WO2000046466A1

WO2000046466A1 - Thin tatami mat and method of manufacturing the mat

Info

Publication number: WO2000046466A1
Application number: PCT/JP2000/000463
Authority: WO
Inventors: Shigeru Komoriya
Original assignee: Shigeru Komoriya
Priority date: 1999-02-03
Filing date: 2000-01-28
Publication date: 2000-08-10
Also published as: AU2321100A

Abstract

A thin mat (1), comprising a mat surface (2) and a mat bed (3) with the same dimension as the mat surface, wherein the thickness of the thin tatami mat (1) is 5 to 30 mm, desirably 10 to 20 mm, the mat surface (2) is connected to the mat bed (3) through adhesive agent (4), the edge part of the mat surface (2) is chamferred all around the periphery, and a protective film (6) made of an adhesive resin material which is spread extending from the chamferred part (5) of the mat surface (2) to the side face of the mat bed (3) is formed on the side faces of the mat (1) in addition to the chamferred part (5), whereby an inexpensive border-free thin tatami mat can be manufactured and laid down without necessitating a traditional skill.

Description

Description Thin tatami mat and method for producing the same

The present invention relates generally to tatami mats, and more particularly to a thin tatami mat having a thickness of 5 to 30 bandages and a method for producing the same. Background art

Traditionally, tatami mats have been used as the material for the floor of the main building B, but recently, tatami mats have been laid on a part of the western floor and used as a carpet. Has been proposed. Here, traditional tatami mats consist of a tatami mat made of straw material, a tatami mat made of rush, placed on and sewn to the tatami mat, extending along the sides (both side edges) of the tatami mat and They are made from tatami floors and sewn rims. Under such circumstances, tatami mats are made of synthetic resin products such as polypropylene instead of rush as a material for tatami mats (see Japanese Patent Application Laid-Open No. Hei 9-960260). In place of straw, foams mainly made of foam such as expanded polystyrene (see Japanese Patent Application Laid-Open Nos. Hei 7-189463 and Hei 8-151774) have begun to be widely used. As described above, traditionally, tatami mats are sewn with fringes that extend along both side edges. Tatami designed in Japan have also begun to appear (see Japanese Patent Application Laid-Open No. 9-195485).

As mentioned above, the use and materials of tatami mats have been diversified, and tatami mats without borders have also emerged.However, the method of making tatami mats is basically the same as before, and even today Be made with different techniques

By the way, if you explain how to make traditional tatami mats according to the process, It is a cage.

(1) Place the tatami mat on the tatami floor;

(2) Fold both ends of the tatami mat to the back of the longitudinal end of the tatami floor, that is, to the back of the frame;

(3) cutting both side edges or side edges of the tatami mat along the side edges of the tatami floor, ie, the sides of the tatami floor;

(4) Place the inverted edge band on both sides of the tatami surface, and sew the edge band on the tatami floor through the tatami surface;

(5) Fold the marginal band along the seam, sew along the side of the tatami floor, and sew it to the side of the tatami floor.

The method of making the tatami disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 9-195485 will be described. Except for the step of sewing the edge band of the traditional tatami manufacturing method described above, It is basically the same as traditional tatami. That is,

(1) Place the tatami mat on the tatami floor;

(3) Fold both sides of the tatami mat so as to cover the sides of the tatami mat floor, and sew it to the side of the tatami mat floor. Disclosure of the invention

SUMMARY OF THE INVENTION An object of the present invention is to provide a thin tatami mat that can be manufactured without requiring an artisan's skill and a method for manufacturing the same.

Another object of the present invention is to provide a thin tatami mat capable of reducing the production cost and a method for producing the same.

Another object of the present invention is to provide a thin tatami mat that can facilitate the work of installing tatami mats in a room. It is a further object of the present invention to provide a borderless thin tatami mat that can be made without the need for craftsmanship skills and a method of making the same.

According to the present invention,

With tatami floors,

A tatami mat having the same size as the tatami floor and adhered to the surface of the tatami floor;

Means for preventing fluffing of the 緣 portion of the tatami mat surface adhered to the tatami mat floor.

