JPS5951902B2 - Chemical bed manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a chemical floor made of a synthetic floor material, in which the floor thickness is thinner than that of a standard bone method.

As is well known in recent years, the traditional bone method of compressing and weaving rice straw has gradually changed to using hard foamed synthetic resin plates as the main core material due to the difficulty in obtaining rice straw as the main raw material and the rising cost of production. Synthetic bone methods with composite structures are becoming widely used.

Naturally, such a composite bone structure is lighter than a bone structure made of rice straw, and since plywood is used as a reinforcing material, sufficient bending strength can be obtained.
Therefore, even if the bone method has a thin floor, which is difficult to produce in large quantities with conventional straw flooring alone, if the bone method has a composite structure with plywood interior, which has high bending strength, it is possible to use foamed material as the core material. By reducing the thickness of the resin board, a bone method with a thin floor can be obtained.

For items thinner than these standard dimensions, tatami can be laid out for a short period of time in large rooms made of other flooring materials (such as wooden floors in community centers, gymnasiums, etc.) and used for special sales at events such as kimono markets. You can use it for events such as this, or change the pattern of a Western-style room by laying tatami to make it look like a Japanese-style room. And because the flooring is raised, it is easy to handle, even though if you lay standard tatami in a Western-style room, the tatami would protrude beyond the threshold, making it inconvenient to enter and exit the room, or causing problems with the appearance. Because of these advantages, it is used in some areas. However, in the composite bone method with a reduced thickness, the foamed synthetic resin plate that is the main part of the core material is made thinner, so the overall warpage and the feeling of stepping on it during use are naturally lower than that of standard size ones. In addition, with this bone method, a tatami mat surface must be pasted on the surface and a sewing process similar to that of conventional tatami mats must be performed, and the work of finishing the tatami mat to the required dimensions requires a long time for the tatami mat surface. Since it is necessary prior to sewing, it is necessary to configure it so as not to cause any hindrance during such work.

However, since the main material of the floor core material is a hard foamed synthetic resin board (e.g. foamed polystyrene resin, foamed polyurethane resin, etc.), when adjusting the dimensions of the frame and sewing the tatami facing, the tatami sash department has to place the tatami facing on the back side. When folding and sewing, there are problems such as the foamed synthetic resin board of the flooring material being chipped, or the sewing thread being difficult to tighten sufficiently, which requires time and effort, and the finish tends to be uneven. The present invention provides a function that allows thin tatami mats that have many of these problems to be used normally without any problems during use or in the process of finishing them as tatami mats, and to the same extent as standard composite tatami mats. It is an object of the present invention to provide a method that enables efficient production of the same.

When manufacturing a composite tatami floor, the present invention provides a core material made of a rigid foamed synthetic resin of a required size that is placed on top of a waterproof paper sheet that is continuously or intermittently supplied in a predetermined size. A shallow step with an appropriate size is formed from both ends of the material, wooden plywood is glued to the entire surface of the step, and a wooden plywood of approximately the same size as the core is layered on the top of the core.
Further, a soft and relatively thick foamed synthetic resin sheet is laminated on the top surface, and the thus laminated sheets are sewn together in large numbers at appropriate intervals in the longitudinal direction. The reason is that the middle part of the sheet between the sewn lines is made to float slightly.

Hereinafter, the present invention will be described in detail with reference to the drawings regarding one embodiment.
As shown in Figures 1 to 3, when constructing the composite tatami floor 1, first a general tatami core, which is slightly larger than the tatami size, is placed on the reinforced waterproof paper sheet 2 placed on the back side of the tatami floor. A hard foamed synthetic resin core material 3 such as a hard foamed polyurethane board sized to a thickness smaller than A shallow stepped portion 3'' with an appropriate width is formed, and wooden plywood pieces 4 having a width that exactly fits into this stepped portion 3'' are glued together, and the wooden plywood pieces 4 are stacked so that they are in contact with the waterproof paper sheet 2 side. Match.

