板紙、厚紙、紙箱等。
再者，薄榻榻米的背面，亦可積層有矽系樹脂、丙烯酸系樹脂，丙烯酸矽系樹脂等所構成的防滑墊、布膠帶等的背面成形墊等。
上述榻榻米，因為接合有底墊的異向性榻榻米表層為防水性，故可從異向性榻榻米表層側進行水洗，薄榻榻米則可對整體進行水洗。又，因為不易發生凹陷(不均勻)，故適合作為櫃子、桌子、椅子等施加載重之處的榻榻米使用。
[實施例]
以下說明本發明之實施例，但本發明並不限於實施例。
(實施例1)
將聚丙烯樹脂(Japan Polypropylene公司製，商品名「NOVATEC PP Series」，MFR 5.0g/10min，密度0.9g/cm3 ，融點155~165℃)100重量份、碳酸鈣(竹原化學工業公司製，商品名「MAX Series」)27重量份及偶氮系無機顔料(東洋油墨公司製，商品名「PPM0866」)2.0重量份所構成的樹脂組成物供給至螺桿70mm的單軸揉合擠製機，在210℃下進行揉合擠製，而得到厚度100μm的聚丙烯樹脂膜。
將所得之聚丙烯樹脂膜供給至設為120℃的加熱板式單軸延伸裝置，並延伸至5倍，得到厚度20μm的帶狀體。將所得之帶狀體在單軸延伸方向上折疊，使其通過直徑2.0mm的貫通孔而形成繩狀後，供給至具有直徑1.0mm之圓形剖面之空隙部的加熱構件，再以65m/分的速度使其通過空隙部，而得到人工藺草。
加熱構件加熱至300℃，在空隙部的出口附近，以45度的間隔設置8個高度0.05mm且前端尖起的突起。所得之人工藺草，其帶狀體部分熔黏，同時於表面形成熔黏被膜，而熔黏被膜上隨機形成有貫通孔及凹凸。又，所得之人工藺草為黑色，其直徑約為1.1mm、空隙率為33%、重量為4700丹尼，使用色彩色差計(Konica Minolta公司製，「GR-410」)測定明度及色度的結果，為L=44.22、a=46.53、b=23.43。
將所得之人工藺草作為横線，將直徑0.5mm的紅色酯線作為縱線，如圖1及圖2所示，得到縱線之間隔4mm、横線之編入數目為90條/10cm，平織且厚度約為2mm的異向性榻榻米表層。
使用色彩色差計(Konica Minolta公司製，「GR-410」)，測定所使用之紅色縱線的明度及色度的結果，為L=25.97、a=0.84、b=-0.22。從此値計算縱線與横線的色差ΔE，色差ΔE為54.5。
所得之異向性榻榻米表層的平面影像顯示於圖3；在與横線平行之方向上，從角度30度的高度所觀察的影像顯示於第4圖；在與縱線平行之方向上，從角度30度的高度所觀察的影像顯示於第5圖。若比較圖3~圖5，則可明確得知平面影像、在與横線平行之方向從角度30度的高度觀察的影像、及在與縱線平行之方向上從角度30度的高度觀察的影像的模樣有所不同。
在所得之異向性榻榻米表層上，積層與異向性榻榻米表層相同形狀、相同面積的厚度60μm的乙烯-乙酸乙烯酯共聚物墊(熱融接合墊)與厚度100μm的聚丙烯樹脂墊(底墊)，再進行加熱加壓以將其接合。即使從垂直方向對於所得之接合有聚丙烯樹脂墊(底墊)的異向性榻榻米表層的人工藺草施加載重，人工藺草亦不會偏移，且異向性榻榻米表層的端部亦無人工藺草脫線的情況。
如圖6所示，將所得之異向性榻榻米表層4，以與聚丙烯樹脂墊(底墊)5相接的方式，積層於厚度約55mm的稻草榻榻米基材6，並將端部捲入稻草榻榻米基材6之端部內側，再將其縫合，而得到厚榻榻米。又，人工藺草的方向，在圖式中為垂直方向。
所得之厚榻榻米品位高尚，且柔軟性、緩衝性良好，即使大力踩踏，人工藺草亦不會偏移。又，若以細棒強力按壓雖會產生凹陷，若移開棒子則馬上復原。又，將異向性榻榻米表層的端部捲入稻草榻榻米基材的端部內側並將其縫合時，人工藺草並無脫線或偏移的情況。
(實施例2)