The thickness of the tatami mat according to the present invention is generally 530, preferably 52 Omm, most preferably 102 Omm. As means for preventing fluffing, for example, an adhesive tape covering the edges of the tatami mat and the sides of the tatami mat floor may be used.Also, the edge of the tatami mat may be chamfered, and the chamfered portion may be covered with a protective film. Alternatively, the edge portion of the tatami mat may be subjected to a heat press treatment to flatten the edge portion, and the flattened portion may be covered with a protective film. The protective film is preferably formed by applying an adhesive resin material such as natural rubber or latex resin to the edge of the tatami mat. The protective film may extend from the edge of the tatami mat to the side of the tatami mat floor.

The tatami mat is typically a natural rush, but as other examples, it may be selected from resin rush (a tatami mat product) made of a synthetic resin and a material made of a wood fiber. The tatami floor may be made of a rubbery or suitably resilient material such as foam or felt. When the tatami mat according to the present invention is discarded and burned, it is preferable to make the tatami mat from a material that generates less harmful components as a measure against environmental problems. A suitable material is a composite foam or felt of calcium carbonate and polyolefin. In addition, according to the present invention,

A method for manufacturing a thin tatami mat having a tatami mat and a tatami mat having a thickness of 53 Omm, comprising: preparing a tatami mat;

Preparing a tatami mat having the same size as the tatami mat floor; Bonding the tatami mat to the tatami mat floor.

The advantages and other objects of the present invention will become apparent from the following description of embodiments of the present invention. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a plan view showing an example of how to lay a tatami mat without a band according to the present invention.

FIG. 2 is a partial cross-sectional view for explaining the chamfering of the edge of the tatami mat in the tatami mat without a band according to the present invention.

FIG. 3 is a partial cross-sectional view of a frame or width edge portion of a tatami mat without a band according to the present invention. FIG. 4 is a plan view of a tatami-mat without rims for illustrating the arrangement of a double-sided adhesive tape adhered to the bottom surface of the tatami mat without mats according to the present invention.

FIG. 5 is a diagram for illustrating fixing a tatami-mat without rims to a curing sheet laid on the floor of a room.

FIG. 6 is a partial sectional view of a tatami floorless tatami mat according to the present invention having a tatami floor laminated structure. FIG. 7 is a partial cross-sectional view for explaining the hot press processing of the edge portion of the tatami mat in the tatami mat without rim band according to the present invention. BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

In FIG. 1, reference numeral 1 denotes a thin tatami mat with a margin band according to the present invention. The thin tatami mat 1 without a rim has a tatami table 2 made of natural rush or synthetic resin product or wood fiber, and a tatami floor 3, and the tatami table 2 and the tatami floor 3 are integrated by an adhesive 4. . The tatami floor 3 may be mainly made of a resin foam, a resin board, or a wood-based board, or may be mainly made of a board made of natural or synthetic rubber. May be combined. The tatami floor 3 may have, for example, a laminated structure in which a rubber G (FIG. 6) is attached to the bottom surface of the wooden board W. As another example, the tatami floor 3 may have a laminated structure of a main layer of natural or synthetic rubber and an upper layer made of a composite foam or felt of calcium carbonate and polyethylene or polyolefin thereon. As another example, the tatami floor 3 is an intermediate layer of wooden board between a main layer of natural or synthetic rubber and an upper layer of composite foam or felt of calcium carbonate and polyethylene or polyolefin. It may have a laminated structure including layers, and may further have a rubber layer on the bottom surface. The tatami floor 3 may have a single-layer structure made of a composite foam of calcium carbonate and polyethylene or polyolefin. As a material of the tatami floor 3, a composite foam or felt of carbonated lime and polyolefin is most preferable in consideration of both cushioning property and environmental issues. This composite foam does not generate any harmful gas when it is burned, and therefore does not cause any environmental problems when the thin tatami 1 is discarded. If the problem of warpage of the tatami mat 1 is taken into consideration, it is advisable to add a rubber layer to the bottom of the layer made of a composite foam of calcium carbonate and polyolefin or phenolate.

As the thin tatami mat 1 without a margin band, it is most preferable to use a tatami mat 2 of a natural rush that has been heated and pressed. Pressing the tatami mat 2 before bonding it to the tatami floor 3 has the advantage that folding and uneven weaving disappear and the quality is stable. In particular, in the case of a tatami mat using natural rush, chlorophyll is leached from the inside of the natural rush by the effect of the heating press, which has the advantage that color unevenness during dyeing can be reduced.