A thin wooden plywood 5 of approximately the same dimensions as the core material 3 is layered on the top surface of the core material 3, and a soft and relatively thick foamed synthetic resin sheet 6 such as a foamed polyethylene sheet is further placed on the top surface of the core material 3. Then, as shown in FIG. 1, they are stacked one on top of the other in a slightly larger size, and then, as shown in FIG. 1, they are sewn together with multi-thread sewing thread 7 at appropriate pitches using a sewing machine while remaining laminated as described above, to form an integral piece. At this time, the foamed synthetic resin sheet 6 of the uppermost layer is constructed so as to float appropriately between the sewn portions 8 as shown in FIG. 3 without tension. The above-mentioned lamination and stitching work can be efficiently carried out by sequentially stacking pre-sized cushioning materials such as core material, plywood, or foamed synthetic resin sheets on a waterproof paper sheet and performing the work continuously. The core material 3 is generally a foamed synthetic resin board formed to a required size, for example, 20 mm in thickness, and sized to be slightly larger than the tatami size (standard size) as described above. A core material with wooden boards attached to both ends is provided, including a step of pre-processing and forming the stepped portion 3'' and a step of gluing and integrating wooden plywood pieces 4 to the shallow step portion 3'' with adhesive. Work efficiency can be improved by being able to supply it to the conveyor line as a raw material. Furthermore, if a long soft synthetic resin sheet is used as the top layer of cushioning material, the stacked core material and wooden plywood can be connected and moved on a conveyor while being fed to the top, making it more effective. This means that you can do the work. By doing this, when manufacturing a composite tatami floor, when the laminated materials are sewn together to produce a thinner tatami floor than a standard tatami floor, it becomes more flexible with respect to the waterproof paper sheet that forms the back side. By sewing multiple threads at appropriate intervals with the high-strength soft foam synthetic resin sheet side released from tension, it is generally possible to cause warping by being pulled toward the top side of the tatami floor. It is now possible to obtain a thin tatami floor with no warpage by sewing it into an almost flat state. When the front edge of the tatami mat is folded back to the back side and sewn to the tatami floor, the sewing force applied to the wooden plywood piece attached to the edge of the core material is used to secure the wooden plywood piece to the edge of the tatami floor stile. Since it covers the board core material, no matter how strong the sewing force is applied, the core material will not chip and can be sewn reliably.

In addition, the cushioning material sheet placed on the top side of the tatami floor is sewn in such a way that it is completely floating except for the seamed part.
When manufacturing the tatami floor, the sheet is fed with a low tension to prevent warpage caused by the stitching as described above.Furthermore, after the tatami is finished, the loose stitching of the cushioning sheet prevents it from warping. It was given cushioning properties comparable to rice straw flooring, and even thin composite tatami mats could now be made to be similar to standard-sized tatami mats.

[Brief Description of the Drawings] Fig. 1 is a partially cutaway perspective view of a tatami floor obtained by the method of the present invention, Fig. 2 is a vertical cross-sectional view of the tatami floor with the middle part omitted, and Fig. 3
The figure is a sectional view taken along line XX in FIG. 2. 1... Composite tatami floor, 2... Waterproof paper sheet, 3... Core material, 3'... Shallow step, 4... - Wooden plywood piece, 5... Wooden plywood, 6... Soft foam synthetic resin sheet, 8...
...Sewing section.

Claims (1)

[Claims] 1. When manufacturing thin composite tatami flooring mainly consisting of a synthetic resin core material, the hard foam synthetic resin core material of the required size is placed on top of a waterproof paper sheet that is supplied continuously or intermittently in a predetermined size. On the lower surface of both ends in the longitudinal direction, shallow steps of appropriate dimensions are formed from both edges of the core material, and wooden plywood pieces are glued to the entire surface of each step, and the upper surface of the core material is is made by layering wooden plywood of approximately the same size as the core material, and then laminating a soft and relatively thick foamed synthetic resin sheet on top,
The laminated material is sewn together in a large number at appropriate intervals in the longitudinal direction, and when sewn together, the uppermost layer of the soft foamed synthetic resin sheet is made so that the middle part between the sewn edges is lifted up. A method of manufacturing a chemical bed.