Tatami mat folding device

Abstract

To provide a tatami facing folding device capable of simultaneously folding two tatami mats of a size of half a tatami mat, capable of folding even a single tatami mat without unflatness by one folding operation, and capable of handling and folding even a single tatami mat with unflatness with the same required area as the size of a machine, and excellent in finishing.SOLUTION: Each of a left folding unit 14a and a right folding unit 14b includes a positioning plate 18 vertically movable with respect to a mounting table 16 in order to determine the folding position of the tatami facing and position other sides of the tatami mat at the folding position, and a folding member 24 arranged so as to face the folding side end of the mounting table 16 and is configured to be separable and contactable with respect to the other side of the tatami mat in order to fold the tatami facing that protrudes outward from the folding end side of the mounting table 16. The left folding unit 14a and the right folding unit 14b can be operated singly or both at the same time.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a tatami table folding device for folding the other side of a tatami table inward and fixing it to the other side of a tatami floor in a state where the side of the tatami table on the frame direction side is fixed to the side on the frame direction of the tatami floor cut to a predetermined size (so-called "front frame method").

Background Art

[0002] Conventionally, regarding tatami mats, instead of ordinary tatami mats with tatami edges, recently, in condominiums and the like, so-called "edgeless tatami mats" without tatami edges are widely used in consideration of design and the like.

[0003] In this case, as shown in FIG. 34, in order to manufacture such an edgeless tatami mat 201, the tatami table 200 needs to be bent at an angle of approximately 90° or more along the sides of the tatami floor 206 (the upper front side 206a and the lower front side 206b) so as to follow the side 208 of the tatami floor 206.

[0004] In FIG. 34, for convenience of explanation, only one side is shown, and in the front frame method, a state where one side 216 on the frame direction side of the tatami table 2 has been fixed to the side 214 on the frame direction of the tatami floor is shown.

[0005] That is, as shown in FIG. 34, the side 202 of the tatami table 200 is bent along the side 208 of the tatami floor 206 in the direction A (the direction of the tatami grass) in which the tatami grass of the tatami table 200 extends along the tatami floor, and the bent side 210 is fixed to the side 208 or the back surface 212 of the tatami floor 206 using, for example, a hand tacker, sewing, an adhesive, or a tape.

[0006] Incidentally, conventionally, such tatami mat folding devices have been proposed in Patent Document 1 (Japanese Patent No. 4375509), Patent Document 2 (Japanese Patent No. 4375511), Patent Document 3 (Japanese Unexamined Patent Publication No. 2019-132069), Patent Document 4 (Japanese Unexamined Patent Publication No. 2020-20200), etc. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] Patent No. 4375509 [Patent Document 2] Patent No. 4375511 [Patent Document 3] Japanese Patent Publication No. 2019-132069 [Patent Document 4] Japanese Patent Publication No. 2020-20200 [Overview of the Initiative] [Problems that the invention aims to solve]

[0008] Incidentally, while the demand for borderless tatami mats has been increasing recently, traditional borderless tatami mats were half-size, but recently there has been a growing demand for full-size borderless tatami mats as well.

[0009] However, in the case of a single-size borderless tatami mat, as shown in Figure 35, the threshold of a room is not necessarily 100% square or rectangular. Therefore, when laying tatami mats, the upper front edge is finished in a straight line, and the lower front edge is shaped to fit snugly against the threshold before laying the tatami mats.

[0010] Therefore, when viewed from above, the shape of the tatami mat will not have perfectly parallel sides (there will be some slight irregularities) between the opposing upper and lower front edges.

[0011] In other words, tatami mats have the aforementioned quirks, and it is common for tatami mats to have at least some of these quirks removed.

[0012] Therefore, taking into account the shape of the tatami mat (tatami base) in this plan view, it is necessary to fold the sides 202 of the tatami surface 200.

[0013] In other words, as shown in Figure 36(A), when folding a tatami mat surface of a single-mat size without a border, it is necessary to fold a tatami mat where the part to be folded is not in a straight line.

[0014] Furthermore, as shown in Figure 36(B), in the case of a half-tatami mat size, even if there are some irregularities in the middle, there is no problem because the entire piece can be tilted and folded in a straight line, as indicated by the arrow in Figure 36(B).

[0015] Thus, when folding the surface of a tatami mat without a border, the tatami mat surface folding device disclosed in the above-mentioned Patent Document 4 (Japanese Patent Application Publication No. 2020-20200) has been proposed as a tatami mat surface folding device for borderless tatami mats that can accommodate the kinks in the middle of the mat.

[0016] In other words, the tatami mat folding device 300 of Patent Document 4 includes a positioning member 312 composed of a first positioning plate 312a and a second positioning plate 312b, as shown in Figure 37 (corresponding to Figure 1 of Patent Document 4).

[0017] In Figure 37, the reference number is the same as the reference number in Figure 1 of Patent Document 4 plus 300. A detailed explanation of this is easily understood by referring to Patent Document 4, so it is omitted here.

[0018] These first positioning plates 312a and second positioning plates 312b are configured to be angularly movable relative to each other around a virtual central axis P.

[0019] Then, with the positioning member 312 lowered to a position where it contacts the tatami mat surface to be folded, the folding member 346 is configured to fold the side edges of the tatami mat surface inward.

[0020] As a result, the tatami mat cover can be bent along the direction of the tatami grass stems (the direction of the tatami grass), and moreover, the side edges of the tatami mat cover (the upper front side edge and the lower front side edge) can be bent to match the side edges of the tatami mat (the upper front side edge and the lower front side edge) into a shape concave in a zigzag shape or a shape conforming to a shape protruding in a zigzag shape.

[0021] That is, the tatami mat cover folding device 300 of Patent Document 4 is configured to perform folding only in one step of bending the left and right sides of the kuse simultaneously.

[0022] However, when an operator bends the tatami mat cover onto the tatami mat with the first positioning plate 312a and the second positioning plate 312b positioning simultaneously as in Patent Document 4, problems may occur when trying to bend the left and right sides of the kuse simultaneously.

[0023] <( That is, at the center (the place of the kuse (valley)), the tatami mat cover bulges out, so it can be bent more neatly by bending one side at a time.

[0024] However, when bending the left side, the second positioning plate 312b on the right side is located very close to the tatami mat (right next to it horizontally), so the second positioning plate 312b on the right side gets in the way and makes it difficult to bend.

[0025] Also, when bending the right side, the first positioning plate 312a on the left side is located very close to the tatami mat (right next to it horizontally), so the first positioning plate 312a gets in the way and makes it difficult to bend.

[0026] Therefore, the tatami mat cover may bulge at the kuse (valley) of the tatami mat.

[0027] Also, even when bending automatically without the intervention of the operator's hand, if trying to bend the left and right sides simultaneously, the tatami mat cover may bulge or wrinkle at the kuse (valley) of the tatami mat.

[0028] Furthermore, in the tatami mat folding device 300 of Patent Document 4, the pivot shaft 316c and the pivot shaft hole 316d constitute a virtual central axis P, and as shown by arrow B in Figure 37, the first positioning plate 312a and the second positioning plate 312b are configured to be angularly movable (rotatable) relative to each other around the virtual central axis P.

[0029] Therefore, the virtual central axis P has a complex structure, requires considerable strength, and is structurally difficult to install.

[0030] Furthermore, although the tatami mat folding device 300 in Patent Document 4 does not describe a mounting table for placing the tatami mat base, such a mounting table actually exists.

[0031] By the way, in order to improve the finish of the tatami mat folding device 300, it is ideal to configure the folding member (lateral pressing block) to bend the tatami mat while pressing it from below.

[0032] Alternatively, the mounting table may be configured to descend relative to the bending member (lateral pressing block).

[0033] However, in the tatami mat folding device 300 of Patent Document 4, it is not possible to fold the folding member (lateral pressing block) while pressing it from below for the following reasons.

[0034] In other words, when the tatami mat base 400, which has a concave shape in the middle, is installed so as not to protrude from the mounting table 402, it will be arranged as shown in the top view of Figure 38(A).

[0035] In this case, as shown in Figure 38(B), in the AA section, the positioning plate 404, the end face 406 of the mounting table 402, the gap between the positioning plate 404 and the bending member (lateral push block) 408, and the end face 400a of the tatami mat base 400 are all on the same line, which is a desirable arrangement.

[0036] On the other hand, as shown in Figure 38(C), in the B-B section, the bending member 410, the positioning plate 404, and the end face 400a of the tatami mat base 400 are not on the same line.

[0037] Therefore, as shown in Figure 38(C), the bending member 410 cannot bend the tatami surface 412 so as to press it against the end surface 400a of the tatami base 400, resulting in a poor finish.

[0038] In other words, if the tatami mat base 400, which has a concave shape in the middle, is installed so that it extends beyond (protrudes from) the mounting table 402, it will be positioned as shown in the top view of Figure 39(A).

[0039] In this case, as shown in Figure 39(B), the DD cross section has a desirable arrangement in which the positioning plate 404, the end face 406 of the mounting table 402, the gap between the positioning plate 404 and the bending member (lateral push block) 410, and the end face 400a of the tatami mat base 400 are all on the same line.

[0040] However, as shown in Figure 39(C), in the CC section, the mounting table 402 cannot press down on the tatami base 400 up to the end face 400a of the tatami base 400, resulting in the tatami surface 412 being lifted and a poor finish.

[0041] Thus, in the tatami mat folding device 300 of Patent Document 4, for the reasons mentioned above, it is not possible to configure the device to fold the folding member (lateral pressing block) while pressing it from below.

[0042] Furthermore, conventionally, there are tatami mat folding devices that fold the surface at the front frame to produce half-size mats, and tatami mat folding devices that fold the surface first and then align it with the tatami base (so-called rear frame) type. In this case, by folding it in half, it is possible to fold a full-size mat regardless of whether or not there is a crease in the middle.

[0043] However, in this case, as shown in Figures 40(A) and 40(B), if we were to fold a full-size tatami mat, we would need space on both sides of the half-size tatami machine to accommodate half a tatami mat on each side, meaning the required area would be approximately three times the size of the machine. In other words, we would need space equivalent to half a tatami mat on both sides of the half-size tatami machine.

[0044] Furthermore, conventional half-size tatami mat folding devices naturally cannot fold an entire tatami mat without any creases in one go.

[0045] Furthermore, there is a conventional tatami mat folding device that folds the mat surface at the front frame, and it can fold two half-mat-sized mats simultaneously.

[0046] Furthermore, a single-size tatami mat without any kinks can be handled with a single folding motion.

[0047] However, in this case, it is not possible to handle irregularly shaped tatami mats of one-mat size.

[0048] Furthermore, due to the frame structure, it is difficult to adopt a method of placing the parts that do not need to be folded outside the machine.

[0049] In this case, by changing the frame structure, it becomes possible to adopt a method where the non-folding parts are placed outside the machine.

[0050] However, in that case, as shown by the dotted line in Figure 40(C), the right side of the tatami mat must extend beyond the device, and the left side must be folded. Then, the tatami mat must be moved in the direction of the arrow in Figure 40(C), so that the left side of the tatami mat extends beyond the device, and the right side must be folded. This requires approximately twice the area of ​​the machine.

[0051] In other words, as shown in Figure 40(C), a space equivalent to half a tatami mat is required on both sides of the machine designed for one tatami mat.

[0052] In view of the current situation, the present invention aims to provide a tatami mat folding device that can fold two half-size tatami mats simultaneously, fold a single tatami mat without any creases in a single folding operation, and also handle tatami mats with creases throughout the entire mat while maintaining the same required area as the machine size, and also provides a superior finish. [Means for solving the problem]

[0053] The present invention was made to achieve the problems and objectives of the prior art described above, and the tatami mat folding device of the present invention is With the side of the tatami mat facing the frame fixed to the side of the tatami base facing the frame, A tatami mat folding device for folding the other side of the tatami mat surface inward relative to the other side of the tatami mat base and fixing it to the other side of the tatami mat base, In the front view of the aforementioned tatami mat folding device, the left folding unit is located on the left side, In the front view of the tatami mat folding device, the right-side folding unit is located on the right side, A placement table for placing the tatami mat surface and tatami base in predetermined positions, Equipped with, The left folding unit and the right folding unit are, respectively, To determine the folding position of the tatami mat surface and to position the other side of the tatami mat base at the folding position, a positioning plate configured to be vertically movable relative to the aforementioned table is provided. The system includes a folding member positioned opposite the folding end of the aforementioned mounting table, and configured to be detachable from the other side of the tatami mat base in order to fold the tatami surface that protrudes outward from the folding end of the aforementioned mounting table, The left-side folding unit and the right-side folding unit are configured to operate either individually or both simultaneously.

[0054] This configuration allows the left-side folding unit and the right-side folding unit to operate either individually or both simultaneously.

[0055] Therefore, by operating both the left-side folding unit and the right-side folding unit simultaneously, it is possible to fold two half-size tatami mats at the same time.

