Method for manufacturing raising material, tatami set, and tatami replacement method

Abstract

To provide a method for manufacturing a raising material capable of reducing the manufacturing cost of the raising material arranged under a floor material such as a tatami mat.SOLUTION: In the manufacturing method of the raising material for manufacturing the raising material 1 arranged under a floor material 2, the raising material 1 thinner than an old tatami mat floor is manufactured by using at least the old tatami mat floor when the used tatami mat floor and the unused tatami mat floor stored without being used for a predetermined period after being manufactured are used as the old tatami mat floor. When the raising material 1 is manufactured by this manufacturing method, the material cost of the raising material 1 can be reduced.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a raising material to be placed under flooring materials such as tatami mats. The present invention also relates to a two-layer tatami mat set comprising a raising material and a thin tatami mat. Furthermore, the present invention relates to a method for replacing tatami mats. [Background technology]

[0002] Heated tatami mats with surface heating elements are known (see, for example, Patent Document 1). The heated tatami mat described in Patent Document 1 comprises an upper tatami mat and a lower floor. The upper tatami mat is composed of an upper floor that forms the upper layer of the tatami floor, a tatami facing fixed on top of the upper floor, and edging cloth attached to both side edges of the tatami facing. The lower floor forms the lower layer of the tatami floor. The surface heating element is fixed to the upper surface of the lower floor. The upper tatami mat is detachably placed on top of the lower floor. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Utility Model Application Publication No. 4-68914 Summary of the Invention [Problem to be solved by the invention]

[0004] The present inventors are considering manufacturing and selling, renting, or leasing a tatami mat set consisting of a thin tatami mat equivalent to the top of the tatami mat described in Patent Document 1 and a padding material placed underneath the thin tatami mat, for example, as a replacement for conventionally used standard tatami mats. With this tatami mat set, the padding material can be continued to be used even when replacing old tatami mats with new ones. Therefore, this tatami mat set reduces the cost of replacing tatami mats and makes the replacement process easier. To promote sales of this tatami mat set, it is preferable to reduce the manufacturing cost of the padding material and lower the initial sales price of the tatami mat set. Furthermore, when replacing conventionally used standard tatami mats with a tatami mat set, various problems can arise if the thickness of the tatami mat before and after replacement differ.

[0005] Therefore, the first object of the present invention is to provide a method for manufacturing a padding material that can reduce the manufacturing cost of padding material placed under flooring materials such as tatami mats.The second object of the present invention is to provide a two-layer tatami mat set that can be used to replace existing tatami mats laid in a tatami room, and that can prevent problems caused by the thickness of the tatami mat set. [Means for solving the problem]

[0006] In order to solve the first problem mentioned above, the method for manufacturing a bulking material of the present invention is a method for manufacturing a bulking material to be placed under flooring, and is characterized in that, if used tatami mats and unused tatami mats that have been stored without being used for a predetermined period after being manufactured are defined as old tatami mats, the method uses at least old tatami mats to manufacture bulking material that is thinner than the old tatami mats.

[0007] In the method for manufacturing the bulking material of the present invention, the bulking material is manufactured using at least old tatami mats. Therefore, by manufacturing the bulking material using the manufacturing method of the present invention, it is possible to reduce the material cost of the bulking material, and as a result, it is possible to reduce the manufacturing cost of the bulking material. Furthermore, since the bulking material is manufactured using at least old tatami mats, it is possible to eliminate the need to dispose of old tatami mats. Therefore, the present invention makes it possible to reduce the disposal cost of old tatami mats.

[0008] Furthermore, in the present invention, because the padding material is thinner than that of old tatami mats, for example, if the flooring material is thin tatami, it is possible to make the thickness of the tatami set consisting of the thin tatami and padding material the same as that of conventional, general tatami. Therefore, in the present invention, for example, if the flooring material is thin tatami, it is possible to replace the conventional, general tatami with a tatami set consisting of thin tatami and padding material.

[0009] In the present invention, the method for manufacturing a bulking material includes, for example, a tatami mat disassembly process in which an old tatami mat composed of multiple stacked materials is disassembled into individual components, and a stacking and sewing process in which, from the multiple disassembled materials, multiple materials are selected whose total thickness is equal to the thickness of the bulking material, and the selected multiple materials are stacked and sewn together. In this case, since it is sufficient to select multiple materials whose total thickness is equal to the thickness of the bulking material in the stacking and sewing process, it is not necessary to adjust the thickness of the materials, for example, by cutting the materials in a direction perpendicular to their thickness. Therefore, the bulking material can be manufactured more easily than when a process including a step of cutting the materials in a direction perpendicular to their thickness is included.

[0010] In the present invention, the method for manufacturing the bulking material includes, for example, a bulking material piece joining step of joining together end faces of a plurality of bulking material pieces that have the same thickness as the bulking material and a smaller outer diameter than the bulking material. Also, in the present invention, for example, the flooring material is tatami mats.

