JP5438366B2 - Synthetic tatami mat - Google Patents

Description

  The present invention relates to a synthetic tatami mat that achieves weight reduction and easy handling by using a rice straw substitute as a core material, and a method of manufacturing the same.

  In recent years, the number of highly airtight and highly insulated houses has increased, and building materials are required to have functions such as airtightness, heat insulation, and waterproofness. As a tatami mat to meet this demand, there is a synthetic tatami mat that uses a core material made of foamed plastic instead of rice straw, which is a natural material. Since this synthetic tatami mat does not escape the room temperature and can prevent cooling from under the floor, there is an advantage that a comfortable house that is cool in summer and warm in winter can be realized.

  By the way, with a foamed plastic core material alone, there is a risk that corners may be damaged due to impact, etc., or sag may occur due to trampling. A material is provided, and the back material prevents damage and deformation of the core material and softens the impact on the load.

  As this back material, for example, as disclosed in Patent Document 1, it is known to use a plastic hollow laminate that is lightweight and has high strength.

  This hollow plastic laminate is called a plastic corrugated cardboard and generally has a three-layer structure. That is, the hollow laminated body is a structure in which a hollow structure such as a cylinder or a square tube is installed between two resin sheets at predetermined intervals, thereby ensuring cushioning properties.

JP-A-8-232447

  However, the plastic corrugated board having a three-layer structure is robust, but requires a large radius of curvature with respect to the warp, and can only be managed in a flat plate shape. Therefore, when using plastic corrugated cardboard, it is common to cut and store one by one and use it after making it into a sheet-like load. As described above, the plastic corrugated cardboard that has been used conventionally has been a factor of high cost when producing synthetic tatami mats because it requires time and effort for storage and handling.

  In addition, in the conventional synthetic tatami mat, when condensation occurs between the floor and the synthetic tatami mat due to the difference between the room temperature and the outside air temperature, the moisture on the back side may remain near the core material and cause mold. It was.

  The present invention has been made in view of the above circumstances, and an object thereof is to provide a synthetic tatami mat that contributes to cost reduction of the synthetic tatami mat and can exhibit a moisture-proof function on the back surface side, and a manufacturing method thereof.

In order to achieve the above object, the synthetic tatami mat according to the present invention comprises a resin sheet and a piece of plastic corrugated cardboard comprising a hollow structure disposed at predetermined intervals on the resin sheet , with the synthetic resin plate as a core material. Rutotomoni is provided as a rear material tatami, there was opened surface not of the resin sheet, it is characterized in that it is arranged so as to face the back surface of the core material.

Further, the synthetic tatami mat manufacturing method according to the present invention includes a sheet from a roll body of a single plastic corrugated cardboard wound in a roll comprising a resin sheet and a hollow structure disposed at predetermined intervals on the resin sheet. The sheet-shaped piece plastic corrugated cardboard is pulled out, and the sheet-shaped piece plastic corrugated cardboard is pulled out of the synthetic resin plate with the core material so that the open surface where the resin sheet does not exist faces the back surface of the core material. It arrange | positions as a back surface material of the tatami floor to perform, and is cut | disconnected from the said roll body as one sheet | seat at the time of sewing.

  With the synthetic tatami mat having such a structure and its manufacturing method, the single plastic corrugated cardboard can be wound in a roll shape, and if drawn from here, it is suitable for use in continuous production, and the manufacturing cost is reduced. be able to. Further, even if moisture may accumulate on the back side of the back material, since the intrusion can be prevented by the single plastic corrugated cardboard, mold or the like does not occur.

  According to the synthetic tatami mat and synthetic tatami mat manufacturing method of the present invention, the piece plastic corrugated cardboard can be wound into a roll at the stage of production. Continuous production is possible. Therefore, the manufacturing cost of the synthetic tatami mat can be reduced.

  Further, according to the synthetic tatami mat of the present invention, since there is no paper member on the back side and only one piece of plastic cardboard is present, moisture resistance can be ensured on the back side of the core material.

FIG. 1 is a sectional view of a synthetic tatami mat according to an embodiment of the present invention. FIG. 2 is a cutaway perspective view of a piece of plastic corrugated cardboard employed in an embodiment of the present invention.

  FIG. 1 is a partial longitudinal sectional view of a synthetic tatami mat A according to an embodiment of the present invention, and is laid on a floor surface in this posture.

  The synthetic tatami mat A has a core material 1 formed by molding foamed plastic into a plate shape having a thickness of 10 mm to 60 mm, for example. Examples of the foamed plastic include those obtained by foaming thermoplastic plastics such as polystyrene, polyethylene, polypropylene, polyvinyl chloride, rigid polyurethane, and phenol resin at an appropriate magnification. Among these, it is preferable to use the trade name Kanelite Foam (manufactured by Kaneka Corporation), which is a polystyrene foam. This foam has excellent heat insulation performance, almost no water absorption / moisture retention, does not contain chlorofluorocarbon or formaldehyde, has good machinability, has compressive strength and bending strength, and is amazing It is effective as a core material for synthetic tatami mats because of its stickiness.

  A reinforcing plate 2 of about 3 mm to 10 mm is installed on the upper surface side of the core material 1.