[0056] Furthermore, even a single tatami mat without any creases can be folded in a single folding motion by operating both the left-side folding unit and the right-side folding unit simultaneously.

[0057] Furthermore, by operating only one of the left-side folding unit and the right-side folding unit, even tatami mats with irregular shapes throughout an entire tatami room can be handled and folded while maintaining the same required area as the machine size.

[0058] In other words, the left folding unit and the right folding unit are, • A positioning plate configured to be vertically movable relative to the mounting table, • A foldable member configured to be detachable from the other side of the tatami mat base, Because it is equipped with such features, it can be folded without interfering with the tatami mat or tatami surface, and it can also be provided with a tatami surface folding device that produces an excellent finish.

[0059] Therefore, this tatami mat folding device can fold two half-size tatami mats simultaneously, fold a single tatami mat without any creases in a single folding operation, and even handle tatami mats with creases throughout, while maintaining the same required area as the machine size, and also provides a tatami mat surface folding device with a superior finish.

[0060] Furthermore, the tatami mat folding device of the present invention is The left-side folding unit and the right-side folding unit are each equipped with a placement table for placing the tatami mat surface and tatami mat base in predetermined positions.

[0061] Thus, the left-side folding unit and the right-side folding unit may each be equipped with a placement table for placing the tatami mat surface and the tatami mat base in their respective positions.

[0062] Furthermore, the tatami mat folding device of the present invention is The left folding unit and the right folding unit are, respectively, In the case of a thin tatami mat, the other side of the tatami surface is folded inward and fixed to the other side and back of the tatami mat base. The tatami mat is characterized by having a detachable folding plate on the back surface that is configured to be detachable from the upper part of the back surface of the other side of the tatami mat base.

[0063] This configuration provides a detachable folding plate on the back surface of the upper back surface of the other side of the tatami mat base.

[0064] This allows the other side of the tatami surface to be folded inward and secured to the other side and back of the tatami base, in case the tatami base is thin.

[0065] Furthermore, the tatami mat folding device of the present invention is The left folding unit and the right folding unit are, respectively, When the aforementioned folded back plate moves in a direction approaching the upper back surface of the other side of the tatami mat, The aforementioned back-folding plate is pressed from above to fold the other side of the tatami surface inward, and is characterized by having a floor edge retainer that is movable up and down to fix it to the other side and back of the tatami base.

[0066] By configuring it in this way, and by providing a floor edge retainer that can move up and down, when the back folding plate moves in a direction that approaches the upper back surface of the other side of the tatami mat base, the floor edge retainer presses the back folding plate from above, folding the other side of the tatami surface inward and securely fixing it to the other side and back surface of the tatami mat base.

[0067] Furthermore, the tatami mat folding device of the present invention is When using the aforementioned tatami mat folding device for half-size tatami mats, The left folding unit and the right folding unit are operated simultaneously. The other side of the tatami mat surface for the half-size tatami mat is folded inward relative to the other side of the tatami mat base for the half-size tatami mat, It is characterized by being configured to be fixed to the other side of a tatami mat base designed for half a tatami mat.

[0068] With this configuration, when using the tatami mat folding device for half-size tatami mats, the left folding unit and the right folding unit can be operated simultaneously to fold the other side of the tatami mat surface inward relative to the other side of the half-size tatami mat base, and then secure it to the other side of the half-size tatami mat base.

[0069] Furthermore, the tatami mat folding device of the present invention is When using the aforementioned tatami mat folding device for a single tatami mat without any creases, The left folding unit and the right folding unit are operated simultaneously. With respect to the other side of the tatami mat surface, which is a single-mat size tatami mat without any irregularities, the other side of the tatami mat surface, which is a single-mat size tatami mat without any irregularities, is folded inward. It is characterized by being designed to be fixed to the other side of a tatami mat base for one tatami mat, which has no irregularities in the middle.

[0070] By configuring it in this way, when using the tatami surface folding device for a single tatami mat without any creases in the middle, the left folding unit and the right folding unit can be operated simultaneously to fold the other side of the tatami surface of a single tatami mat without any creases inward and fix it to the other side of the tatami base of a single tatami mat without any creases in the middle.

[0071] Furthermore, the tatami mat folding device of the present invention is When using the aforementioned tatami mat folding device for a single tatami mat with a slight crease in the middle, By activating either the left folding unit or the right folding unit, One side of the tatami mat surface of the tatami mat with the aforementioned curvature is folded inward relative to one side of the other side of the tatami mat base with the aforementioned curvature. After fixing it to one side of the other edge of the tatami mat base for a single tatami mat that has a slight irregularity throughout, By activating either the left-side folding unit or the right-side folding unit, The other side of the tatami mat surface of the tatami mat with the aforementioned curvature is folded inward relative to the other side of the other side of the tatami mat base of the tatami mat with the aforementioned curvature. It is characterized by being configured to be fixed to the other side of the other edge of a tatami mat base for a single tatami mat that has a slight irregularity in the middle.

[0072] With this configuration, when using the tatami mat folding device for a single tatami mat with a slight curvature in the middle, either the left folding unit or the right folding unit is activated.

[0073] This allows one side of the tatami mat surface for a single tatami mat with a central curvature to be folded inward and fixed to one side of the other side of the tatami mat base for a single tatami mat with a central curvature.

[0074] Then, activate either the left-side folding unit or the right-side folding unit.

[0075] This allows the other side of the tatami mat surface, which has a natural curve in the middle, to be folded inward and fixed to the other side of the other side of the tatami mat base, which has a natural curve in the middle.

[0076] Therefore, even for tatami mats with irregular shapes throughout a single tatami mat area, it is possible to provide a tatami mat folding device that can handle and fold the mat surface while maintaining the same required area as the machine size, and also produces a superior finish.

[0077] Furthermore, the tatami mat folding device of the present invention is The aforementioned mounting table is configured to be able to move up and down, The aforementioned support table is configured to lower when the other side of the tatami surface is folded inward relative to the other side of the tatami base and fixed to the other side of the tatami base.

[0078] In this way, the mounting table may be configured to lower when the other side of the tatami surface is folded inward relative to the other side of the tatami base and fixed to the other side of the tatami base.

[0079] Furthermore, the tatami mat folding device of the present invention is The aforementioned mounting table is configured to be unable to move up and down. The bending member is characterized by being configured to be able to move up and down.

[0080] In this way, by fixing the mounting table (making it impossible to move up and down) and configuring the folding member to be able to move up and down, the other side of the tatami surface can be folded inward and fixed to the other side of the tatami base.

[0081] Furthermore, the tatami mat folding device of the present invention is The other end of the tatami mat surface is secured with a chuck, and with the surface stretched and tension applied, To fold the other side of the tatami surface inward and secure it to the other side of the tatami base, The tatami mat surface is characterized by being equipped with a surface-covering device configured to be vertically movable.

[0082] This configuration provides a surface-covering device that is configured to move up and down relative to the tatami surface.

[0083] This allows the other end of the tatami surface to be chucked, and with tension applied while the surface is stretched, the other end of the tatami surface can be folded inward and fixed to the other end of the tatami base.

[0084] Therefore, when folding the other sides of the tatami mat surface (for example, the upper and lower front sides), tension can be applied to the side that is folded later to achieve a neat finish.

[0085] Furthermore, the tatami mat folding device of the present invention is The aforementioned bending member is equipped with a heating device, The initial position of the bending member is configured to be close to the other side of the tatami mat base. The device is characterized by being configured to heat the tatami mat surface that protrudes outward from the folded end side of the aforementioned table, which is located above the aforementioned folding member.

[0086] With this configuration, the bending member is equipped with a heating device, and the initial position of the bending member is in close proximity to the other side of the tatami mat base.

[0087] This heats the tatami mat surface that protrudes outward from the folded end side of the aforementioned table, which is located above the folding member. For example, by moistening the tatami mat surface and warming it, it becomes possible to fold it neatly and achieve a clean finish.

[0088] Furthermore, the tatami mat folding device of the present invention is The positioning plates of the left bending unit and the right bending unit are It is provided on a common positioning frame member that moves up and down, The positioning plates of the left-side bending unit and the right-side bending unit are configured to be independently movable up and down.

[0089] In other words, in order to divide the positioning frame member into left and right sections, it is necessary to attach a linear guide that supports the top and bottom of the positioning frame member in the middle, but this is structurally difficult due to interference with the tatami mat.

[0090] In contrast, by configuring the system as described in the present invention, the positioning plates for the left folding unit and the right folding unit are provided on a common positioning frame member that moves up and down, and the positioning plates for the left folding unit and the right folding unit can be configured to move up and down independently, thus preventing interference with the tatami mat. [Effects of the Invention]

[0091] According to the present invention, the left-side folding unit and the right-side folding unit are configured to operate either individually or both simultaneously.

[0092] Therefore, by operating both the left-side folding unit and the right-side folding unit simultaneously, it is possible to fold two half-size tatami mats at the same time.

[0093] Furthermore, even a single tatami mat without any creases can be folded in a single folding motion by operating both the left-side folding unit and the right-side folding unit simultaneously.

[0094] Furthermore, by operating only one of the left-side folding unit and the right-side folding unit, even tatami mats with irregular shapes throughout an entire tatami room can be handled and folded while maintaining the same required area as the machine size.

[0095] In other words, the left folding unit and the right folding unit are, • A positioning plate configured to be vertically movable relative to the mounting table, • A foldable member configured to be detachable from the other side of the tatami mat base, Because it is equipped with such features, it can be folded without interfering with the tatami mat or tatami surface, and it can also be provided with a tatami surface folding device that produces an excellent finish.

[0096] Therefore, this tatami mat folding device can fold two half-size tatami mats simultaneously, fold a single tatami mat without any creases in a single folding operation, and even handle tatami mats with creases throughout, while maintaining the same required area as the machine size, and also provides a tatami mat surface folding device with a superior finish. [Brief explanation of the drawing]

[0097] [Figure 1] Figure 1 is a front view of the tatami mat folding device of the present invention. [Figure 2] Figure 2 is a top view of the tatami mat folding device shown in Figure 1. [Figure 3] Figure 3 is a side view of the tatami mat folding device along line AA in Figure 1, showing the case where the initial position of the folding member is separated from the other side of the tatami mat base. [Figure 4] Figure 4 is a side view of the tatami mat folding device along line BB in Figure 1, showing the case where the initial position of the folding member is separated from the other side of the tatami mat base. [Figure 5] Figure 5 is a side view of the tatami mat folding device along line CC in Figure 1, showing the case where the initial position of the folding member is separated from the other side of the tatami mat base. [Figure 6] Figure 6 is a schematic top view showing the operating state of a tatami mat with a valley-shaped curvature in a single tatami mat area in the tatami mat folding device 10 of the present invention. Figure 6(A) is a schematic top view illustrating the state of a tatami mat with a valley-shaped curvature in a single tatami mat area, Figure 6(B) is a schematic top view illustrating the state when only the right folding unit 14b is operated, and Figure 6(C) is a schematic top view illustrating the state when only the left folding unit 14a is operated. [Figure 7]Figure 7 is a schematic top view showing the operating state of a tatami mat with a curved shape in the middle of a single tatami mat in the tatami mat folding device 10 of the present invention. Figure 7(A) is a schematic top view illustrating the state of a tatami mat with a curved shape in the middle of a single tatami mat. Figure 7(B) is a schematic top view illustrating the state when only the right folding unit 14b is operated. Figure 7(C) is a schematic top view illustrating the state when only the left folding unit 14a is operated. [Figure 8] Figure 8 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 9] Figure 9 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 10] Figure 10 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 11] Figure 11 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 12] Figure 12 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 13] Figure 13 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 14] Figure 14 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 15] Figure 15 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 16] Figure 16 is a schematic diagram illustrating the operation of the tatami mat folding device of the present invention. [Figure 17] Figure 17 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 18] Figure 18 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 19] Figure 19 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 20] Figure 20 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 21] Figure 21 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 22]Figure 22 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 23] Figure 23 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 24] Figure 24 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 25] Figure 25 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 26] Figure 26 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 27] Figure 27 is a schematic diagram showing the operation of the tatami mat folding device of the present invention. [Figure 28] Figure 28 is a side view of the tatami mat folding device along line AA in Figure 1, showing another embodiment of the tatami mat folding device of the present invention, where the initial position of the folding member is close to the other side of the tatami mat base. [Figure 29] Figure 29 is a side view of the tatami mat folding device along line BB in Figure 1, showing the case where the initial position of the folding member is close to the other side of the tatami mat base. [Figure 30] Figure 30 is a side view of the tatami mat folding device along line CC in Figure 1, showing the case where the initial position of the folding member is close to the other side of the tatami mat base. [Figure 31] Figure 31 is a side view of the tatami mat folding device along line CC in Figure 1, showing the state when the surface covering device is activated, with the initial position of the folding member being close to the other side of the tatami mat base. [Figure 32] Figure 32 is a flowchart showing the operation of the tatami mat folding device of the present invention. [Figure 33] Figure 33 is a flowchart showing the operation of the tatami mat folding device of the present invention. [Figure 34] Figure 34 is a schematic diagram showing the process of manufacturing a borderless tatami mat 201 by folding the tatami surface 200 along the sides of the tatami base 206 (upper front side 206a and lower front side 206b) so that it aligns with the side 208 of the tatami base 206 at an angle of approximately 90° or more. [Figure 35]Figure 35 is a top view illustrating the state of having tatami mats laid out. [Figure 36] Figure 36 is a top view illustrating the problem of folding the tatami mat surface 200 along the side edge 208 of the tatami mat base 206. [Figure 37] Figure 37 is a schematic diagram of the tatami mat folding device 300 described in Patent Document 4. [Figure 38] Figure 38 is a top view illustrating the problem of folding the tatami mat surface 200 along the side edge 208 of the tatami mat base 206. [Figure 39] Figure 39 is a top view illustrating the problem of folding the tatami mat surface 200 along the side edge 208 of the tatami mat base 206. [Figure 40] Figure 40 is a top view illustrating the problem of folding the tatami mat surface 200 along the side edge 208 of the tatami mat base 206. [Modes for carrying out the invention]