將聚丙烯樹脂(Japan Polypropylene公司製，商品名「NOVATEC PP Series」，MFR 5.0g/10min，密度0.9g/cm3 ，融點155~165℃)100重量份、碳酸鈣(竹原化學工業公司製，商品名「MAX Series」)27重量份及偶氮系無機顔料(東洋油墨公司製，商品名「PPM54700」)2.2重量份所構成的樹脂組成物供給至螺桿70mm的單軸揉合擠製機，在210℃下進行揉合擠製，而得到厚度100μm的聚丙烯樹脂膜。
使用所得之聚丙烯樹脂膜，以與實施例1相同的方式，進行延伸、成形及加熱，而得到綠色的人工藺草。所得之人工藺草的直徑約為1.1mm，空隙率為33%，重量為4700丹尼。
將聚丙烯樹脂(Japan Polypropylene公司製，商品名「NOVATEC PP Series」，MFR 5.0g/10min，密度0.9g/cm3 ，融點155~165℃)100重量份、碳酸鈣(竹原化學工業公司製，商品名「MAX Series」)27重量份及偶氮系無機顔料(東洋油墨公司製，商品名「PPM8YA094VLT」)2.2重量份所構成的樹脂組成物供給至螺桿70mm的單軸揉合擠製機，在210℃下進行揉合擠製，而得到厚度100μm的聚丙烯樹脂膜。
使用所得之聚丙烯樹脂膜，以與實施例1相同的方式，進行延伸、成形及加熱，得到紫色的人工藺草。所得之人工藺草的直徑約為1.1mm，空隙率為33%，重量為4700丹尼。
將所得之綠色人工藺草與紫色人工藺草交互作為横線，並將直徑0.5mm的紅色酯線作為縱線，如圖1及圖2所示，以縱線間隔4mm、横線的編入數為90條/10cm進行平織，而得到厚度約2mm的異向性榻榻米表層。以色彩色差計(Konica Minolta公司製，「GR-410」)測定時，綠色人工藺草與縱線的色差ΔE為54.7，紫色人工藺草與縱線的色差ΔE為51.0。
將丙烯酸系黏著劑塗布在與所得之異向性榻榻米表層相同形狀、面積稍大的厚度1mm的獨立氣泡發泡聚乙烯樹脂墊(底墊)上，並進行乾燥，而形成黏著劑層。在黏著劑層上，積層所得之異向性榻榻米表層再進行加壓接合，得到厚度約3.0mm的積層榻榻米表層。即使從垂直方向對所得之積層榻榻米表層的人工藺草施加載重，人工藺草亦不會偏移，積層榻榻米表層端部的人工藺草亦不會脫線。
如圖7所示，在厚度4mm、密度0.48g/cm3 、彎強度9N/mm2 的中密度纖維板(MDF)所構成的芯材8之一面上積層厚度4mm的緩衝墊7，該緩衝墊7係將厚度2mm、每單位面積重量200mg/m2 的聚酯纖維製不織布重疊2片而成；再於其上積層所得之厚度約3.0mm的異向性榻榻米表層4，而成為獨立氣泡發泡聚乙烯樹脂墊(底墊)5與緩衝墊7相接的態樣；再將異向性榻榻米表層4端部沿著芯材8及緩衝墊7的側面彎折，並且折入芯材8的內側，藉由高頻熔黏裝置加熱加壓以進行加熱熔黏。
接著，芯材8背面無異向性榻榻米表層4的部分，積層厚度2mm、每單位面積重量200g/m2 (厚度2mm)的聚酯纖維製不織布所構成的段差調整墊10，再於整個背面上積層由厚度2mm、每單位面積重量200mg/m2 的聚酯纖維製不織布所構成的內側緩衝墊11，藉由高頻熔黏裝置將端部加熱加壓以進行加熱熔黏，而得到厚度15.0mm的薄榻榻米。
所得之薄榻榻米品位高尚，且柔軟性、緩衝性優良，即使大力踩踏人工藺草亦不會偏移。又，若以細棒強力按壓雖會產生凹陷，若移開棒子則馬上復原。又，將積層榻榻米表層的端部捲入芯材及緩衝墊的端部內側且加熱熔黏時，人工藺草並無脫線或偏移的情況。
(實施例3)
在1.0~2.5重量份的範圍內添加各種無機顔料(東洋油墨公司製，商品名「PPM Series」)，以代替2.0重量份的偶氮系無機顔料(東洋油墨公司製，商品名「PPM0866」)，除此之外，以與實施例1相同的方式，得到具有各種顏色、厚度100μm的聚丙烯樹脂膜。
