Thin tatami mat and method for manufacturing the same

Abstract

To provide a thin tatami mat capable of surely preventing reverse bending which has occurred when a mat surface is stuck to a mat floor as it is formed thinner than a conventional tatami mat.SOLUTION: This thin tatami mat comprises: a mat floor; and a mat surface stuck to the surface of the mat floor. The mat floor is provided with a core member, a glass fiber-containing sheet bonded to the surface of the core member, and a polyolefin-based resin sheet. The resin sheet is bonded to the backside of the core member through heat-pressing.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a thin tatami mat and a method for manufacturing a thin tatami mat. [Background technology]

[0002] Tatami is a traditional flooring material mainly used in Japan, and is manufactured by attaching a tatami facing to the surface of a tatami floor, which serves as a core material. In addition, tatami edges are often sewn to the edges of the tatami, which serve to reinforce the corners of the tatami facing, but there are also tatami that do not have tatami edges. Traditional tatami are about 55mm to 60mm thick.

[0003] In recent years, as lifestyles have become more Westernized, the number of homes that no longer have Japanese-style rooms has increased, but there has been a demand for tatami mats. In such cases, it is possible to lay tatami mats on the floor of a Western-style room, but traditional tatami mats are thick, and laying them on the floor creates a step that can be tripped over. In addition, because they are thick, they are heavy, making them difficult to lay and take down.

[0004] For this reason, so-called thin tatami mats with a thickness of about 40 mm or less, which are easy to lay out and put away, have come to be used. However, because the thickness of thin tatami mats is thinner than that of conventional tatami mats, when the tatami mat surface is attached, the tension generated when the tatami mat surface is attached causes the tatami mat to warp backwards. To solve this problem, as disclosed in Patent Document 1, an invention is known in which glass fiber-containing sheets are attached to both sides of the tatami mat base, which is the core material of the tatami mat, to improve the strength of the tatami mat base and reduce reverse warping. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2010-144452 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, even if the strength of the tatami mat base, which serves as the core material for the tatami mat, is improved by attaching glass fiber-containing sheets to both sides of the tatami mat base as in Patent Document 1, in principle it is not possible to completely prevent reverse warping when the tatami mat covering is attached.

[0007] The present invention has been made in consideration of the problems with such conventional inventions, and aims to provide a thin tatami mat and a method for manufacturing a thin tatami mat that more reliably prevents reverse warping when the tatami mat covering is attached to a tatami floor. [Means for solving the problem]

[0008] In order to achieve the above object, the present invention has at least the following configuration or executes the following procedure. In the following description, reference numerals and the like shown in the drawings may be added to facilitate understanding of the present invention, but each component of the present invention is not limited to those shown in the drawings, and should be interpreted broadly to the extent that a person skilled in the art can technically understand.

[0009] A thin tatami mat according to one aspect of the present invention is a thin tatami mat comprising a tatami bed and a tatami covering attached to the surface of the tatami bed, and is characterized in that it comprises a core member, a glass fiber-containing sheet adhered to the surface of the core member, and a polyolefin-based resin sheet, the resin sheet being adhered to the back side of the core member by heat pressing. With this configuration, the polyolefin resin sheet is adhered to the underside of the tatami mat in a shrunken state, so that the central part of the surface of the tatami mat warps forward so as to become convex, thereby providing a thin tatami mat that prevents reverse warping when the tatami surface is attached to the tatami mat.

[0010] A thin tatami mat according to one aspect of the present invention is a thin tatami mat comprising a tatami bed and a tatami covering attached to the surface of the tatami bed, the tatami bed comprising a core member, a glass fiber-containing sheet adhered to both sides of the core member, and a polyolefin-based resin sheet, the resin sheet being adhered to the outer portion of the glass fiber-containing sheet arranged on the back side of the core member by heat pressing. With this configuration, the polyolefin-based resin sheet is adhered to the glass fiber-containing sheet in a shrunken state, so that the central part of the surface of the tatami floor warps forward so as to become convex, thereby providing a thin tatami mat that prevents reverse warping when the tatami covering is attached to the tatami floor.