[0098] The embodiments (examples) of the present invention will be described in more detail below with reference to the drawings. (Example 1)

[0099] Figure 1 is a front view of the tatami mat bending device of the present invention, Figure 2 is a top view of the tatami mat bending device of Figure 1, Figure 3 is a side view of the tatami mat bending device along line AA in Figure 1, showing the case where the initial position of the bending member is separated from the other side edge of the tatami mat base, Figure 4 is a side view of the tatami mat bending device along line BB in Figure 1, showing the case where the initial position of the bending member is separated from the other side edge of the tatami mat base, and Figure 5 is a side view of the tatami mat bending device along line CC in Figure 1, showing the case where the initial position of the bending member is separated from the other side edge of the tatami mat base.

[0100] In Figures 1 and 2, reference numeral 10 denotes the tatami mat folding device of the present invention as a whole.

[0101] The tatami mat folding device 10 of the present invention is for manufacturing so-called "borderless tatami mats," and as shown in Figure 34, in order to manufacture such borderless tatami mats 201, it is used to fold the tatami mat surface 200 along the side edges of the tatami mat base 206 (upper front side edge 206a and lower front side edge 206b) so that it aligns with the side edge 208 of the tatami mat base 206 at an angle of approximately 90° or more.

[0102] Note that in Figure 34, for the sake of explanation, only one side is shown, and it illustrates the state in which, in the frame-frame method, one side 216 of the tatami surface 200 on the frame-frame side is fixed to the side 214 of the tatami base 206 on the frame-frame side.

[0103] In other words, as shown in Figure 34, the stems of the rush grass on the tatami mat surface 200 are bent in the direction A along the tatami mat base (the direction of the rush grass), and the side edges 202 of the tatami mat surface 200 are bent along the side edges 208 of the tatami mat base 206. The bent side edges 210 are then fixed to the side edges 208 or the back surface 212 of the tatami mat base 206, for example, by using a hand tacker, sewing, or securing with adhesive or tape.

[0104] Note that in Figure 34, for the sake of clarity, the weave pattern of the rush grass in the tatami mat 200 has been omitted.

[0105] Although not shown in the diagram, tatami mats are typically wider on the top surface and narrower on the bottom surface.

[0106] Furthermore, in the tatami mat folding device 10 of the present invention, the "other side 202" of the tatami mat 200, which is the side of the tatami mat 200 to be folded, refers to the longitudinal side of the tatami mat 200 when it is for a full tatami mat, and to the side that is perpendicular or nearly perpendicular to the frame side 204 (for example, the upper front side and the lower front side) when it is for a half tatami mat.

[0107] Furthermore, in the tatami mat folding device 10 of the present invention, the "other side 208" of the tatami mat base 206 refers to the longitudinal side of the tatami mat base 206 when it is for a full tatami mat, and to the side that is perpendicular or nearly perpendicular to the frame side 214 when it is for a half tatami mat (for example, the upper front side and the lower front side).

[0108] Furthermore, the tatami mat surface 200 targeted by the tatami mat surface bending device 10 of the present invention can be applied to all types of tatami mat surfaces, such as tatami mat surfaces 200 made from natural rush grass, tatami mat surfaces 200 made from Japanese paper rush grass, and tatami mat surfaces 200 made from resin rush grass.

[0109] Furthermore, the tatami mat folding device 10 of the present invention is used in a state in which one side 216 of the tatami mat surface 200 on the frame direction side is fixed to the frame direction side 214 of the tatami mat base 206 which has been cut to a predetermined size.

[0110] In this state, the tatami mat folding device 10 folds the other side 202 of the tatami mat surface 200 inward relative to the other side 208 of the tatami mat base 206 and fixes it to the other side 208 of the tatami mat base 206.

[0111] As shown in Figures 1 to 5, the tatami mat folding device 10 is equipped with a support frame 12.

[0112] As shown in Figures 1 and 2, the left-side folding unit 14a is located on the left side of the tatami mat folding device in the front view, on this support frame 12.

[0113] Furthermore, as shown in Figures 1 and 2, the tatami mat folding device 10 is equipped with a right-side folding unit 14b located on the right side in the front view.

[0114] As shown in Figures 3 to 5, a placement table 16 is provided for placing the tatami mat surface 200 and the tatami mat base 206 in their respective positions.

[0115] In this embodiment, the mounting table 16 is configured to move up and down by a mounting table drive mechanism 11, which is composed of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0116] Furthermore, in the case of a piston cylinder mechanism, the mounting table 16 is configured to descend due to the downward pressure of the floor retainer 20, which is lowered by the floor retainer drive mechanism 15. In other words, although not shown in the diagram, the mounting table drive mechanism 11 has four air cylinders.

[0117] Furthermore, a biasing force is constantly acting on the air cylinders of the mounting table drive mechanism 11 to push them upward. During step S9 (the folding process of the tatami mat surface 200), which will be described later, the output of two air cylinders is cut off, and the downward pressure of the floor retainer 20 is stronger than the upward pressure of the remaining two, causing the mounting table 16 to descend.

[0118] This configuration allows the mounting table 16 to descend when the other side 202 of the tatami surface 200 is folded inward relative to the other side 208 of the tatami base 206 and fixed to the other side 208 of the tatami base 206.

[0119] Furthermore, the left-side folding unit 14a is equipped with a left-side positioning plate 18a that is configured to move up and down relative to the mounting table 16 by a left-side positioning plate drive mechanism 13a, which consists of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0120] Furthermore, the left positioning plate 18a is configured to determine the folding position of the tatami mat surface 200, and to position the other side 208 of the tatami mat base 206 at the folding position.

[0121] Furthermore, the tatami mat base 206 is equipped with a floor retainer 20 that is configured to move up and down by a floor retainer drive mechanism 15, which consists of, for example, a piston cylinder mechanism, a servo motor, or a ball screw.

[0122] Furthermore, the floor retainer 20 is configured to hold the tatami mat base 206, which is placed and positioned on the mounting table 16.

[0123] Furthermore, the left-side folding unit 14a is equipped with a left-side folding member (lateral push block) 24a that is positioned opposite the folding end 22a of the mounting table 16 and is configured to be able to move toward and away from the other side 208 of the tatami mat base 206 by a left-side movement assist mechanism 17a, which consists of, for example, a piston cylinder mechanism, a servo motor, or a ball screw.

[0124] Furthermore, a left-side moving mechanism 25a, consisting of, for example, a piston cylinder mechanism, a servo motor, or a ball screw, is provided to move the left-side folding member 24a from an approach position Q, which is close to the other side 208 of the tatami mat base 206, to a retracted position R, which is away from the other side 208 of the tatami mat base 206.

[0125] Furthermore, the left-side folding member 24a is configured to allow the tatami mat surface 200, which protrudes outward from the folding end 22a side of the mounting table 16, to be folded.

[0126] In this case, the left-side moving mechanism 25a alone is insufficient to press the left-side folding member 24a against the other side 208 of the tatami mat base 206. Therefore, the left-side moving assist mechanism 17a is provided to rotate the left-side folding member 24a, thereby enabling it to be pressed against the other side 208 of the tatami mat base 206.

[0127] Furthermore, the right-side folding unit 14b is equipped with a right-side positioning plate 18b that is configured to move up and down relative to the mounting table 16 by a right-side positioning plate drive mechanism 13b, which consists of, for example, a piston cylinder mechanism, a servo motor, or a ball screw.

[0128] Furthermore, the right-side positioning plate 18b is configured to determine the folding position of the tatami mat surface 200, and to position the other side 208 of the tatami mat base 206 at the folding position.

[0129] Furthermore, the right-side bending unit 14b is equipped with a right-side bending member (lateral pushing block) 24b, which is positioned opposite the bending end 22a of the mounting table 16 and is configured to be able to move toward and away from the other side 208 of the tatami mat base 206 by a right-side movement assist mechanism 17b, which consists of, for example, a piston cylinder mechanism, a servo motor, or a ball screw.

[0130] Furthermore, a right-side moving mechanism 25b, consisting of, for example, a piston cylinder mechanism, a servo motor, or a ball screw, is provided to move the right-side folding member 24b from an approach position Q, which is close to the other side 208 of the tatami mat base 206, to a retracted position R, which is away from the other side 208 of the tatami mat base 206.

[0131] Furthermore, the right-side bending member 24b is configured to allow the tatami mat surface 200, which protrudes outward from the bending end 22a side of the mounting table 16, to be folded.

[0132] In this case, the right-side moving mechanism 25b alone cannot press the right-side bending member 24b against the other side 208 of the tatami mat base 206. Therefore, the right-side moving assist mechanism 17b is configured to rotate the right-side bending member 24b, thereby enabling it to be pressed against the other side 208 of the tatami mat base 206.

[0133] Furthermore, as shown in Figures 3 to 5, the left-side folding unit 14a is configured to fold the other side 202 of the tatami surface 200 inward and fix it to the other side 208 and back surface 212 of the tatami base 206, in case the tatami base 206 is a thin tatami mat.

[0134] Therefore, a left-side back folding plate 26a is provided on the upper part of the back surface 212 of the other side 208 of the tatami mat base 206, which is configured to be able to move toward and away from it by a left-side back folding plate driving mechanism 19a, which consists of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0135] Furthermore, as shown in Figures 3 to 5, the left-side folding unit 14a is equipped with a left-side floor edge retainer 28a that can move up and down, driven by a left-side floor edge retainer drive mechanism 21a, which consists of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0136] Furthermore, when the left rear folding plate 26a moves in a direction approaching the upper part of the back surface 212 of the other side 208 of the tatami base 206, the left floor edge retainer 28a presses down on the left rear folding plate 26a from above, folding the other side 202 of the tatami surface 200 inward and fixing it to the other side 208 and back surface 212 of the tatami base 206.

[0137] Similarly, as shown in Figures 3 to 5, the right-side bending unit 14b is equipped with a right-side floor edge retainer 28b that can move up and down, driven by a right-side floor edge retainer drive mechanism 21b, which consists of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0138] Then, when the right-side folding unit 14b moves the right-side back folding plate 26b toward the upper part of the back surface 212 of the other side 208 of the tatami base 206, the right-side floor edge retainer 28b presses down on the right-side back folding plate 26b from above, folding the other side 202 of the tatami surface 200 inward and fixing it to the other side 208 and back surface 212 of the tatami base 206.

[0139] Furthermore, as shown in Figures 3 to 5, the left folding unit 14a is equipped with a left surface covering device 30a that is configured to move up and down relative to the tatami surface 200 by a left surface covering device drive mechanism 23a, which consists of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0140] Then, the left-side surface-covering device 30a chucks the end of the other side 202 of the tatami surface 200, and while the surface is covered and tension is applied, the other side 202 of the tatami surface 200 is folded inward against the other side 208 of the tatami base 206 and fixed to the other side 208 of the tatami base 206.

[0141] Similarly, as shown in Figures 3 to 5, the right-side folding unit 14b is equipped with a right-side surface covering device 30b that is configured to move up and down relative to the tatami surface 200 by a right-side surface covering device drive mechanism 23b, which consists of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0142] Then, the right-side surface-covering device 30b chucks the end of the other side 202 of the tatami surface 200, and while the surface is covered and tension is applied, the other side 202 of the tatami surface 200 is folded inward against the other side 208 of the tatami base 206 and fixed to the other side 208 of the tatami base 206.

[0143] Therefore, the left-side surface-covering device 30a and the right-side surface-covering device 30b are configured to apply tension to the side that is folded later when folding the other side 202 of the tatami surface 200 (for example, the upper front side and the lower front side), so that it can be finished neatly.