使用所得之聚丙烯樹脂膜，以與實施例1相同的方式延伸以進行成形及加熱，而得到人工藺草。所得之人工藺草的直徑約為1.1mm，空隙率為33%，重量為4700丹尼。以色彩色差計(Konica Minolta公司製，「GR-410」)測定所得之人工藺草的L、a、b，其與顏色一起顯示於表1。
將所得之人工藺草作為横線，顯示於表2之顏色的直徑0.5mm聚酯線作為縱線，如圖1及圖2所示，以縱線間隔4mm、横線的編入數90條/10cm進行平織，而得到厚度約2mm的異向性榻榻米表層。以色彩色差計(Konica Minolta公司製，「GR-410」)測定各色聚酯線(縱線)的L、a、b，顯示於表2。又，計算所得之異向性榻榻米表層的横線(人工藺草)與縱線的色差ΔE，結果顯示於表3。
[表1]
Figure 106105407-A0304-0001
[表2]
Figure 106105407-A0304-0002
[表3]
Figure 106105407-A0304-0003
[產業上的利用可能性]
本發明之異向性榻榻米表層，其色相根據視角而不同因而設計性優良，藉由將積層此異向性榻榻米表層的榻榻米配置於室內等，可在室內等，根據視角而使色相不同，進而可提升室內等的裝飾性，故可廣泛用於建築領域。
1‧‧‧人工藺草9‧‧‧人工榻榻米基材2‧‧‧横線10‧‧‧段差調整墊3‧‧‧縱線11‧‧‧內側緩衝墊4‧‧‧異向性榻榻米表層21‧‧‧狹小部5‧‧‧底墊22‧‧‧寬幅部6‧‧‧稻草榻榻米基材200‧‧‧縱線7‧‧‧緩衝墊300‧‧‧横線(藺草)8‧‧‧芯材
圖1係顯示本發明之異向性榻榻米表層之一例的俯視圖。     圖2係圖1中的A-A剖面圖。     圖3係實施例1之異向性榻榻米表層的平面影像。 圖4係在與實施例1之異向性榻榻米表層之縱線平行的方向上，從角度30度的高度觀察的影像。 圖5係在與實施例1之異向性榻榻米表層之横線平行的方向上，從角度30度的高度觀察的影像。 圖6係顯示厚榻榻米之一例的剖面圖。 圖7係顯示薄榻榻米之一例的剖面圖。 圖8係顯示習知榻榻米表層之一例的剖面圖。
1‧‧‧人工藺草
2‧‧‧横線
3‧‧‧縱線
21‧‧‧狹小部
22‧‧‧寬幅部

Claims (7)

  1. 一種異向性榻榻米表層，其係由藺草、合成樹脂所製造的人工藺草、或捻紙人工藺草且直徑為0.5~2mm之橫線與直徑為前述橫線的直徑的5~50%之縱線所構成，相鄰的前述橫線係以彼此緊密連接的方式織成，相鄰的前述縱線係以間隔5~30mm的方式織成，而前述橫線形成狹小部與寬幅部交互的態樣，前述縱線在前述狹小部處通過前述橫線的上部，在前述寬幅部處則通過前述橫線的下方，且以前述縱線在前述狹小部處於榻榻米表層的表面露出的方式織成的榻榻米表層，前述橫線與前述縱線的色差△E為6.0以上。
  2. 如申請專利範圍第1項所述之異向性榻榻米表層，其中，前述合成樹脂所製造的人工藺草，是將烯烴系樹脂、無機填充劑、著色劑所構成的樹脂膜進行單軸延伸而得到帶狀體，再將該帶狀體纏繞為繩狀體，接著使經纏繞的該繩狀體通過具有狹窄的空隙部之加熱構件的該空隙部中，藉此使該繩狀體彼此不規則熔黏成束且表面形成熔黏被膜的人工藺草。
  3. 如申請專利範圍第1項所述之異向性榻榻米表層，其中，前述橫線的顏色為1種或2種以上。
  4. 如申請專利範圍第1項所述之異向性榻榻米表層，其中，前述縱線為麻線、綿線、聚酯線或綿與聚酯的混合線。
  5. 如申請專利範圍第1項所述之異向性榻榻米表層，其中，前述縱線的顏色為1種或2種以上。
  6. 如申請專利範圍第1項所述之異向性榻榻米表層，其藉由平織或斜紋織所織成。
  7. 如申請專利範圍第1項所述之異向性榻榻米表層，其中，更於背面接合底墊。
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