  Examples of the reinforcing plate 2 include a glass fiber press board in which glass fiber is mixed with polypropylene. This glass fiber press board is a mixed plate widely used for automobile interior parts and the like, and is commercially available, for example, under the trade name GF-PP press board from Nakagawa Sangyo Co., Ltd. Such a glass fiber press board has advantages such as extremely high tensile strength, excellent heat resistance, incombustibility, resistance to chemicals, good electrical insulation, low moisture absorption, and excellent sound absorption.

A sheet-like protective material 4 is provided on the upper side of the reinforcing plate 2. This protective material 4 is made of polyester nonwoven fabric or polypropylene nonwoven fabric that can protect the tatami front and back surfaces and the reinforcing material, and has a thickness of 1 to 3 m.
It is set to about m. The surface side of the protective material 4 is covered with a tatami surface 7 made of rush of about 3 mm.

  On the other hand, a back surface material is provided on the back surface side of the core material 1, that is, the lower side in the drawing.

  As shown in FIG. 2, this back material is composed of a single plastic corrugated cardboard 5.

Here, in the present specification, as shown in FIG. 2, the single plastic corrugated cardboard 5 includes a single resin sheet 8 and a hollow structure 9 made of resin on one side of the resin sheet 8 at predetermined intervals. Means the one installed in Therefore, in the single plastic corrugated cardboard 5, one side of the hollow structure 9 is open, and when another resin sheet 8 is welded to the open surface, a three-layer plastic corrugated cardboard is formed. Incidentally, the hollow structure 9, if the structure constituting the air chamber 9a inside, such as square-shaped or circular, may be any shape.

  Examples of the plastic composing the single plastic corrugated board 5 include thermoplastic plastics such as vinyl chloride, polypropylene, polyethylene, and ABS resin. This piece plastic corrugated board 5 is used by setting the thickness to 1 to 10 mm, preferably about 5 to 7 mm.

  Since the piece plastic corrugated board 5 used in this embodiment is opened without a resin sheet welded on one side, a long object having the cross-sectional structure of FIG. 2 is wound into a small-diameter roll. The sheet can be pulled out from the roll body.

  Therefore, when using such a piece plastic corrugated cardboard 5 for synthetic mat A, it can be used, for example, by drawing it from a roll body into a sheet form, without cutting into a predetermined size and then stacking. Therefore, it can be cut one by one when it is pulled out from the roll body and laminated on the lower surface side of the core material 1 and is secured by sewing with a sewing thread. If used in this way, continuous work can be performed as compared with the case of cutting one sheet at a time in advance, so that workability is good and synthetic tatami mats can be manufactured at low cost.

  In the present embodiment, the open surface of the piece plastic corrugated cardboard 5 where the resin sheet does not exist is disposed so as to face the back surface of the core material 1.

  The tatami mat 7, the protective material 4, the reinforcing material 2, the core material 1, and the piece plastic corrugated cardboard 5 (back surface material) are stitched together with a sewing thread (not shown) to produce a synthetic tatami mat A. As the sewing thread, a vinylon type or polypropylene type thread is used.

  According to the synthetic tatami mat A having the above configuration, when a load is applied from the upper side, the load is transmitted to the core member 1 through the upper reinforcing member 2 and further has a sufficient strength in the compression direction. Since the load is transmitted to the corrugated cardboard 5, the load can be absorbed. Further, the single plastic corrugated cardboard 5 prevents settling and can withstand long-term use.

  Although the synthetic tatami mat A and the manufacturing method thereof according to one embodiment of the present invention have been described above, the present invention is not limited to the above embodiment.

  For example, in the synthetic tatami mat A of the above embodiment, the reinforcing material 2 is provided only on the upper side, but the present invention is not limited to this, and the reinforcing material 2 may be installed on both the upper side and the lower side.

Moreover, when arrange | positioning the reinforcing material 2 up and down, the thickness of these reinforcing materials 2 does not need to be the same, and can be adjusted suitably.

  The present invention is applicable to any synthetic tatami mat as long as the back mat is installed on the lower surface side of the core material, and the configuration above the core material is not limited at all. .

1 Core material 2 Reinforcement material 4 Protective material 5 Back material (single plastic cardboard)
7 Tatami Table 8 Resin Sheet 9 Hollow Structure 9a Air Chamber A Synthetic Tatami

Claims (2)

And the resin sheet, single plastic cardboard consisting of a hollow structure and arranged in every predetermined intervals on the resin sheet, is provided with a synthetic resin plate as a rear material tatami that the core material Rutotomoni, of the resin sheet A synthetic tatami mat , wherein the open surface that does not exist is disposed so as to face the back surface of the core member . The sheet-shaped piece plastic corrugated cardboard is pulled out from the roll body of the piece plastic corrugated cardboard wound in the form of a roll consisting of a resin sheet and a hollow structure disposed at predetermined intervals on the resin sheet . A sheet-like piece of plastic corrugated cardboard is placed as a back surface material of a tatami floor with a synthetic resin plate as a core material so that the open surface where the resin sheet does not exist faces the back surface of the core material. A synthetic tatami mat manufacturing method, wherein the sheet is cut from the roll body as a single sheet.

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