[0011] Furthermore, in order to solve the second problem mentioned above, the tatami set of the present invention is a two-layered tatami set that is used to replace existing tatami that is laid in a tatami room, and is characterized in that it comprises a raising material and a thin tatami that are separated in the thickness direction of the tatami set, the thin tatami being formed thinner than the existing tatami and being placed on top of the raising material, so that when the raising material and the thin tatami are stacked together the thickness is equal to the thickness of the existing tatami.

[0012] In the tatami set of the present invention, the thickness of the padding material and the thin tatami mats stacked together is the same as the thickness of the existing tatami mats. In other words, in this invention, the thickness of the existing tatami mats before replacement and the thickness of the tatami set after replacement are the same. Therefore, this invention makes it possible to prevent problems caused by the thickness of the tatami set after replacing the existing tatami mats with the tatami set.

[0013] In the present invention, when replacing tatami mats in a tatami room, for example, when replacing existing tatami mats, the existing tatami mats are replaced with the above-mentioned tatami set, and the next time, only the thin tatami mats are replaced. In this case, even when replacing old thin tatami mats with new ones, the padding material continues to be used as is, which reduces the cost of replacing thin tatami mats with new ones and makes the thin tatami mat replacement work easier. [Effects of the Invention]

[0014] As described above, by manufacturing a bulking material using the manufacturing method of the present invention, it is possible to reduce the manufacturing cost of the bulking material. Furthermore, the present invention makes it possible to prevent problems caused by the thickness of a two-layer tatami mat set that is used to replace existing tatami mats laid in a tatami room. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a perspective view for explaining the configuration of a bulking material manufactured by a bulking material manufacturing method according to an embodiment of the present invention; [Figure 2] FIG. 10 is a perspective view illustrating the tatami mat disassembly process in the method for manufacturing the bulking material. [Figure 3] 10A and 10B are diagrams for explaining the edge cutting step in the method for manufacturing the bulking material. [Figure 4] 10A and 10B are diagrams illustrating a layering and sewing process in a method for manufacturing a bulking material. [Figure 5] 10 is a diagram for explaining the bulking material piece joining step in the manufacturing method of the bulking material. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0017] (Tatami set configuration, heightening material configuration, and tatami replacement method) FIG. 1 is a perspective view for explaining the configuration of a bulking material 1 manufactured by a manufacturing method of a bulking material according to an embodiment of the present invention.

[0018] The bulking material 1 manufactured by the bulking material manufacturing method of this embodiment is placed under the flooring material 2. In other words, the flooring material 2 is placed on top of the bulking material 1. The flooring material 2 of this embodiment is a tatami mat. Therefore, hereinafter, the flooring material 2 will be referred to as "tatami mat 2." The tatami mat 2 is made up of, for example, a tatami facing, a thin tatami mat base, and a tatami edge. The tatami mat 2 is thinner than the general tatami mats that have been used conventionally. It is noted that the tatami mat 2 does not have to have a tatami edge.

[0019] In this embodiment, a two-layered tatami set 3 is made up of a raising material 1 and a tatami mat 2, which are used to replace existing tatami mats laid in a tatami room. That is, the tatami set 3 comprises a raising material 1 and a tatami mat 2, which are separated in the thickness direction of the tatami set 3. The existing tatami mats are ordinary tatami mats that have been used traditionally, and the tatami mat 2 is thinner than the existing tatami mats. The tatami mat 2 in this embodiment is a thin tatami mat that is thinner than the existing tatami mats.

[0020] The thickness of the raised floor mat 1 and tatami mat 2 when stacked together is equal to the thickness of a conventional, standard tatami mat, and the thickness of the raised floor mat 1 and tatami mat 2 when stacked together is equal to the thickness of an existing tatami mat. In other words, the thickness of the tatami set 3 made up of the raised floor mat 1 and tatami mat 2 is equal to the thickness of a conventional, standard tatami mat and equal to the thickness of an existing tatami mat. Furthermore, the outer shapes of the raised floor mat 1 and tatami mat 2 are equal to the outer shapes of a conventional, standard tatami mat and an existing tatami mat. In other words, the outer shapes of the tatami set 3 are equal to the outer shapes of a conventional, standard tatami mat and an existing tatami mat.

[0021] The tatami set 3 is used to replace conventional, ordinary tatami mats. That is, as mentioned above, the tatami set 3 is used to replace the existing tatami mats laid in the tatami room. When replacing the existing tatami mats in the tatami room, the existing tatami mats are replaced with the tatami set 3. Furthermore, when the next replacement is carried out in the tatami room after that, only the tatami mats 2 are replaced.