[0144] Furthermore, as shown in Figures 1 to 5, in the tatami mat folding device 10 of the present invention, the left positioning plate 18a of the left folding unit 14a and the right positioning plate 18b of the right folding unit 14b are mounted on a common frame member 35 that moves up and down by a frame member drive mechanism 29 composed of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0145] Furthermore, when the frame member 35 is lowered by the frame member drive mechanism 29 and the floor edge retainer 28 is lowered by the floor edge retainer drive mechanism 21 at the same time, the lowering of the frame member 35 by the frame member drive mechanism 29 and the lowering of the floor edge retainer 28 by the floor edge retainer drive mechanism 21 are configured so that they do not each lower to their maximum length.

[0146] In other words, the downward pressure exerted by the floor edge retainer drive mechanism 21 on the floor edge retainer 28 is stronger than the downward pressure exerted by the frame member drive mechanism 29 on the frame member 35. Therefore, when the frame member 35 is to be lowered by the frame member drive mechanism 29 and the floor edge retainer 28 is to be lowered by the floor edge retainer drive mechanism 21, The floor edge retainer 28 is lowered by the floor edge retainer drive mechanism 21 until it reaches its lowest point (using up to its maximum stroke). The frame member 35 is lowered by the frame member drive mechanism 29 until the floor edge retainer 28 contacts the tatami mat base 206 (the full stroke is not used). It is structured in this way.

[0147] To operate in this manner, the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b) and the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are configured to always operate simultaneously on both the left and right sides.

[0148] Furthermore, when the frame member 35 driven by the frame member drive mechanism 29 is descending, and the floor edge retainer 28 driven by the floor edge retainer drive mechanism 21 is descending, after the floor edge retainer 28 has come into contact with the tatami mat floor 206, the frame member 35 driven by the frame member drive mechanism 29 is configured to rise by the amount that it is unable to withstand the downward pressure of the floor edge retainer 28 driven by the floor edge retainer drive mechanism 21.

[0149] Furthermore, the left positioning plate 18a of the left bending unit 14a and the right positioning plate 18b of the right bending unit 14b are configured to move up and down independently by a left positioning plate drive mechanism 13a and a right positioning plate drive mechanism 13b, which are composed of, for example, a piston cylinder mechanism, a servo motor, and a ball screw.

[0150] In other words, in order to divide the frame member 35 into left and right sections, it is necessary to attach a linear guide that supports the top and bottom of the positioning frame member in the middle, but this is structurally difficult due to interference with the tatami mat.

[0151] In contrast, by configuring the present invention as described above, the left positioning plate 18a of the left folding unit 14a and the right positioning plate 18b of the right folding unit 14b can each be configured to move up and down independently, thus preventing interference with the tatami mat.

[0152] Furthermore, the positioning plates 18 (left positioning plate 18a, right positioning plate 18b) are provided (attached) to a common frame member 35 that moves up and down by the frame member drive mechanism 29, and are configured to operate without being interfered with by other mechanisms.

[0153] Furthermore, since the positioning plate 18 is provided (attached) to a common frame member 35 that moves up and down by the frame member drive mechanism 29, when the downward pressure on the frame member 35 by the frame member drive mechanism 29 is overcome by the downward pressure on the floor edge retainer 28 by the floor edge retainer drive mechanism 21, the positioning plate 18 also rises. At this time, the positioning plate drive mechanism 13a is not operating.

[0154] Furthermore, when the floor edge retainer 28 is raised by the floor edge retainer drive mechanism 21, while both the floor edge retainer drive mechanism 21 is lowering the floor edge retainer 28 and the frame member drive mechanism 29 is lowering the frame member drive mechanism 29 by the amount that was lost to the lowering of the floor edge retainer 28 by the floor edge retainer drive mechanism 21, thus utilizing the maximum amount of stroke.

[0155] In this configuration, the positioning plate 18 is provided (attached) to a common frame member 35 that moves up and down by the frame member drive mechanism 29, and is configured to also move downward.

[0156] Furthermore, as shown in Figures 4 and 5, above the frame 12 of the tatami mat bending device 10 of the present invention, a pair of upper and lower floor bending devices, an upper floor bending device 32 and a lower floor bending device 34, are provided for bending the floor.

[0157] These upper floor bending devices 32 and lower floor bending devices 34 are each equipped with an upper floor bending drive mechanism 36 and a lower floor bending drive mechanism 38, respectively, which are composed of, for example, a piston cylinder mechanism, a servo motor, and a ball screw.

[0158] Furthermore, as shown in Figures 4 and 5, above the frame 12 of the tatami mat folding device 10 of the present invention, there is a temporary holder 33 that is configured to be vertically movable by a temporary holder drive mechanism 31 for temporarily holding down the tatami mat base 206.

[0159] Furthermore, as shown in Figure 1, a control device 40 is provided at the upper center of the frame 12 of the tatami mat folding device 10 of the present invention.

[0160] Furthermore, the control panel 42 of the control device 40 is equipped with a left-side operation switch 44a and a right-side operation switch 44b, respectively.

[0161] Furthermore, the two operating switches, the left-side operating switch 44a and the right-side operating switch 44b, are provided for safety reasons, and are configured to operate only when both are pressed simultaneously.

[0162] The left folding unit 14a, the right folding unit 14b, and the left folding unit 14a and the right folding unit 14b are all operated by pressing both the left operation switch 44a and the right operation switch 44b simultaneously.

[0163] Furthermore, the control panel 42 of the control device 40 is equipped with an automatic / manual changeover switch 46, a circuit breaker 48, a circuit breaker lamp 50, and a home position return switch 52.

[0164] Furthermore, the control panel 42 of the control device 40 is equipped with ON / OFF switches 54 for the heaters built into the bending members 24 (left bending member 24a, right bending member 24a).

[0165] Furthermore, a heater temperature setting display unit 56 is provided that displays the set temperature of the heaters built into the bending members 24 (left bending member 24a, right bending member 24a).

[0166] Furthermore, the control panel 42 of the control device 40 is equipped with an upward switch 58 for raising the upward floor bending device 32 and a downward switch 60 for lowering the downward floor bending device 34.

[0167] The tatami mat folding device 10 of the present invention, configured in this manner, is used as follows.

[0168] In other words, the left-side folding unit 14a and the right-side folding unit 14b are configured to operate either individually or both simultaneously.

[0169] Therefore, by operating both the left folding unit 14a and the right folding unit 14b simultaneously, two half-size tatami mats can be folded at the same time.

[0170] Furthermore, even a tatami mat without any creases can be folded in a single folding operation by simultaneously operating both the left-side folding unit 14a and the right-side folding unit 14b.

[0171] Furthermore, by operating only one of the left-side folding unit 14a and the right-side folding unit 14b, even tatami mats with irregular shapes throughout a single tatami mat area can be handled and folded while maintaining the same required area as the machine size.

[0172] Specifically, Figure 6 is a schematic top view showing the operating state of a tatami mat with a valley-shaped curvature in the tatami mat surface folding device 10 of the present invention, where Figure 6(A) is a schematic top view illustrating the state of a tatami mat with a valley-shaped curvature in the tatami mat surface, Figure 6(B) is a schematic top view illustrating the state when only the right folding unit 14b is operated, and Figure 6(C) is a schematic top view illustrating the state when only the left folding unit 14a is operated.

[0173] Figure 7 is a schematic top view showing the operating state of a tatami mat with a curved shape in the middle of a single tatami mat in the tatami mat folding device 10 of the present invention. Figure 7(A) is a schematic top view illustrating the state of a tatami mat with a curved shape in the middle of a single tatami mat. Figure 7(B) is a schematic top view illustrating the state when only the right folding unit 14b is operated. Figure 7(C) is a schematic top view illustrating the state when only the left folding unit 14a is operated.

[0174] Specifically, although not shown in the diagram, if the tatami mat base 206 has a valley-shaped curvature, the tatami mat surface 200 is cut parallel to the curvature, and then cuts are made in the middle.

[0175] Then, from the state shown in Figure 6(A), rotate it counterclockwise to the state shown in Figure 6(B), and activate only the right-side folding unit 14b to fold only the right side of the tatami mat surface 200.

[0176] On the other hand, from the state shown in Figure 6(A), rotate it clockwise to the state shown in Figure 6(C), and activate only the left folding unit 14a to fold only the left side of the tatami mat surface 200.

[0177] Therefore, by operating only one of the left folding unit 14a and the right folding unit 14b, even tatami mats with irregular shapes throughout a single tatami mat area can be handled and folded while maintaining the same required area as the machine size.

[0178] Specifically, although not shown in the diagram, if the tatami mat base 206 has a mountain-like shape, the middle section is cut in a V-shape so that it does not overlap when the tatami mat surface 200 is folded.

[0179] Then, from the state shown in Figure 7(A), rotate it clockwise to the state shown in Figure 7(B), and activate only the right-side folding unit 14b to fold only the right side of the tatami mat surface 200.

[0180] On the other hand, from the state shown in Figure 7(A), rotate it counterclockwise to the state shown in Figure 7(C), and activate only the left folding unit 14a to fold only the left side of the tatami mat surface 200.

[0181] Therefore, by operating only one of the left folding unit 14a and the right folding unit 14b, even tatami mats with irregular shapes throughout a single tatami mat area can be handled and folded while maintaining the same required area as the machine size.

[0182] Thus, in the tatami mat folding device 10 of the present invention, the left folding unit 14a and the right folding unit 14b are, respectively, • Positioning plates 18 (left positioning plate 18a, right positioning plate 18b) configured to move vertically relative to the mounting table 16, • A folding member 24 (left folding member 24a, right folding member 24a) is configured to be detachable from the other side 208 of the tatami mat base 206, Because it is equipped with such features, it can be folded without interfering with the tatami mat or tatami surface, and it can also be provided with a tatami surface folding device that produces an excellent finish.

[0183] Therefore, it is possible to provide a tatami mat folding device 10 that can fold two half-size tatami mats simultaneously, fold a single tatami mat without any creases in a single folding operation, and even handle tatami mats with creases throughout the entire surface while maintaining the same required area as the machine size, and also produce a superior finish.

[0184] The tatami mat folding device 10 of the present invention, configured in this manner, will be described below based on the flowcharts in Figures 8 to 27 and 32 to 33.

[0185] For parts that are divided into left and right sections, the left side will be designated "a" and the right side "b".

[0186] In addition, tatami mats with a thickness of 30mm or more are generally called "thick tatami," and those with a thickness of 25mm or less are called "thin tatami."

[0187] Furthermore, in the case of thick tatami mats, the tatami surface 200 is fixed to the other sides 202 of the tatami surface 200 (for example, the upper front side and the lower front side).

[0188] In the case of thin tatami mats, the tatami surface 200 is folded up to the underside 212 of the side edge 208 of the tatami base 206 and secured on the underside.

[0189] Furthermore, the driving modes—both left and right, left only, or right only—can be selected in advance.

[0190] For example, the control panel 42 of the control device 40 can be configured to perform automatic control via an input device. (Example 2) (A) Activate only the left folding unit 14a (when folding only the left side)

[0191] The following describes the operation of only the left-side folding unit 14a (when folding only the left side). (1) Step S1 (Origin state)

[0192] As shown in the flowcharts in Figures 3, 5, 8, and 32, in step S1, the origin state is established (origin state).

[0193] In other words, the left bending unit 14a and the right bending unit 14b are moved to a retracted position R away from the other side 208 of the tatami mat base 206 by pressing the home position return switch 52.

[0194] In this state, the frame member 35 is raised by the frame member drive mechanism 29.

[0195] Furthermore, the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b position the left positioning plate 18a and the right positioning plate 18b in a raised position.

[0196] Furthermore, the left-side moving mechanism 25a and the right-side moving mechanism 25b position the left-side folding member 24a and the right-side folding member 24b in a retracted position R, separated from the other side 208 of the tatami mat base 206.

[0197] Furthermore, the left floor edge retainer drive mechanism 21a and the right floor edge retainer drive mechanism 21b position the left floor edge retainer 28a and the right floor edge retainer 28b in a raised position.

[0198] Furthermore, the floor retainer 20 is held in a raised position by a floor retainer drive mechanism 15, which consists of, for example, a piston cylinder mechanism, a servo motor, a ball screw, etc.

[0199] Furthermore, the temporary retainer 33 is held in a raised position by a temporary retainer drive mechanism 31, which consists of, for example, a piston cylinder mechanism, a servo motor, and a ball screw.

[0200] Furthermore, the back-side folding plate drive mechanism 19 (left-side back-side folding plate drive mechanism 19a, right-side back-side folding plate drive mechanism 19b) positions the back-side folding plate drive mechanism 19 (left-side back-side folding plate drive mechanism 19a, right-side back-side folding plate drive mechanism 19b) in a retracted position R that is separated from the other side edges 208 of the tatami mat base 206. (2) Step S2 (Set of 200 tatami mats)

[0201] Next, as shown in the flowcharts in Figures 9 and 32, in step S2, the tatami mat base 206 is set on the mounting table 16 with the tatami mat surface 200 facing downwards (setting the tatami mat surface 200).