[0011] A method for producing thin tatami mats according to one aspect of the present invention includes a first step of using an adhesive to adhere a glass fiber-containing sheet to the surface of a core member, which is a component of a tatami mat bed; a second step of using an adhesive to heat press the back side of the core member at 80°C to 150°C for no more than 7 seconds to adhere a polyolefin-based resin sheet to the back side of the core member, causing the polyolefin-based resin sheet to shrink and warp the surface of the core member to which the polyolefin-based resin sheet is adhered so that it becomes convex; and a third step of attaching a tatami covering to the surface of the tatami mat bed produced in the second step. With this configuration, when a tatami covering is attached to the surface of the tatami bed, the central part of the surface of the tatami bed is warped forward so as to be convex, thereby making it possible to provide a thin tatami mat that prevents reverse warping.

[0012] A method for producing thin tatami mats according to one aspect of the present invention includes the following steps: a first step of using an adhesive to bond glass fiber-containing sheets to both sides of a core member, which is a component of a tatami mat bed; a second step of using an adhesive to heat press the back side of the core member to which the glass fiber-containing sheet is bonded at 80°C to 150°C for no more than 7 seconds, thereby bonding a polyolefin-based resin sheet, thereby shrinking the polyolefin-based resin sheet and warping the surface of the core member to which the polyolefin-based resin sheet is bonded so that it becomes convex; and a third step of attaching a tatami covering to the surface of the tatami mat bed produced in the second step. With this configuration, when a tatami covering is attached to the surface of the tatami bed, the central part of the surface of the tatami bed is warped forward so as to be convex, thereby making it possible to provide a thin tatami mat that prevents reverse warping. Effect of the Invention

[0013] As described above, according to the present invention, it is possible to provide a thin tatami mat that more reliably prevents reverse warping when the tatami facing is attached to a tatami floor. [Brief description of the drawings]

[0014] [Figure 1] 1 is a cross-sectional view showing a cross section of a tatami mat bed 200 of a thin tatami mat 100 according to a first embodiment of the present invention. [Diagram 2] FIG. 1 is a cross-sectional view showing a cross section of a thin tatami mat 100 according to a first embodiment of the present invention. [Diagram 3] FIG. 11 is a cross-sectional view showing a cross section of a tatami mat bed 300 of a thin tatami mat 400 according to a second embodiment of the present invention. [Figure 4] FIG. 4 is a cross-sectional view showing a cross section of a thin tatami mat 400 according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, each embodiment of the present invention will be specifically described with reference to the drawings. Note that the embodiment described below is merely a specific example for carrying out the present invention, and is not intended to limit the present invention.

[0016] FIG. 1 is a cross-sectional view showing a cross section of a tatami mat 200 of a thin tatami mat 100 according to a first embodiment of the present invention, and FIG. 2 is a cross-sectional view showing a cross section of a thin tatami mat 100 according to a first embodiment of the present invention. The tatami mat 200, which is a member forming the thin tatami mat 100, is the core of the thin tatami mat 100, and is equipped with a core member 210, a glass fiber-containing sheet 220 bonded to the surface of the core member 210, and a polyolefin-based resin sheet 230. The polyolefin-based resin sheet 230 is bonded to the back side of the core member 210 by heat pressing. Since it is bonded by heat pressing, the polyolefin-based resin sheet 230 shrinks while being bonded, and the back side of the core member 210 also shrinks, and the surface of the core member 210 has a forward-warping shape that rises in a bowl shape so that it becomes convex. Note that the shape of the tatami mat 200 of the thin tatami mat 100 in FIG. 1 is exaggerated and differs from the actual shape. The thin tatami mat 100 is formed by attaching a tatami surface 110 to a tatami mat floor 200. A cushioning material 120 is provided between the tatami mat floor 200 and the tatami surface 110, and an anti-slip material 130 is provided on the back side to prevent the thin tatami mat 100 from slipping.