[0022] If we define old tatami mats 4 as used tatami mats (i.e., second-hand tatami mats) and unused tatami mats that have been stored without being used for a certain period after production (i.e., new second-hand tatami mats or stock tatami mats), the padding material 1 is manufactured using at least old tatami mats 4 (see Figure 2). Old tatami mats 4 are conventional, general second-hand, new second-hand, or stock tatami mats from which the tatami facing and tatami edge have been removed. Alternatively, old tatami mats 4 are stock tatami mats that have been stored for a certain period without the tatami facing and tatami edge attached.

[0023] The old tatami mat bed 4 in this embodiment is made up of multiple stacked materials 5-7. For example, the old tatami mat bed 4 is made up of three (three layers) materials 5-7 formed in the shape of rectangular flat plates. The materials 5-7 are stacked in this order. Materials 5 and 7 are, for example, insulating foam. Material 6 is, for example, urethane foam or polystyrene foam. The thickness of the padding material 1 is thinner than the thickness of the old tatami mat bed 4. Also, in this embodiment, for example, the total thickness of materials 6 and 7 is equal to the thickness of padding material 1.

[0024] (Manufacturing method of bulking material) Fig. 2 is a perspective view illustrating the tatami mat disassembly step in the method for manufacturing a bulking material. Fig. 3 is a diagram illustrating the edge cutting step in the method for manufacturing a bulking material. Fig. 4 is a diagram illustrating the stacking and sewing step in the method for manufacturing a bulking material. Fig. 5 is a diagram illustrating the bulking material piece joining step in the method for manufacturing a bulking material.

[0025] The manufacturing method for the padding material of this embodiment includes a tatami mat disassembly process in which the old tatami mat 4 is disassembled into individual pieces 5-7. In this process, the threads that sew the three pieces 5-7 together are removed, and the three pieces 5-7 are separated (see Figure 2). In addition, in this process, multiple types of old tatami mats 4 are disassembled. Once the tatami mat disassembly process is complete, multiple types of materials 5-7 with different thicknesses and materials can be used. In the case of old tatami mats 4, the edges of the materials 5-7 may be severely damaged due to the effects of stitching, etc. Therefore, before or after the tatami mat disassembly process, the edges of the materials 5-7 may be cut, for example, at the positions indicated by the dotted lines in Figure 3 (edge ​​cutting process).

[0026] The manufacturing method of the padding material also includes a layering and sewing process in which a plurality of materials 5 to 7 whose total thickness is equal to the thickness of the padding material 1 are selected from the materials 5 to 7 disassembled in the tatami mat disassembly process, and the selected plurality of materials 5 to 7 are layered and sewn together. In the layering and sewing process, for example, two materials 6 and 7 are selected from the three materials 5 to 7, and the selected two materials 6 and 7 are layered and sewn together (see Figure 4).

[0027] In the layering and sewing process, materials 6 and 7 are sewn together using new thread. That is, new thread is included in the bulking material 1. In the layering and sewing process, a new sheet may be placed below material 7 or above material 6 in FIG. 4 and sewn together with materials 6 and 7. If necessary, materials 6 and 7 may be cut to a predetermined size before or after the layering and sewing process (material cutting process). If the material cutting process is not performed, for example, the bulking material 1 is completed when the layering and sewing process is completed.

[0028] Furthermore, when the stacking and sewing process is completed, or when the material cutting process is completed if it is performed after the stacking and sewing process, for example, bulking material pieces 8 (see FIG. 5) that have the same thickness as the bulking material 1 but a smaller outer diameter than the bulking material 1 may be completed. In this case, after the stacking and sewing process, the end faces of the multiple bulking material pieces 8 are joined together (bulking material piece joining process). In the bulking material piece joining process, for example, the end faces of three bulking material pieces 8 are joined together as shown in FIG. 5(A) or FIG. 5(B). When the bulking material pieces 8 are manufactured, for example, the bulking material 1 is completed when the bulking material piece joining process is completed.

[0029] (Main effect of this form) As explained above, in this embodiment, the bulking material 1 is manufactured using at least old tatami mats 4. Therefore, if the bulking material 1 is manufactured using the manufacturing method of this embodiment, it is possible to reduce the material cost of the bulking material 1, and as a result, it is possible to reduce the manufacturing cost of the bulking material 1. Furthermore, in this embodiment, since the bulking material 1 is manufactured using at least old tatami mats 4, it is possible to eliminate the need to dispose of the old tatami mats 4. Therefore, in this embodiment, it is possible to reduce the disposal cost of the old tatami mats 4.