[0202] In this case, the end face of the tatami mat to be folded (the other side 208 of the tatami mat 206) is positioned a few millimeters inward from the tip of the mounting table 16.

[0203] At this time, the left bending member (lateral push block) 24a and the right bending member (lateral push block) 24b are in the retracted position R, as shown in Figure 9.

[0204] Furthermore, as mentioned above, although not shown in the illustration, notches are made in the other sides 202 of the tatami mat surface 200 at the midpoint. (3) Step S3 (Operation of the operating switch)

[0205] Next, as shown in the flowcharts in Figures 10 and 32, in step S3, the operation of the left bending unit 14a is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0206] As a result, as shown in Figure 10, the frame member 35 is lowered by the frame member drive mechanism 29.

[0207] Furthermore, the left positioning plate 18a is lowered by the left positioning plate drive mechanism 13a.

[0208] Furthermore, the floor retainer 20 is lowered by the floor retainer drive mechanism 15.

[0209] In this configuration, the left positioning plate 18a and the floor retainer 20 are configured to descend while leaving a gap that does not sandwich the tatami surface 200 and the tatami base 206.

[0210] Then, the left-side moving mechanism 25a moves the left-side folding member 24a to a position Q that is close to the other side 208 of the tatami mat base 206.

[0211] At this time, the left-side movement assist mechanism 17a is not yet activated, and the left-side folding member 24a is not pressing against the other side 208 of the tatami mat base 206. (4) Step S4 (Positioning of the left positioning plate 18a on the back surface)

[0212] Next, as shown in the flowcharts in Figures 11 and 32, in step S4, the worker presses the other side 208 of the tatami mat base 206 against the back surface of the left positioning plate 18a from the back side of the tatami mat folding device 10 of the present invention, as indicated by the arrow in Figure 11 (positioning of the left positioning plate 18a to the back surface).

[0213] At this time, the tatami mat base 206 is pressed down so that the midpoint of the curve (the intersection of the left and right curves) aligns with the back surface of the left positioning plate 18a. (5) Step S5 (Floor bending, surface laying)

[0214] Next, as shown in the flowcharts in Figures 12-13 and 32, in step S5, the workers perform floor bending and surface laying as necessary (floor bending and surface laying).

[0215] In other words, as shown in Figure 12, the upper floor bending drive mechanism 36 and the lower floor bending drive mechanism 38 lower the upper floor bending device 32 and the lower floor bending device 34 to perform floor bending.

[0216] Furthermore, as shown in Figure 13, the left-side surface covering device drive mechanism 23a lowers the left-side surface covering device 30a, which then chucks the end of the other side 208 of the tatami mat base 206. In Figure 13, the left-side surface covering device 30a is moved to the left (away from the other side 208 of the tatami mat base 206) to cover the surface and apply tension. (6) Step S6 (Tatami mat pressing process)

[0217] Next, as shown in the flowcharts in Figures 14 and 32, the tatami pressing process is performed in step S6.

[0218] In other words, as shown in Figure 14, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0219] Furthermore, the temporary retainer 33 is lowered by the temporary retainer drive mechanism 31.

[0220] Furthermore, the left positioning plate 18a is raised by the left positioning plate drive mechanism 13a.

[0221] Furthermore, the left-side facing device 30a is raised by the left-side facing device drive mechanism 23a.

[0222] Furthermore, the upper floor bending drive mechanism 36 and the lower floor bending drive mechanism 38 raise the upper floor bending device 32 and the lower floor bending device 34. (7) Step S7 (grooving process)

[0223] Next, as shown in the flowchart in Figure 32, the worker uses a creasing tool to make creases (to make neat folds, a creasing tool such as a border is used to make creases on the other side 202 of the tatami mat surface 200 at the folding position) (creasing process). (A-1) In the case of thick tatami mats

[0224] If a thick tatami mat is used, steps S8 to S13 are performed after step S7. (8) Step S8 (Operation of the operating switch) (In the case of thick tatami mats)

[0225] Next, as shown in the flowcharts in Figures 15 and 32, in step S8, the operation of the left bending unit 14a is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0226] As a result, as shown in Figure 15, the left positioning plate 18a is lowered by the left positioning plate drive mechanism 13a.

[0227] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0228] In this state, as shown in Figure 15, the frame member 35 is not raised. (9) Step S9 (folding process of tatami mat surface 200) (for thick tatami mats)

[0229] Next, as shown in the flowcharts in Figures 16 and 32, in step S9, the folding process of the tatami mat surface 200 is performed (folding process of the tatami mat surface 200).

[0230] In other words, as shown in Figure 16, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0231] Also, the left positioning plate drive mechanism 13a moves the left positioning plate 18a to a slightly raised position.

[0232] Furthermore, the floor presser drive mechanism 15 lowers the floor presser 20.

[0233] Also, the floor presser 20 and the placement table drive mechanism 11 lower the placement table 16.

[0234] Note that the placement table 16 is configured to lower, for example, in the case of a piston cylinder mechanism, by the downward pressure of the floor presser 20 that is lowered by the floor presser drive mechanism 15. That is, although not shown, four air cylinders of the placement table drive mechanism 11 are arranged.

[0235] And, an urging force to always raise acts on the air cylinders of the placement table drive mechanism 11, the output of two air cylinders fails, and since the downward pressure of the floor presser 20 is stronger than the upward pressure of the remaining two, the placement table 16 descends.

[0236] Thereby, the folding process of the tatami mat 200 is performed.

[0237] That is, since the downward pressure of the floor presser 20 is stronger than that of the left positioning plate 18a, the left positioning plate 18a moves to a slightly raised position.

[0238] Also, since the downward pressure of the floor presser 20 is stronger than that of the placement table 16, the placement table 16 will descend.

[0239] Note that at this time, the amount of descent of the placement table 16 basically descends by an amount approximately the same as the thickness of the tatami mat (of the tatami floor 206), but the maximum is 30 mm. (10) Step S10 (Pressing step by the left folding member 24a) (in the case of a thick tatami mat)

[0240] Next, as shown in the flowcharts of FIGS. 17 and 32, in step S10, the left movement assisting mechanism 17a moves and presses the left bending member 24a to a position closer than the approaching position Q shown by the arrow in FIG. 17 with respect to the other side 208 of the folding floor 206 (pressing step by the left bending member 24a). (11) Step S11 (folding table fixing step) (in the case of a thick folding mat)

[0241] Next, as shown in the flowcharts of FIGS. 18 and 32, in step S11, the other side 202 of the folded folding table 200 is fixed to the other side 208 of the folding floor 206 with, for example, a tacker, tape, adhesive, or the like.

[0242] At this time, as shown in FIG. 18, the frame member driving mechanism 29 raises the frame member 35.

[0243] Also, the left positioning plate driving mechanism 13a positions the left positioning plate 18a at a raised position.

[0244] Also, the floor edge presser driving mechanism 21 (left floor edge presser driving mechanism 21a, right floor edge presser driving mechanism 21b) raises the floor edge presser 28 (left floor edge presser 28a, right floor edge presser 28b). (12) Step S12 (operation switch operation) (in the case of a thick folding mat)

[0245] Next, as shown in the flowcharts of FIGS. 19 and 32, in step S12, the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 are simultaneously pressed to start the operation of the left bending unit 14a (operation switch operation).

[0246] Also, the floor presser driving mechanism 15 raises the floor presser 20.

[0247] Also, the temporary presser driving mechanism 31 raises the temporary presser 33.

[0248] Furthermore, the mounting table 16 is raised by the mounting table drive mechanism 11.

[0249] Furthermore, the left-side moving mechanism 25a and the left-side moving assist mechanism 17a move the left-side folding member 24a to a retracted position R that is separated from the other side edge 208 of the tatami mat base 206. (13) Step S13 (Removal process) (In the case of thick tatami mats)

[0250] Next, as shown in the flowchart in Figure 32, in step S13, the finished tatami mats are removed (removal process). (A-2) In the case of thin tatami mats

[0251] On the other hand, if a thin tatami mat is used, steps S14 to S22 are performed after step S7. (14) Step S14 (Operation of the operating switch) (In the case of thin tatami mats)

[0252] After step S7, as shown in the flowcharts in Figures 20 and 33, in the case of thin folding, the operation of the left folding unit 14a is started by simultaneously pressing both the left operation switch 44a and the right operation switch 44b on the control panel 42 of the device 40 (operation switch operation).

[0253] As a result, as shown in Figure 20, the left positioning plate 18a is lowered by the left positioning plate drive mechanism 13a.

[0254] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0255] Furthermore, in this state, as shown in Figure 20, the frame member 35 is in a lowered position due to the frame member drive mechanism 29. (15) Step S15 (Folding process of tatami mat surface 200) (for thin tatami mats)

[0256] Next, as shown in the flowcharts of FIGS. 21 and 33, in step S15, the folding process of the folding table 200 is performed (folding process of the folding table 200).

[0257] That is, as shown in FIG. 21, the floor edge retainers 28 (left floor edge retainer 28a and right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a and right floor edge retainer drive mechanism 21b).

[0258] Also, the left positioning plate 18a is moved to a slightly raised position by the frame member drive mechanism 29.

[0259] That is, as described above, when the floor edge retainer 28 by the floor edge retainer drive mechanism 21 is lowered while the frame member 35 by the frame member drive mechanism 29 is in a lowered state, after the floor edge retainer 28 abuts against the folding floor 206, the frame member 35 by the frame member drive mechanism 29 is configured to rise by the amount that it yields to the downward pressure of the floor edge retainer 28 by the floor edge retainer drive mechanism 21.

[0260] Furthermore, the floor retainer 20 is lowered by the floor retainer drive mechanism 15.

[0261] Also, the placement table 16 is lowered by the placement table drive mechanism 11.

[0262] Thereby, the folding process of the folding table 200 is performed.

[0263] That is, since the downward pressure of the floor retainer 20 is stronger than that of the left positioning plate 18a, the left positioning plate 18a is moved to a slightly raised position.

[0264] Also, since the downward pressure of the floor retainer 20 is stronger than that of the placement table 16, the placement table 16 is lowered. (16) Step S16 (Pressing process by the left folding member 24a) [[ID=​Next, as shown in the flowcharts in Figures 22 and 33, in step S16, the left-side moving assist mechanism 17a moves the left-side bending member 24a to a position even closer to the other side edge 208 of the tatami mat base 206 than the approach position Q, as indicated by the arrow in Figure 22, and presses it against the other side edge 208 (pressing step by the left-side bending member 24a). (17) Step S17 (Operation of the operating switch) (In the case of thin tatami mats)

[0266] Next, as shown in the flowcharts in Figures 23 and 33, in step S17, the operation of the left bending unit 14a is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0267] As a result, the frame member 35 is raised by the frame member drive mechanism 29, as shown in Figure 23.

[0268] In this process, the left-side moving mechanism 25a and the left-side moving assist mechanism 17a maintain a lateral pressure state in which the left-side bending member 24a is even closer to the other side edge 208 of the tatami mat base 206 than the approach position Q. (18) Step S18 (Folding the tatami mat base 206 to the back surface 212 by the left back surface folding plate 26a) (in the case of thin tatami mats)

[0269] In other words, as shown in the flowcharts in Figures 24 and 33, in step S18, the left folding unit 14a is configured to fold the other side 202 of the tatami surface 200 inward and fix it to the other side 208 and back surface 212 of the tatami base 206, corresponding to the case where the tatami base 206 is a thin tatami mat.

[0270] Therefore, the left rear folding plate 26a moves in a direction approaching the upper part of the back surface 212 of the other side 208 of the tatami base 206 by the left rear folding plate driving mechanism 19a, as indicated by the arrow in Figure 24.

[0271] This causes the other side 202 of the tatami surface 200 to be folded inward and along the underside 212 of the other side 208 of the tatami base 206. (19) Step S19 (Pressing the back surface 212 of the tatami mat base 206) (In the case of thin tatami mats)

[0272] Then, the frame member 35 is lowered by the frame member drive mechanism 29.

[0273] As a result, as shown in the flowcharts in Figures 25 and 33, in step S19, the left floor edge retainer 28a descends due to the descent of the frame member 35. Then, the upwardly curved tip of the left back surface folding plate 26a is fitted into a recess formed on the lower surface of the left floor edge retainer 28a, relative to the upper part of the back surface 212 of the other side 208 of the tatami base 206.

[0274] Furthermore, the upward-curving tip of the left-side back folding plate 26a is intended to avoid catching on the other side edges 202 of the tatami surface 200, making it easier to fold the other side edges 202 of the tatami surface 200 inward and align it with the back surface 212 of the tatami base 206.