As the material of Tatami Table 2, a material in which a plurality of natural rushes are connected in the middle may be used. Tatami Table 2 generally uses a single rush that extends in the width direction, and the portion that is used is the portion that is sandwiched between the tip of a single rush and the root. In other words, since the front part and the root part of the rush are cut off and used enough, the rush trade is 1 m taking into account the width of about 90 Omm or about 88 Omm of the tatami mat. In the above rush The fact is that trade is limited, and shorter rushes are discarded as unusable.

In the case of high-class tatami mats, only the best part of the rush that is longer than 1 m is used, and tatami mats are made using a material that is joined in the width direction of the tatami mats. In the industry, this tying technique is called “medium tying”. The tatami mat 2 of the thin tatami mat 1 of the present invention is preferably made of a material having a predetermined length by connecting two or three short rushes to be disposed of.

The tatami table 2 is preferably adhered to the entire surface of the tatami floor 3 with an adhesive 4 applied in a streaky manner at intervals of, for example, 1 Omm. The adhesive 4 used here may be a commercially available adhesive having appropriate durability, but because it does not generate harmful substances such as formaldehyde, and has flexibility and strong adhesive strength. Preferably, a hot melt adhesive is used, and most preferably, a heat-resistant hot melt agent is used. By heating and pressing the tatami table 2 as described above, it is easy to appropriately bond the tatami table 2 to the tatami floor 3 and, thereby, to improve the flatness of the thin tatami mat 1 without the rim band. The advantage is that you can do it.

After bonding the tatami mat 2 on the tatami mat floor 3, the thin tatami mat 1 with no rim band should take measures to prevent “fraying”, “fuzz” or “peeling” of the edge of the tatami mat 2. As one of these measures, the edge of Tatami Table 2 is chamfered over the entire circumference (Fig. 2). As a modification, the periphery of the tatami table 2 may be flattened by hot pressing (FIG. 7). After treating the peripheral portion 5 in this manner, a protective film 6 is formed on at least the peripheral portion 5 of the tatami table 2. The protective film 6 may extend to the side of the thin tatami mat 1 (the side of the tatami floor 3). The protective film 6 is slightly infiltrated into the tatami mat and the tatami mat floor and solidified, and retains appropriate flexibility when solidified. For example, it is preferable to use a natural rubber or a latex resin thin ₃無し1 can improve the appearance when tatami mat 1 is laid by chamfering and / or pressing the edge of tatami mat 2. Wear. Further, by covering the edge portion 5 of the thin tatami mat 1 without a margin band with the protective film 6, "fraying", "fuzz" or "peeling" in the tatami table 2 can be prevented. As another means to prevent “fraying”, “fuzz” or “peeling” of the edge of the tatami table 2, prepare a transparent or colored adhesive tape, and use this adhesive tape to It may be attached to the side of the tatami floor 3.

The method of manufacturing the thin tatami mat 1 according to the present invention will be described below.

(1) Apply adhesive 4 to the entire surface of tatami floor 3;

(2) Glue the tatami table 2 onto the tatami floor 3;

(3) The integrated tatami table 2 and tatami floor 3 are cut to a fixed size, such as a single tatami mat or a half tatami mat, or to a size determined by measuring the room to be laid;

(4) chamfering or edge-pressing the edge portion 5 of the tatami table 2 all around;

(5) At least the edge portion 5 of the tatami mat 2 is coated with an adhesive resin such as a latetus resin to form a protective film 6.

As can be understood from the above description of the manufacturing method, a thin tatami mat 1 according to the present invention can be produced even by a non-tatami craftsman, and the number of steps is smaller than in the past, so that the manufacturing cost can be reduced. It is possible to provide thin tatami 1 at low cost.