[0017] The core member 210 uses a fiberboard molded from plant fibers such as wood. The fiberboard is composed of 96% to 99% wood fiber and 1% to 4% starch-based adhesive. This material is excellent in terms of heat insulation, heat retention, and sound absorption. Plywood, synthetic resin foam, and laminated boards made by layering these may also be used.

[0018] The glass fiber-containing sheet 220 used is excellent in dimensional stability, durability, etc. Strength, etc. is improved by attaching the glass fiber-containing sheet 220 to the surface of the core member 210. In addition, since the glass fiber-containing sheet 220 is relatively expensive, the manufacturing cost can be reduced by attaching the glass fiber-containing sheet 220 only to the surface compared to attaching it to both sides.

[0019] The resin sheet 230 is made of a sheet formed by weaving threads made of polyethylene, a polyolefin resin. This allows the warp and weft threads to shrink in the same way when the resin sheet 230 is bonded and shrunk by heat pressing, so that the core member 210 can be warped stably into a forward warp shape. To improve strength, craft paper may be attached to the resin sheet 230. In addition to polyethylene, polyolefin resins such as polypropylene and polystyrene may be used.

[0020] The tatami mat 110 is made of a resin blend of polypropylene and hygroscopic calcium carbonate, but is not limited to this and may be made of natural rush grass or Japanese paper.

[0021] Although foamed resin is used as the cushioning material 120, the material is not limited to this and nonwoven fabric or the like may also be used.

[0022] The anti-slip material 130 is a resin sheet that has been treated to be anti-slip.

[0023] Next, a manufacturing method for the thin tatami mat 100 according to the present invention will be described. The manufacturing method for the thin tatami mat 100 according to the present invention includes a first step of using an adhesive to bond a glass fiber-containing sheet 220 to the surface of a core member 210, which is a component of a tatami mat bed 200, a second step of using an adhesive to perform a heat press on the back surface of the core member 210 at 80°C to 150°C for 7 seconds or less to bond a polyolefin resin sheet 230, causing the polyolefin resin sheet to shrink and warp the surface of the core member 210 to which the polyolefin resin sheet 230 is bonded so that it becomes convex, and a third step of attaching a tatami covering 110 to the surface of the tatami mat bed 200 manufactured in the second step.

[0024] In the first step, the glass fiber-containing sheet 220 is adhered to the surface of the core member 210, and the adhesive used here is a rubber-based adhesive. This is because a rubber-based adhesive is suitable for adhering the glass fiber-containing sheet 220. When adhering the adhesive, after pressure is applied, heat pressing is performed under conditions of 80°C to 150°C for 7 seconds or less. Furthermore, when a rubber-based adhesive is used, it is more preferable to perform heat pressing under conditions of 100°C for 5 seconds after pressure is applied. Note that since the glass fiber-containing sheet 220 has excellent dimensional stability, no particular shrinkage or the like occurs.

[0025] In the second process, a polyolefin resin sheet 230 is attached with an adhesive, and the surface side of the core member 210 is warped into a bowl shape so that it becomes convex. A heat-resistant bond is used as the adhesive. When the floor is warm due to floor heating or the like, distortion is likely to occur due to heat, so using a heat-resistant bond on the back side can improve the durability of the thin tatami mat 100. When the adhesive is applied, after pressure is applied, a heat press is performed under conditions of 80°C to 150°C for 7 seconds or less. In this way, the surface of the core member 210 is moderately warped to a convex shape to manufacture the tatami mat floor 200.

[0026] In the third step, the tatami facing 110 is attached to the tatami mat 200 produced in the second step. When the tatami facing 110 is attached to the tatami mat 200, it is pulled in a direction that causes the tatami mat to be warped backwards. However, since the tatami mat 200 produced in the second step has a forward warp so that the surface is convex, the warps cancel each other out, and the thin tatami mat 100 is formed to be smooth or slightly warped forwards. When attaching the tatami facing 110, a cushioning material 120 is attached between the tatami mat 200 and the tatami facing 110. The tatami facing 110 is formed to be larger than the tatami mat 200, and the excess part is attached so as to wrap around the tatami mat 200. After attaching the tatami facing 110 to the tatami mat 200, the anti-slip material 130 is attached to produce the thin tatami mat 100.