[0275] As a result, when the left rear folding plate 26a moves in a direction that approaches the upper part of the back surface 212 of the other side 208 of the tatami base 206, the left floor edge retainer 28a presses down on the left rear folding plate 26a from above, folding the other side 202 of the tatami surface 200 inward and fixing it to the back surface 212 of the tatami base 206. (20) Step S20 (Tatami mat surface fixing process) (In the case of thin tatami mats)

[0276] Next, as shown in the flowcharts in Figures 26 and 33, in step S20, the other side 202 of the folded tatami mat surface 200 is fixed to the back surface 212 of the other side 208 of the tatami base 206 using, for example, a stapler, tape, or adhesive.

[0277] At this time, as shown in Figure 26, the frame member 35 is raised by the frame member drive mechanism 29.

[0278] Furthermore, the left positioning plate 18a is in a raised position due to the left positioning plate drive mechanism 13a.

[0279] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b). (21) Step S21 (Operation of the operating switch) (In the case of thin tatami mats)

[0280] Next, as shown in the flowcharts in Figures 27 and 33, in step S21, the operation of the left bending unit 14a is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0281] As a result, as shown in Figure 27, the floor retainer 20 is raised by the floor retainer drive mechanism 15.

[0282] Furthermore, the temporary retainer 33 is raised by the temporary retainer drive mechanism 31.

[0283] Furthermore, the mounting table 16 is raised by the mounting table drive mechanism 11.

[0284] Furthermore, the left-side moving mechanism 25a and the left-side moving assist mechanism 17a move the left-side folding member 24a to a retracted position R that is separated from the other side 208 of the tatami mat base 206, as shown by the arrow in Figure 27. (22) Step S22 (Removal process) (in the case of thin tatami mats)

[0285] Next, as shown in the flowchart in Figure 33, in step S22, the completed tatami mat is removed (removal process). (Example 3) (B) Activate only the right-side folding unit 14b (when folding only the right side)

[0286] The following describes the operation of only the right-side folding unit 14b (when folding only the right side).

[0287] Basically, the operation of the left-side bending unit 14a in the above embodiment 2 can be replaced with that of the right-side bending unit 14b. Therefore, the same step numbers are used for the same steps. (1) Step S1 (Origin state)

[0288] As shown in the flowcharts in Figures 3, 5, 8, and 32, in step S1, the origin state is established (origin state).

[0289] In other words, the left bending unit 14a and the right bending unit 14b are moved to a retracted position R away from the other side 208 of the tatami mat base 206 by pressing the home position return switch 52.

[0290] In this state, the frame member 35 is raised by the frame member drive mechanism 29.

[0291] Furthermore, the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b position the left positioning plate 18a and the right positioning plate 18b in a raised position.

[0292] Furthermore, the left-side moving mechanism 25a and the right-side moving mechanism 25b position the left-side folding member 24a and the right-side folding member 24b in a retracted position R, separated from the other side 208 of the tatami mat base 206.

[0293] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are in a raised position due to the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0294] Furthermore, the floor retainer 20 is in a raised position due to the floor retainer drive mechanism 15.

[0295] Furthermore, the temporary retainer 33 is in the raised position due to the temporary retainer drive mechanism 31.

[0296] Furthermore, the back-side folding plate drive mechanism 19 (left-side back-side folding plate drive mechanism 19a, right-side back-side folding plate drive mechanism 19b) positions the back-side folding plate drive mechanism 19 (left-side back-side folding plate drive mechanism 19a, right-side back-side folding plate drive mechanism 19b) in a retracted position R that is separated from the other side edges 208 of the tatami mat base 206. (2) Step S2 (Set of 200 tatami mats)

[0297] Next, as shown in the flowcharts in Figures 9 and 32, in step S2, the tatami mat base 206 is set on the mounting table 16 with the tatami mat surface 200 facing downwards (setting the tatami mat surface 200).

[0298] In this case, the end face of the tatami mat to be folded (the other side 208 of the tatami mat 206) is positioned a few millimeters inward from the tip of the mounting table 16.

[0299] At this time, the left bending member (lateral push block) 24a and the right bending member (lateral push block) 24b are in the retracted position R, as shown in Figure 9.

[0300] Furthermore, as mentioned above, although not shown in the illustration, notches are made in the other sides 202 of the tatami mat surface 200 at the midpoint. (3) Step S3 (Operation of the operating switch)

[0301] Next, as shown in the flowcharts in Figures 10 and 32, in step S3, the operation of the right bending unit 14b is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0302] As a result, as shown in Figure 10, the frame member 35 is lowered by the frame member drive mechanism 29.

[0303] Furthermore, the right positioning plate 18b is lowered by the right positioning plate drive mechanism 13b.

[0304] Furthermore, the floor retainer 20 is lowered by the floor retainer drive mechanism 15.

[0305] In this configuration, the right-side positioning plate 18b and the floor retainer 20 are configured to descend while leaving a gap that does not sandwich the tatami surface 200 and the tatami base 206.

[0306] Then, the right-side moving mechanism 25b moves the right-side folding member 24b to a position Q that is close to the other side 208 of the tatami mat base 206.

[0307] At this time, the right-side movement assist mechanism 17b is not yet activated, and the right-side folding member 24b is not pressing against the other side 208 of the tatami mat base 206. (4) Step S4 (Positioning of the right positioning plate 18b on the back surface)

[0308] Next, as shown in the flowcharts in Figures 11 and 32, in step S4, the worker presses the other side 208 of the tatami mat base 206 against the back surface of the right positioning plate 18b from the back side of the tatami mat folding device 10 of the present invention, as indicated by the arrow in Figure 11 (positioning of the right positioning plate 18b to the back surface).

[0309] At this time, the tatami mat base 206 is pressed down so that the midpoint of the curve (the intersection of the left and right curves) aligns with the back surface of the right positioning plate 18b. (5) Step S5 (Floor bending, surface laying)

[0310] Next, as shown in the flowcharts in Figures 12-13 and 32, in step S5, the workers perform floor bending and surface laying as necessary (floor bending and surface laying).

[0311] In other words, as shown in Figure 12, the upper floor bending drive mechanism 36 and the lower floor bending drive mechanism 38 lower the upper floor bending device 32 and the lower floor bending device 34 to perform floor bending.

[0312] Furthermore, as shown in Figure 13, the right-side surface covering device drive mechanism 23b lowers the right-side surface covering device 30b, which then chucks the end of the other side 208 of the tatami mat base 206. In Figure 13, the right-side surface covering device 30b is moved to the left (away from the other side 208 of the tatami mat base 206) to cover the surface and apply tension. (6) Step S6 (Tatami mat pressing process)

[0313] Next, as shown in the flowcharts in Figures 14 and 32, the tatami pressing process is performed in step S6.

[0314] In other words, as shown in Figure 14, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0315] Furthermore, the temporary retainer 33 is lowered by the temporary retainer drive mechanism 31.

[0316] Furthermore, the right positioning plate 18b is raised by the right positioning plate drive mechanism 13b.

[0317] Furthermore, the right-side facing device 30b is raised by the right-side facing device drive mechanism 23b.

[0318] Furthermore, the upper floor bending drive mechanism 36 and the lower floor bending drive mechanism 38 raise the upper floor bending device 32 and the lower floor bending device 34. (7) Step S7 (grooving process)

[0319] Next, as shown in the flowchart in Figure 32, the worker uses a creasing tool to make creases (to make neat folds, a creasing tool such as a border is used to make creases on the other side 202 of the tatami mat surface 200 at the folding position) (creasing process). (B-1) In the case of thick tatami mats

[0320] If a thick tatami mat is used, steps S8 to S13 are performed after step S7. (8) Step S8 (Operation of the operating switch) (In the case of thick tatami mats)

[0321] Next, as shown in the flowcharts in Figures 15 and 32, in step S8, the operation of the right bending unit 14b is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0322] As a result, as shown in Figure 15, the right positioning plate 18b is lowered by the right positioning plate drive mechanism 13b.

[0323] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0324] In this state, as shown in Figure 15, the frame member 35 is in a lowered position due to the frame member drive mechanism 32. (9) Step S9 (folding process of tatami mat surface 200) (for thick tatami mats)

[0325] Next, as shown in the flowcharts in Figures 16 and 32, in step S9, the folding process of the tatami mat surface 200 is performed (folding process of the tatami mat surface 200).

[0326] In other words, as shown in Figure 16, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0327] Furthermore, the right positioning plate drive mechanism 13b moves the right positioning plate 18b to a slightly elevated position.

[0328] Furthermore, the floor retainer 20 is lowered by the floor retainer drive mechanism 15.

[0329] Furthermore, the floor retainer 20 and the mounting table drive mechanism 11 cause the mounting table 16 to descend.

[0330] Furthermore, in the case of a piston cylinder mechanism, the mounting table 16 is configured to descend due to the downward pressure of the floor retainer 20, which is lowered by the floor retainer drive mechanism 15. In other words, although not shown in the diagram, the mounting table drive mechanism 11 has four air cylinders.

[0331] Then, a biasing force is constantly acting on the air cylinders of the mounting table drive mechanism 11 to try to raise it, and when the output of two air cylinders is cut off, the downward pressure of the floor retainer 20 is stronger than the upward pressure of the remaining two, causing the mounting table 16 to descend.

[0332] This is how the folding process for the tatami mat surface 200 is carried out.

[0333] In other words, because the downward pressure of the floor retainer 20 is stronger than that of the right positioning plate 18b, the right positioning plate 18b moves to a slightly higher position.

[0334] Furthermore, because the downward pressure of the floor retainer 20 is stronger than that of the mounting table 16, the mounting table 16 will descend.

[0335] In this case, the amount the mounting table 16 lowers is basically about the same as the thickness of the tatami mat (of the tatami base 206), but the maximum is 30 mm. (10) Step S10 (Pressing process by right-side bending member 24b) (in the case of thick tatami mats)

[0336] Next, as shown in the flowcharts in Figures 17 and 32, in step S10, the right-side moving assist mechanism 17b moves the right-side bending member 24b to a position even closer to the other side edge 208 of the tatami mat 206 than the approach position Q, and presses it against it (pressing step by the right-side bending member 24b). (11) Step S11 (Tatami mat surface fixing process) (In the case of thick tatami mats)

[0337] Next, as shown in the flowcharts in Figures 18 and 32, in step S11, the other side 202 of the folded tatami mat surface 200 is fixed to the other side 208 of the tatami base 206 using, for example, a stapler, tape, or adhesive.

[0338] At this time, as shown in Figure 18, the frame member 35 is raised by the frame member drive mechanism 29.

[0339] Furthermore, the right positioning plate 18b is in a raised position due to the right positioning plate drive mechanism 13b.

[0340] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b). (12) Step S12 (Operation of the operating switch) (In the case of thick tatami mats)

[0341] Next, as shown in the flowcharts in Figures 19 and 32, in step S12, the operation of the right bending unit 14b is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0342] Furthermore, the floor retainer 20 is raised by the floor retainer drive mechanism 15.

[0343] Furthermore, the temporary retainer 33 is raised by the temporary retainer drive mechanism 31.

[0344] Furthermore, the mounting table 16 is raised by the mounting table drive mechanism 11.

[0345] Furthermore, the right-side moving mechanism 25b and the right-side moving assist mechanism 17b move the right-side folding member 24b to a retracted position R that is separated from the other side 208 of the tatami mat base 206. (13) Step S13 (Removal process) (In the case of thick tatami mats)

[0346] Next, as shown in the flowchart in Figure 32, in step S13, the finished tatami mats are removed (removal process). (B-2) In the case of thin tatami mats

[0347] On the other hand, if a thin tatami mat is used, steps S14 to S22 are performed after step S7. (14) Step S14 (Operation of the operating switch) (In the case of thin tatami mats)

[0348] After step S7, as shown in the flowcharts in Figures 20 and 33, in the case of thin folding, the operation of the right folding unit 14b is started by simultaneously pressing both the left operation switch 44a and the right operation switch 44b on the control panel 42 of the device 40 (operation switch operation).

[0349] As a result, as shown in Figure 20, the right positioning plate 18b is lowered by the right positioning plate drive mechanism 13b.

[0350] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0351] Furthermore, in this state, as shown in Figure 20, the frame member 35 is in a lowered position due to the frame member drive mechanism 29. (15) Step S15 (Folding process of tatami mat surface 200) (for thin tatami mats)

[0352] Next, as shown in the flowcharts in Figures 21 and 33, in step S15, the folding process of the tatami mat surface 200 is performed (folding process of the tatami mat surface 200).

[0353] In other words, as shown in Figure 21, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0354] Furthermore, the frame member drive mechanism 29 moves the right positioning plate 18b to a slightly elevated position.

[0355] In other words, as described above, when the frame member 35 driven by the frame member drive mechanism 29 is descending, and the floor edge retainer 28 driven by the floor edge retainer drive mechanism 21 is descending, after the floor edge retainer 28 has come into contact with the tatami mat floor 206, the frame member 35 driven by the frame member drive mechanism 29 is configured to rise by the amount that it is unable to withstand the downward pressure of the floor edge retainer 28 driven by the floor edge retainer drive mechanism 21.