FIG. 1 illustrates a method of using the thin tatami mat 1 without a border according to the present invention, and illustrates a laying example that can give unexpectedness to the arrangement of eyes and the combination of geometric shapes in the tatami table 2. Things. In this example, after measuring the room to be laid and the space to be laid between the oceans, determining the size and shape of each tatami mat from this measured data, and Manufactured. Of course, it is also possible to carry the standardized thin tatami mat 1 without borders for mass production to the laying site, and cut the tatami 1 appropriately at this site to lay the tatami mat 1 as shown in Fig. 1. Good. Since the tatami mat 1 according to the present invention has the tatami mat 2 adhered to the entire surface of the tatami mat floor 3, any part of the tatami mat 1 can be cut. The newly exposed cut surface obtained by cutting Tatami 1 has an appropriate adhesive property after chamfering the edge of Tatami Table 2. The protective film 6 may be formed by applying a resin material. Such a series of work can be sufficiently performed by a layman even if he is not a tatami craftsman. Therefore, even if it is a special way of laying as shown in Fig. 1, a tatami craftsman is not required to do this, and it is possible to cope with the work alone.

The thin tatami mat 1 without a margin band according to the present invention can be provided to the general public through a different route from before, as described below. That is, for example, one tatami mat (approximately 900 thighs X 180 thighs or about 880 mm tall XI 760 thighs) or half tatami mats (approximately 90 O mm X 900 mm or about 880 thighs X 8 (80 mm), a large number of thin tatami mats 1 without borders standardized to an appropriate size and sold to the general public. For example, a part of the flooring between the oceans can be cut into tatami mats. When the tatami 1 is laid, it is preferable to set the thickness of the thin tatami 1 without borders to be relatively thin in order to facilitate the cutting work of the tatami 1. Specifically, the tatami 1 has a thickness of about 5 to 30 mm, preferably about 5 to 25 thighs, more preferably 5 to 20 mm, and most preferably 10 to 20 mm. You should be awake. Tatami with a thickness of about 30 mm is called “thin tatami” in the industry, but making it thinner than before is advantageous for cost and cutting tatami floors.緣 When the thin tatami without obi 1 is manufactured as a thin tatami mat, when it is laid between Japan, if the thickness dimension is insufficient compared to the height dimension of the sill, it will be A thickness adjustment board (not shown) is laid between Japan in advance, and a thin tatami-mat 1 is laid on the thickness adjustment board, so that the upper surface of the thin tatami 1 and the upper face of the threshold are laid. What is necessary is just to make it the same height level.

As described above, such an operation can be adequately performed by an unskilled person. That is, the newly exposed cut surface obtained by cutting the tatami 1 can be sufficiently covered with the protective film 6 by chamfering the edge of the tatami mat 2 and then applying an appropriate adhesive. The cutting tool and the resin material for forming the protective film 6 may be sold as a set. If desired, lay thin tatami mats 1 After that, an edge band member for retrofitting may be attached between the outermost tatami mat and the sill, for example, as described in JP-A-9-195485.

The problem of "warpage" that may occur after the laying of the thin tatami mat 1 without rims, particularly the problem of "warping" that is likely to occur when the thin tatami mat 1 without a rim according to the present invention is manufactured as a thin tatami mat is For example, at the time of shipment from the factory, as shown in FIG. 4, a plurality of double-sided adhesive tapes 7 provided with a release tape (not shown) are attached to appropriate locations on the bottom of the thin tatami mat 1 without a border band. At the time of laying, the peeling tape of the double-sided adhesive tape may be removed, and the thin tatami mat 1 without a band may be adhered to the floor of the room. As described above, the "warp" problem of the thin tatami mat 1 can be dealt with by forming the tatami floor 3 into a laminated structure including a plurality of layers. For example, as described above, if a tatami floor 3 having a rubber layer at the bottom is adopted, not only can the cushioning property of the tatami 1 be added to the tatami mat 1 by this rubber layer, but also the warp of the tatami mat 1 Can be prevented. In particular, when the tatami mat 1 is used in an environment in which the warp of the tatami mat is likely to be induced, a layer made of a material having relatively low elasticity, for example, a PVC resin layer is laminated on the bottom of the tatami mat floor 3. Is also good.