[0027] As the adhesive, Diabond DC7000, Diabond DW234W, Diabond DW992, etc. can be used as appropriate.

[0028] Next, a thin tatami mat 400 using a tatami mat bed 300 formed by attaching glass fiber-containing sheets 220 to both sides of a core member 210 will be described. FIG. 4 is a cross-sectional view showing a cross section of a tatami mat bed 300 of a thin tatami mat 400 according to a second embodiment of the present invention, and FIG. 5 is a cross-sectional view showing a cross section of a thin tatami mat 400 according to a second embodiment of the present invention. Note that the same reference symbols are used for FIG. 3 and FIG. 4, and detailed explanations will be omitted. In this embodiment, the configuration different from the first embodiment of the present invention will mainly be described.

[0029] The tatami mat 300 is the core of the thin tatami mat 400, and is equipped with a core member 210, a glass fiber-containing sheet 220 bonded to both sides of the core member 210, and a polyolefin-based resin sheet 230. The polyolefin-based resin sheet 230 is bonded to the outer part of the glass fiber-containing sheet 220 arranged on the back side of the core member 210 by heat pressing. Since it is bonded by heat pressing, the polyolefin-based resin sheet 230 shrinks while being bonded, and the back side of the core member 210 also shrinks, and the surface of the core member 210 has a forward-warping shape that rises in a bowl shape so that it becomes convex. Note that the tatami mat 300 in FIG. 3 is drawn in an exaggerated manner and differs from the actual shape. The thin tatami mat 400 is formed by attaching a tatami surface 110 to the tatami mat 300. In addition, a cushioning material 120 is provided between the tatami mat floor 300 and the tatami mat surface 110, and an anti-slip material 130 is provided on the back surface to prevent the thin tatami mat 100 from slipping.

[0030] Next, a method for manufacturing the thin tatami mat 400 according to the present invention will be described. The method for manufacturing the thin tatami mat 400 according to the present invention includes a first step of bonding glass fiber-containing sheets 220 to both sides of the core member 210, which is a component of the tatami mat floor 300, using an adhesive, a second step of heat pressing the back side of the core member 210 at 80°C to 150°C for 7 seconds or less using an adhesive to bond a polyolefin resin sheet 230, causing the polyolefin resin sheet to shrink and warp the surface of the core member 210 to which the polyolefin resin sheet 230 is bonded so that it becomes convex, and a third step of attaching a tatami covering 110 to the surface of the tatami mat floor 300 manufactured in the second step.

[0031] In the first step, the glass fiber-containing sheet 220 is bonded to both sides of the core member 210, and the adhesive used here is a rubber-based adhesive. This is because a rubber-based adhesive is suitable for bonding the glass fiber-containing sheet 220. When bonding the adhesive, after pressure is applied, heat pressing is performed under conditions of 80°C to 150°C for 7 seconds or less. Furthermore, when a rubber-based adhesive is used, it is more preferable to perform heat pressing under conditions of 100°C for 5 seconds after pressure is applied. Note that since the glass fiber-containing sheet 220 has excellent dimensional stability, no particular shrinkage or the like occurs.

[0032] In the second process, a polyolefin resin sheet 230 is attached with an adhesive, and the surface side of the core member 210 is warped into a bowl shape so that it becomes convex. A heat-resistant bond is used as the adhesive. When the floor is warm due to floor heating or the like, distortion is likely to occur due to heat, so using a heat-resistant bond on the back side can improve the durability of the thin tatami mat 400. When the adhesive is applied, after pressure is applied, a heat press is performed under conditions of 80°C to 150°C for 7 seconds or less. In this way, the tatami mat floor 200 is manufactured by appropriately adjusting the surface of the core member 210 so that it becomes convex.