[0356] Furthermore, the floor retainer 20 is lowered by the floor retainer drive mechanism 15.

[0357] Furthermore, the mounting table 16 is lowered by the mounting table drive mechanism 11.

[0358] This is how the folding process for the tatami mat surface 200 is carried out.

[0359] In other words, because the downward pressure of the floor retainer 20 is stronger than that of the right positioning plate 18b, the right positioning plate 18b moves to a slightly higher position.

[0360] Furthermore, because the downward pressure of the floor retainer 20 is stronger than that of the mounting table 16, the mounting table 16 will descend. (16) Step S16 (Pressing step by right-side bending member 24b)

[0361] Next, as shown in the flowcharts in Figures 22 and 33, in step S16, the right-side moving assist mechanism 17b moves the right-side bending member 24b to a position even closer to the other side edge 208 of the tatami mat 206 than the approach position Q, and presses it against it (pressing step by the right-side bending member 24b). (17) Step S17 (Operation of the operating switch) (In the case of thin tatami mats)

[0362] Next, as shown in the flowcharts in Figures 23 and 33, in step S17, the operation of the right bending unit 14b is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0363] As a result, as shown in Figure 23, the frame member 35 is raised by the frame member drive mechanism 29.

[0364] In this process, the right-side moving mechanism 25b and the right-side moving assist mechanism 17b maintain a lateral pressure state in which the left-side bending member 24a is even closer to the other side edge 208 of the tatami mat base 206 than the approach position Q. (18) Step S18 (Folding the tatami mat base 206 to the back surface 212 using the right back surface folding plate 26b) (in the case of thin tatami mats)

[0365] In other words, as shown in the flowcharts of Figures 24 and 33, in step S18, the right-side folding unit 14b is configured to fold the other side 202 of the tatami surface 200 inward and fix it to the other side 208 and back surface 212 of the tatami base 206, in accordance with the case where the tatami base 206 is a thin tatami mat.

[0366] Therefore, the right-side back folding plate drive mechanism 19b moves the right-side back folding plate 26b in a direction that approaches the upper part of the back surface 212 of the other side 208 of the tatami base 206.

[0367] This causes the other side 202 of the tatami surface 200 to be folded inward and along the underside 212 of the other side 208 of the tatami base 206. (19) Step S19 (Pressing the back surface 212 of the tatami mat base 206) (In the case of thin tatami mats)

[0368] Next, as shown in the flowcharts in Figures 25 and 33, in step S19, the right rear folding plate 26b is fitted into the recess of the right floor edge retainer 28b by the right rear folding plate drive mechanism 19b against the upper part of the back surface 212 of the other side 208 of the tatami floor 206.

[0369] Then, the frame member 35 is lowered by the frame member drive mechanism 29.

[0370] As a result, when the right-side back folding plate 26b moves in a direction that approaches the upper part of the back surface 212 of the other side 208 of the tatami base 206, the right-side floor edge retainer 28b presses down on the right-side back folding plate 26b from above, folding the other side 202 of the tatami surface 200 inward and fixing it to the back surface 212 of the tatami base 206. (20) Step S20 (Tatami mat surface fixing process) (In the case of thin tatami mats)

[0371] Next, as shown in the flowcharts in Figures 26 and 33, in step S20, the other side 202 of the folded tatami mat surface 200 is fixed to the back surface 212 of the other side 208 of the tatami base 206 using, for example, a stapler, tape, or adhesive.

[0372] At this time, as shown in Figure 26, the frame member 35 is raised by the frame member drive mechanism 29.

[0373] Furthermore, the right positioning plate 18b is in a raised position due to the right positioning plate drive mechanism 13b.

[0374] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b). (21) Step S21 (Operation of the operating switch) (In the case of thin tatami mats)

[0375] Next, as shown in the flowcharts in Figures 27 and 33, in step S21, the operation of the right bending unit 14b is started by simultaneously pressing the left operation switch 44a and the right operation switch 44b on the control panel 42 of the control device 40 (operation switch operation).

[0376] As a result, as shown in Figure 27, the floor retainer 20 is raised by the floor retainer drive mechanism 15.

[0377] Furthermore, the temporary retainer 33 is raised by the temporary retainer drive mechanism 31.

[0378] Furthermore, the mounting table 16 is raised by the mounting table drive mechanism 11.

[0379] Furthermore, the right-side moving mechanism 25b and the right-side moving assist mechanism 17b move the right-side folding member 24b to a retracted position R that is separated from the other side 208 of the tatami mat base 206. (22) Step S22 (Removal process) (in the case of thin tatami mats)

[0380] Next, as shown in the flowchart in Figure 33, in step S22, the completed tatami mat is removed (removal process). (Example 4) (C) Activate both the left folding unit 14b and the right folding unit 14b (when folding both sides)

[0381] The following describes the operation of both the left folding unit 14b and the right folding unit 14b (when both sides are folded).

[0382] Basically, the left bending unit 14a and the right bending unit 14b in Examples 1 and 2 should be operated simultaneously. Therefore, the same step numbers are used for the same steps. (1) Step S1 (Origin state)

[0383] As shown in the flowcharts in Figures 3, 5, 8, and 32, in step S1, the origin state is established (origin state).

[0384] In other words, the left bending unit 14a and the right bending unit 14b are moved to a retracted position R away from the other side 208 of the tatami mat base 206 by pressing the home position return switch 52.

[0385] In this state, the frame member 35 is raised by the frame member drive mechanism 29.

[0386] Furthermore, the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b position the left positioning plate 18a and the right positioning plate 18b in a raised position.

[0387] Furthermore, the left-side moving mechanism 25a and the right-side moving mechanism 25b position the left-side folding member 24a and the right-side folding member 24b in a retracted position R, separated from the other side 208 of the tatami mat base 206.

[0388] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are in a raised position due to the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0389] Furthermore, the floor retainer 20 is in a raised position due to the floor retainer drive mechanism 15.

[0390] Furthermore, the temporary retainer 33 is in the raised position due to the temporary retainer drive mechanism 31.

[0391] Furthermore, the back-side folding plate drive mechanism 19 (left-side back-side folding plate drive mechanism 19a, right-side back-side folding plate drive mechanism 19b) positions the back-side folding plate drive mechanism 19 (left-side back-side folding plate drive mechanism 19a, right-side back-side folding plate drive mechanism 19b) in a retracted position R that is separated from the other side edges 208 of the tatami mat base 206. (2) Step S2 (Set of 200 tatami mats)

[0392] Next, as shown in the flowcharts in Figures 9 and 32, in step S2, the tatami mat base 206 is set on the mounting table 16 with the tatami mat surface 200 facing downwards (setting the tatami mat surface 200).

[0393] In this case, the end face of the tatami mat to be folded (the other side 208 of the tatami mat 206) is positioned a few millimeters inward from the tip of the mounting table 16.

[0394] At this time, the left bending member (lateral push block) 24a and the right bending member (lateral push block) 24b are in the retracted position R, as shown in Figure 9.

[0395] Furthermore, as mentioned above, although not shown in the illustration, notches are made in the other sides 202 of the tatami mat surface 200 at the midpoint. (3) Step S3 (Operation of the operating switch)

[0396] Next, as shown in the flowcharts in Figures 10 and 32, in step S3, the operation of the left bending unit 14a and the right bending unit 14b is started by simultaneously pressing the left operating switch 44a and the right operating switch 44b on the control panel 42 of the control device 40 (operating switch operation).

[0397] As a result, as shown in Figure 10, the frame member 35 is lowered by the frame member drive mechanism 29.

[0398] Furthermore, the left positioning plate 18a and the right positioning plate 18b are lowered by the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b.

[0399] Furthermore, the floor retainer 20 is lowered by the floor retainer drive mechanism 15.

[0400] In this configuration, the left positioning plate 18a, the right positioning plate 18b, and the floor retainer 20 are configured to descend while leaving a gap that does not sandwich the tatami surface 200 and the tatami base 206.

[0401] Then, the left-side moving mechanism 25a and the right-side moving mechanism 25b move the left-side bending member 24a and the right-side bending member 24b so that they are positioned at an approach position Q close to the other side 208 of the tatami mat base 206.

[0402] At this time, the left-side movement assist mechanism 17a and the right-side movement assist mechanism 17b are not yet activated, and the left-side bending member 24a and the right-side bending member 24b are not pressing against the other side edges 208 of the tatami mat base 206. (4) Step S4 (Positioning of the left positioning plate 18a and the right positioning plate 18b on their back surfaces)

[0403] Next, as shown in the flowcharts in Figures 11 and 32, in step S4, the worker presses the other side 208 of the tatami mat base 206 against the back surface of the left positioning plate 18a and the right positioning plate 18b from the back side of the tatami mat folding device 10 of the present invention, as indicated by the arrow in Figure 11 (positioning of the left positioning plate 18a and the right positioning plate 18b against their back surfaces).

[0404] At this time, the tatami mat base 206 is pressed down so that its central position (without any creases in the middle) aligns with the back surfaces of the left positioning plate 18a and the right positioning plate 18b. (5) Step S5 (Floor bending, surface laying)

[0405] Next, as shown in the flowcharts in Figures 12-13 and 32, in step S5, the workers perform floor bending and surface laying as necessary (floor bending and surface laying).

[0406] In other words, as shown in Figure 12, the upper floor bending drive mechanism 36 and the lower floor bending drive mechanism 38 lower the upper floor bending device 32 and the lower floor bending device 34 to perform floor bending.

[0407] Furthermore, as shown in Figure 13, the left surface covering device drive mechanism 23a and the right surface covering device drive mechanism 23b lower the left surface covering device 30a and the right surface covering device 30b, and the left surface covering device 30a and the right surface covering device 30b chuck the end of the other side 208 of the tatami base 206, and in Figure 13, the left surface covering device 30a and the right surface covering device 30b are moved to the left (in the direction away from the other side 208 of the tatami base 206) to cover the surface and apply tension. (6) Step S6 (Tatami mat pressing process)

[0408] Next, as shown in the flowcharts in Figures 14 and 32, the tatami pressing process is performed in step S6.

[0409] In other words, as shown in Figure 14, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0410] Furthermore, the temporary retainer 33 is lowered by the temporary retainer drive mechanism 31.

[0411] Furthermore, the left positioning plate 18a and the right positioning plate 18b are raised by the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b.

[0412] Furthermore, the left-side covering device drive mechanism 23a and the right-side covering device drive mechanism 23b cause the left-side covering device 30a and the right-side covering device 30b to rise.

[0413] Furthermore, the upper floor bending drive mechanism 36 and the lower floor bending drive mechanism 38 raise the upper floor bending device 32 and the lower floor bending device 34. (7) Step S7 (grooving process)

[0414] Next, as shown in the flowchart in Figure 32, the worker uses a creasing tool to make creases (to make neat folds, a creasing tool such as an edge crease is used to make creases on the other side 202 of the tatami mat surface 200 at the folding position) (creasing process). (C-1) In the case of thick tatami mats

[0415] If a thick tatami mat is used, steps S8 to S13 are performed after step S7. (8) Step S8 (Operation of the operating switch) (In the case of thick tatami mats)

[0416] Next, as shown in the flowcharts in Figures 15 and 32, in step S8, the operation of the left bending unit 14a and the right bending unit 14b is started by simultaneously pressing the left operating switch 44a and the right operating switch 44b on the control panel 42 of the control device 40 (operating switch operation).

[0417] As a result, as shown in Figure 15, the left positioning plate 18a and the right positioning plate 18b are lowered by the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b.

[0418] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0419] In this state, as shown in Figure 15, the frame member 35 is in a lowered position due to the frame member drive mechanism 32. (9) Step S9 (folding process of tatami mat surface 200) (for thick tatami mats)

[0420] Next, as shown in the flowcharts in Figures 16 and 32, in step S9, the folding process of the tatami mat surface 200 is performed (folding process of the tatami mat surface 200).

[0421] In other words, as shown in Figure 16, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0422] Furthermore, the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b move the left positioning plate 18a and the right positioning plate 18b to a slightly elevated position.

[0423] Furthermore, the floor retainer 20 is lowered by the floor retainer drive mechanism 15.

[0424] Furthermore, the floor retainer 20 and the mounting table drive mechanism 11 cause the mounting table 16 to descend.

[0425] Furthermore, in the case of a piston cylinder mechanism, the mounting table 16 is configured to descend due to the downward pressure of the floor retainer 20, which is lowered by the floor retainer drive mechanism 15. In other words, although not shown in the diagram, the mounting table drive mechanism 11 has four air cylinders.