[0030] In this embodiment, in the layering and sewing step, a plurality of materials 6, 7 whose total thickness is equal to the thickness of the bulking material 1 are selected from the plurality of disassembled materials 5-7, and the selected materials 6, 7 are layered and sewn together. Therefore, in this embodiment, it is not necessary to adjust the thickness of the materials 5-7, for example, by cutting the materials 5-7 in a direction perpendicular to the thickness direction of the materials 5-7. Therefore, in this embodiment, it is possible to manufacture the bulking material 1 more easily than when a step of cutting the materials 5-7 in a direction perpendicular to the thickness direction of the materials 5-7 is included.

[0031] In this embodiment, the thickness of the padding material 1 and tatami mat 2 when stacked is the same as the thickness of the existing tatami mat, and the thickness of the existing tatami mat before replacement is the same as the thickness of the replaced tatami mat set 3. Therefore, in this embodiment, it is possible to prevent problems caused by the thickness of the tatami mat set 3 after replacing the existing tatami mat with the tatami mat set 3.

[0032] In this embodiment, when replacing existing tatami mats in a tatami room, the existing tatami mats are replaced with the tatami mat set 3, but when the next replacement is carried out in the tatami room, only the tatami mats 2 are replaced. In other words, in this embodiment, the padding material 1 is not replaced at the next replacement and continues to be used as is. Therefore, in this embodiment, it is possible to reduce the cost of replacing tatami mats 2 with new ones, and it is also possible to easily replace the tatami mats 2.

[0033] (Other embodiments) In the above-described embodiment, the manufacturing method of the bulking material may include a step of cutting the materials 5-7 in a direction perpendicular to the thickness direction of the materials 5-7. Also, in the above-described embodiment, the old tatami mat 4 may be composed of a single piece of material. In this case, the manufacturing method of the bulking material does not include a tatami mat disassembly step and a stacking and sewing step. Also, in this case, the manufacturing method of the bulking material includes a step of cutting the old tatami mat 4 in a direction perpendicular to the thickness direction of the old tatami mat 4, and in this step, the old tatami mat 4 is cut so that the thickness of the cut old tatami mat 4 is equal to the thickness of the bulking material 1. When this step is completed, for example, the bulking material 1 is completed. In this case, for example, the bulking material 1 does not include new components.

[0034] In the above-described embodiment, the outer shape of the bulking material 1 may be larger or smaller than that of a conventional, general tatami mat. If the outer shape of the bulking material 1 is smaller than that of a conventional, general tatami mat, the joined multiple bulking material pieces 8 may be cut to a predetermined size after the bulking material piece joining process. Also, in the above-described embodiment, the outer shape of the tatami mat 2 may be larger or smaller than that of a conventional, general tatami mat.

[0035] In the above-described embodiment, the thickness of the raising material 1 may be equal to or thicker than the thickness of the old tatami mat 4. Also, in the above-described embodiment, the raising material 1 may be manufactured without using the old tatami mat 4. For example, the raising material 1 may be manufactured using new insulating foam, new urethane foam, or new polystyrene foam. Furthermore, in the above-described embodiment, the flooring material 2 may be something other than tatami. For example, the flooring material 2 may be tile or carpet, or may be flooring, etc. [Explanation of symbols]

[0036] 1. Raising material 2 tatami mats (flooring, thin tatami mats) 3 tatami mat set 4 Old tatami floor 5~7 Materials 8 Raising piece

Claims

1. A method for manufacturing a raising material to be placed under a floor material, comprising: Used tatami mats and unused tatami mats that have been stored for a certain period of time after being manufactured are considered old tatami mats. A method for manufacturing a raising material, characterized in that the raising material is thinner than the old tatami mat using at least the old tatami mat.

2. A tatami mat disassembly process in which the old tatami mat, which is composed of a plurality of stacked materials, is disassembled into each material; A method for manufacturing a bulking material as described in claim 1, characterized in that it includes a stacking and sewing process in which a plurality of materials whose total thickness is equal to the thickness of the bulking material are selected from the plurality of disassembled materials, and the selected plurality of materials are stacked and sewn together.

3. A method for manufacturing a bulking material as described in claim 1 or 2, characterized in that it includes a bulking material piece joining process for joining the end faces of multiple bulking material pieces that have the same thickness as the bulking material and a smaller outer diameter than the bulking material.

4. 3. The method for manufacturing a floor raising material according to claim 1, wherein the floor material is a tatami mat.

5. A two-layer tatami set that is used to replace existing tatami mats laid in a tatami room. The tatami set includes a raising material and a thin tatami mat that are separated in the thickness direction of the tatami set, The thin tatami mat is formed thinner than the existing tatami mat and is placed on the raising material, This tatami set is characterized in that the thickness of the raised material and the thin tatami mats stacked together is equal to the thickness of the existing tatami mats.

6. A method for replacing tatami mats in the tatami room, comprising: A tatami mat replacement method characterized in that when replacing the existing tatami mat, the existing tatami mat is replaced with the tatami mat set according to claim 5, and at the next replacement, only the thin tatami mat is replaced.

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