[0033] In the third step, the tatami facing 110 is attached to the tatami mat 300 produced in the second step. When the tatami facing 110 is attached to the tatami mat 300, it is pulled in a direction that causes the tatami mat to be warped backwards. However, since the tatami mat 300 produced in the second step has a forward warp so that the surface is convex, the warps cancel each other out, and the thin tatami mat 400 is formed to be smooth or slightly warped forwards. When attaching the tatami facing 110, a cushioning material 120 is attached between the tatami mat 300 and the tatami facing 110. The tatami facing 110 is formed to be larger than the tatami mat 300, and the excess part is attached so as to wrap around the tatami mat 300. After attaching the tatami facing 110 to the tatami mat 200, the anti-slip material 130 is attached to produce the thin tatami mat 100.

[0034] As the adhesive, Diabond DC7000, Diabond DW234W, Diabond DW992, etc. can be used as appropriate.

[0035] In the present invention, the front side is the side that becomes the top side when the tatami mat is placed, and the back side is the side that becomes the bottom side. Furthermore, forward warping refers to a convex warp that rises in the center of the tatami mat when placed on a floor, and reverse warping refers to a concave warp that rises in the edge of the tatami mat when placed on a floor.

[0036] As described above, by using the thin tatami mat of the present invention, reverse warping can be prevented when the tatami mat surface is attached to the tatami floor. [Industrial Applicability]

[0037] By using the thin tatami mat of the present invention, reverse warping can be prevented when the tatami mat surface is attached to a tatami floor, making it possible to provide a thin tatami mat that feels good to the touch. [Explanation of symbols]

[0038] 100 thin tatami 110 Tatami mat 120 Cushioning material 130 Anti-slip material 200 Tatami floor 210 Core material 220 Glass fiber sheet 230 Resin Sheet 300 Tatami floor 400 thin tatami

Claims

1. A thin tatami mat comprising a tatami mat bed and a tatami surface attached to the surface of the tatami mat bed, The tatami mat comprises a core member, a glass fiber-containing sheet bonded to the surface of the core member, and a polyolefin-based resin sheet, The thin tatami mat is characterized in that the resin sheet is bonded to the back side of the core member by heat pressing.

2. A thin tatami mat comprising a tatami mat bed and a tatami surface attached to the surface of the tatami mat bed, The tatami mat comprises a core member, a glass fiber-containing sheet bonded to both sides of the core member, and a polyolefin-based resin sheet, The thin tatami mat is characterized in that the resin sheet is bonded to an outer portion of a glass fiber-containing sheet arranged on the back side of the core member by heat pressing.

3. A method for producing thin tatami mats, comprising the steps of: A first step of adhering a glass fiber-containing sheet to a surface of a core member, which is a component of a tatami mat bed, using an adhesive; a second step of performing a heat press on the back surface of the core member using an adhesive at 80° C. to 150° C. for 7 seconds or less to adhere a polyolefin-based resin sheet to the back surface of the core member, thereby shrinking the polyolefin-based resin sheet and warping the surface of the core member to which the polyolefin-based resin sheet is adhered so as to have a convex shape; A third step of attaching a tatami covering to the surface of the tatami mat produced in the second step.

4. A method for producing thin tatami mats, comprising the steps of: A first step of bonding glass fiber-containing sheets to both sides of a core member, which is a component of a tatami mat bed, using an adhesive; a second step of performing a heat press using an adhesive on the back surface of the core member to which the glass fiber-containing sheet is adhered under conditions of 80° C. to 150° C. for 7 seconds or less to adhere a polyolefin-based resin sheet, thereby shrinking the polyolefin-based resin sheet and warping the surface of the core member to which the polyolefin-based resin sheet is adhered so as to have a convex shape; A third step of attaching a tatami covering to the surface of the tatami mat produced in the second step.

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