The problem of warpage of the thin tatami mat 1 without margin can be solved from the viewpoint of the method of laying it. 'That is, before the tatami mat 1 is laid, as shown in Fig. 5, a plurality of curing sheets 8 are partially overlapped with each other on the floor of the room R, and the thin tatami mat 1 without a border band is laid thereon. Fixing with double-sided adhesive tape (not shown) has the advantage that warpage can be prevented without damaging the room floor. Therefore, for example, even if a plurality of tatami mats 1 are laid in whole or part of the flooring in the ocean, the tatami mats 1 are not directly fixed to the flooring. Even if removed, there is no problem in restoring room R. Industrial applicability ADVANTAGE OF THE INVENTION According to this invention, a thin tatami can be manufactured without requiring the skill of a tatami craftsman, and since the number of processes is smaller than before, the manufacturing cost can be reduced and a thin tatami can be provided at low cost. can do. Also, the work of installing tatami mats in the room can be facilitated, and the construction cost can be significantly reduced.

Claims

The scope of the claims

1. Tatami floor and

Means for preventing fluffing of an edge portion of the tatami mat surface adhered to the tatami mat floor.

2. The thin tatami mat according to claim 1, wherein the tatami mat floor and the tatami mat table are adhered by an adhesive applied in a streak shape.

3. The method according to claim 1 or 2, wherein the means for preventing fluffing comprises, after chamfering an edge portion of the tatami mat surface, covering the chamfered portion with a protective film. Thin tatami.

4. The method according to claim 1, wherein the means for preventing fluffing comprises applying heat press treatment to an edge portion of the tatami surface, flattening the flat portion, and covering the flattened portion with a protective film. Item 3. The thin tatami mat according to item 2 or.

5. The thin tatami mat according to any one of claims 1 to 4, wherein the tatami mat is made of a material selected from a natural rush, a tatami mat product made of a synthetic resin, and a wood fiber.

6. The thin tatami mat according to any one of claims 1 to 5, wherein the tatami mat comprises a tatami mat subjected to heat press working.

7. The thin tatami mat according to any one of claims 1 to 6, wherein the tatami mat floor is made of a composite foam or felt of calcium carbonate and polyethylene or polyolefin.

8. The tatami floor according to claim 1, wherein the tatami floor has a rubber layer or a resin layer having relatively little elasticity provided at the bottom of the layer made of the composite foam or the composite of calcium carbonate and polyolefin. 7. A thin tatami mat according to any one of claims 6 to 6.

9. The method according to claim 1, wherein the thin tatami mat has a thickness of 5 to 30 marauders. The thin tatami mat described in somewhere.

10. The thin tatami according to claim 1, wherein the thin tatami has a thickness of 10 to 20 mm.

11. The thin tatami mat according to claim 3, wherein the protective film is formed by applying an adhesive resin to the chamfered portion.

12. The thin tatami mat according to claim 11, wherein the adhesive resin is a latex resin.

13. The thin tatami mat without a border band according to any one of claims 1 to 12, wherein the tatami mat is made from a middle rush of natural rushes joined together.

14. A tatami floor having a layer composed of a composite foam of calcium carbonate and polyolefin,

A tatami mat having the same size as the tatami mat floor and bonded to the surface of the tatami mat with a hot melt adhesive;

The edge portion of the tatami mat surface bonded to the tatami floor is flattened by chamfering and / or hot pressing, and formed by applying a natural rubber or latex resin to the chamfered portion and the Z or flattened portion. A thin tatami mat without a band, characterized by having a protective film provided.

15. A method for producing thin tatami mats having a tatami mat surface and a tatami mat floor and having a thickness of 5 to 3 O mm,

Preparing a tatami floor,

Preparing a tatami mat having the same size as the tatami floor,

Bonding the tatami mat to the tatami floor,

Providing means for preventing fluffing of the edges of the tatami mat adhered to the tatami mat floor.

1 6. The step of providing a means for preventing fluffing of the edge of the tatami mat comprises:

The peripheral part of the tatami mat surface bonded to the tatami floor is hot pressed to flatten or The process of taking

16. The method for producing a thin tatami mat according to claim 15, comprising: forming a protective film by applying an adhesive resin to the flattened or chamfered portion.

17. The method according to claim 15, wherein the step of bonding the tatami mat to the tatami mat floor includes a step of applying an adhesive to the tatami mat floor and / or the tatami mat in a streak form. 16. The method for producing a thin tatami mat according to item 6.