[0426] Then, a biasing force is constantly acting on the air cylinders of the mounting table drive mechanism 11 to try to raise it, and when the output of two air cylinders is cut off, the downward pressure of the floor retainer 20 is stronger than the upward pressure of the remaining two, causing the mounting table 16 to descend.

[0427] This is how the folding process for the tatami mat surface 200 is carried out.

[0428] In other words, because the downward pressure of the floor retainer 20 is stronger than that of the left positioning plate 18a and the right positioning plate 18b, the left positioning plate 18a and the right positioning plate 18b move to a slightly higher position.

[0429] Furthermore, because the downward pressure of the floor retainer 20 is stronger than that of the mounting table 16, the mounting table 16 will descend.

[0430] In this case, the amount the mounting table 16 lowers is basically about the same as the thickness of the tatami mat (of the tatami base 206), but the maximum is 30 mm. (10) Step S10 (Pressing process using left-side bending member 24a and right-side bending member 24b) (in the case of thick tatami mats)

[0431] Next, as shown in the flowcharts in Figures 17 and 32, in step S10, the movement assist mechanism 25c and the right-side movement assist mechanism 17b move and press the left-side bending member 24a and the right-side bending member 24b so that they are positioned at an approach position Q close to the other side 208 of the tatami mat base 206 (pressing process by the left-side bending member 24a and the right-side bending member 24b). (11) Step S11 (Tatami mat surface fixing process) (In the case of thick tatami mats)

[0432] Next, as shown in the flowcharts in Figures 18 and 32, in step S11, the other side 202 of the folded tatami mat surface 200 is fixed to the other side 208 of the tatami base 206 using, for example, a stapler, tape, or adhesive.

[0433] At this time, as shown in Figure 18, the frame member 35 is raised by the frame member drive mechanism 29.

[0434] Furthermore, the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b position the left positioning plate 18a and the right positioning plate 18b in a raised position.

[0435] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b). (12) Step S12 (Operation of the operating switch) (In the case of thick tatami mats)

[0436] Next, as shown in the flowcharts in Figures 19 and 32, in step S12, the operation of the left bending unit 14a and the right bending unit 14b is started by simultaneously pressing the left operating switch 44a and the right operating switch 44b on the control panel 42 of the control device 40 (operating switch operation).

[0437] Furthermore, the floor retainer 20 is raised by the floor retainer drive mechanism 15.

[0438] Furthermore, the temporary retainer 33 is raised by the temporary retainer drive mechanism 31.

[0439] Furthermore, the mounting table 16 is raised by the mounting table drive mechanism 11.

[0440] Furthermore, the left-side moving mechanism 25a, the left-side moving assist mechanism 17a, the right-side moving mechanism 25b, and the right-side moving assist mechanism 17b move the left-side folding member 24a and the right-side folding member 24b to a retracted position R that is separated from the other side 208 of the tatami mat base 206. (13) Step S13 (Removal process) (In the case of thick tatami mats)

[0441] Next, as shown in the flowchart in Figure 32, in step S13, the finished tatami mats are removed (removal process). (B-2) In the case of thin tatami mats

[0442] On the other hand, if a thin tatami mat is used, steps S14 to S22 are performed after step S7. (14) Step S14 (Operation of the operating switch) (In the case of thin tatami mats)

[0443] After step S7, as shown in the flowcharts in Figures 20 and 33, in the case of thin folding, the operation of the left folding unit 14a and the right folding unit 14b is started by simultaneously pressing both the left operating switch 44a and the right operating switch 44b on the control panel 42 of the device 40 (operating switch operation).

[0444] As a result, as shown in Figure 20, the left positioning plate 18a and the right positioning plate 18b are lowered by the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b.

[0445] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0446] Furthermore, in this state, as shown in Figure 20, the frame member 35 is in a lowered position due to the frame member drive mechanism 29. (15) Step S15 (Folding process of tatami mat surface 200) (for thin tatami mats)

[0447] Next, as shown in the flowcharts in Figures 21 and 33, in step S15, the folding process of the tatami mat surface 200 is performed (folding process of the tatami mat surface 200).

[0448] In other words, as shown in Figure 21, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are lowered by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b).

[0449] Furthermore, the frame member drive mechanism 29 moves the left positioning plate 18a and the right positioning plate 18b to a slightly elevated position.

[0450] In other words, as described above, when the frame member 35 driven by the frame member drive mechanism 29 is descending, and the floor edge retainer 28 driven by the floor edge retainer drive mechanism 21 is descending, after the floor edge retainer 28 has come into contact with the tatami mat floor 206, the frame member 35 driven by the frame member drive mechanism 29 is configured to rise by the amount that it is unable to withstand the downward pressure of the floor edge retainer 28 driven by the floor edge retainer drive mechanism 21.

[0451] Furthermore, the floor retainer 20 is lowered by the floor retainer drive mechanism 15.

[0452] Furthermore, the mounting table 16 is lowered by the mounting table drive mechanism 11.

[0453] This is how the folding process for the tatami mat surface 200 is carried out.

[0454] In other words, because the downward pressure of the floor retainer 20 is stronger than that of the left positioning plate 18a and the right positioning plate 18b, the left positioning plate 18a and the right positioning plate 18b move to a slightly higher position.

[0455] Furthermore, because the downward pressure of the floor retainer 20 is stronger than that of the mounting table 16, the mounting table 16 will descend. (16) Step S16 (Pressing process using left-side bending member 24a and right-side bending member 24b)

[0456] Next, as shown in the flowcharts in Figures 22 and 33, in step S16, the left-side moving assist mechanism 17a and the right-side moving assist mechanism 17b move the left-side bending member 24a and the right-side bending member 24b to a position even closer to the other side edge 208 of the tatami mat 206 than the approach position Q, and press them against it (pressing process by the left-side bending member 24a and the right-side bending member 24b). (17) Step S17 (Operation of the operating switch) (In the case of thin tatami mats)

[0457] Next, as shown in the flowcharts in Figures 23 and 33, in step S17, the operation of the left bending unit 14a and the right bending unit 14b is started by simultaneously pressing the left operating switch 44a and the right operating switch 44b on the control panel 42 of the control device 40 (operating switch operation).

[0458] In this process, as shown in Figure 23, the frame member 35 is raised by the frame member drive mechanism 29.

[0459] In this process, the left-side moving mechanism 25a, the left-side moving assist mechanism 17a, the right-side moving mechanism 25b, and the right-side moving assist mechanism 17b maintain a lateral pressure state in which the left-side bending member 24a and the right-side bending member 24b are even closer to the other side edge 208 of the tatami mat 206 than the approach position Q. (18) Step S18 (Folding the tatami mat base 206 to the back surface 212 using the left back surface folding plate 26a and the right back surface folding plate 26b) (in the case of a thin tatami mat)

[0460] In other words, as shown in the flowcharts in Figures 24 and 33, in step S18, the left folding unit 14a and the right folding unit 14b are configured to fold the other side 202 of the tatami surface 200 inward and fix it to the other side 208 and back surface 212 of the tatami base 206, corresponding to the case where the tatami base 206 is a thin tatami mat.

[0461] Therefore, the left rear folding plate 26a and the right rear folding plate 26b move in a direction toward the upper part of the back surface 212 of the other side 208 of the tatami base 206, by the left rear folding plate drive mechanism 19a and the right rear folding plate drive mechanism 19b.

[0462] This causes the other side 202 of the tatami surface 200 to be folded inward and along the underside 212 of the other side 208 of the tatami base 206. (19) Step S19 (Pressing the back surface 212 of the tatami mat base 206) (In the case of thin tatami mats)

[0463] Then, the frame member 35 is lowered by the frame member drive mechanism 29.

[0464] As a result, as shown in the flowcharts in Figures 25 and 33, in step S19, the left floor edge retainer 28a and the right floor edge retainer 28b descend as the frame member 35 descends. Then, the left-side back folding plate 26a and the right-side back folding plate 26b are fitted into the recesses of the left-side floor edge retainer 28a and the right-side floor edge retainer 28b, respectively, on the upper part of the back surface 212 of the other side edge 208 of the tatami base 206.

[0465] Then, the frame member 35 is lowered by the frame member drive mechanism 29.

[0466] As a result, when the left rear folding plate 26a and the right rear folding plate 26b move in a direction that approaches the upper part of the back surface 212 of the other side edge 208 of the tatami base 206, the left floor edge retainer 28a and the right floor edge retainer 28b press down on the left rear folding plate 26a and the right rear folding plate 26b from above, folding the other side edge 202 of the tatami surface 200 inward and fixing it to the back surface 212 of the tatami base 206. (20) Step S20 (Tatami mat surface fixing process) (In the case of thin tatami mats)

[0467] Therefore, the left rear folding plate 26a and the right rear folding plate 26b move in a direction toward the upper part of the back surface 212 of the other side 208 of the tatami base 206, by the left rear folding plate drive mechanism 19a and the right rear folding plate drive mechanism 19b.

[0468] This causes the other side 202 of the tatami surface 200 to be folded inward and along the underside 212 of the other side 208 of the tatami base 206.

[0469] Next, as shown in the flowcharts in Figures 26 and 33, in step S20, the other side 202 of the folded tatami mat surface 200 is fixed to the back surface 212 of the other side 208 of the tatami base 206 using, for example, a stapler, tape, or adhesive.

[0470] At this time, as shown in Figure 26, the frame member 35 is raised by the frame member drive mechanism 29.

[0471] Furthermore, the left positioning plate drive mechanism 13a and the right positioning plate drive mechanism 13b position the left positioning plate 18a and the right positioning plate 18b in a raised position.

[0472] Furthermore, the floor edge retainers 28 (left floor edge retainer 28a, right floor edge retainer 28b) are raised by the floor edge retainer drive mechanism 21 (left floor edge retainer drive mechanism 21a, right floor edge retainer drive mechanism 21b). (21) Step S21 (Operation of the operating switch) (In the case of thin tatami mats)

[0473] Next, as shown in the flowcharts in Figures 27 and 33, in step S21, the operation of the left bending unit 14a and the right bending unit 14b is started by simultaneously pressing the left operating switch 44a and the right operating switch 44b on the control panel 42 of the control device 40 (operating switch operation).

[0474] As a result, as shown in Figure 27, the floor retainer 20 is raised by the floor retainer drive mechanism 15.

[0475] Furthermore, the temporary retainer 33 is raised by the temporary retainer drive mechanism 31.

[0476] Furthermore, the mounting table 16 is raised by the mounting table drive mechanism 11.

[0477] Furthermore, the left-side moving mechanism 25a, the left-side moving assist mechanism 17a, the right-side moving mechanism 25b, and the right-side moving assist mechanism 17b move the right-side folding member 24b to a retracted position R that is separated from the other side 208 of the tatami mat base 206. (22) Step S22 (Removal process) (in the case of thin tatami mats)

[0478] Next, as shown in the flowchart in Figure 33, in step S22, the completed tatami mat is removed (removal process). (Example 5)

[0479] Figure 28 is a side view of the tatami surface folding device along line AA in Figure 1, showing another embodiment of the tatami surface folding device of the present invention, where the initial position of the folding member is close to the other side edge of the tatami base; Figure 29 is a side view of the tatami surface folding device along line BB in Figure 1, where the initial position of the folding member is close to the other side edge of the tatami base; Figure 30 is a side view of the tatami surface folding device along line CC in Figure 1, where the initial position of the folding member is close to the other side edge of the tatami base; and Figure 31 is a side view of the tatami surface folding device along line CC in Figure 1, showing the state in which the surface stretching device is operated when the initial position of the folding member is close to the other side edge of the tatami base.

[0480] The tatami mat folding device 10 in this embodiment has basically the same configuration as the tatami mat folding device 10 shown in Figures 1 to 27, and the same reference numerals are used for the same components, and their detailed descriptions are omitted.

[0481] In this embodiment, the bending members 24 (left bending member 24a, right bending member 24b) are equipped with a heating device, such as a heater, although this is not shown.

[0482] As shown in Figures 28 to 30, the initial position of the folding member 24 is configured to be in a close proximity position Q relative to the other side 208 of the tatami mat base 206.

[0483] Furthermore, it is configured to heat the tatami mat surface 200 that protrudes outward from the folded end side of the mounting table 16, which is located above the folding member 24.

[0484] In this process, as shown in Figure 31, the surface covering device drive mechanism 23 (left surface covering device drive mechanism 23a, right surface covering device drive mechanism 23b) lowers the surface covering device 30 (left surface covering device 30a, right surface covering device 30b) onto the ends of the other sides 202 of the tatami surface 200 (for example, the upper front side and the lower front side), chucks the ends of the other sides 202 of the tatami surface 200, and applies tension to the surface covering.

[0485] As a result, the tatami mat surface 200, which is located above the bending member 24 and protrudes outward from the bending end side of the mounting table 16, is heated. For example, by moistening the tatami mat surface 200 and warming it, it becomes possible to fold it neatly and achieve a clean finish.

[0486] Although preferred embodiments of the present invention have been described above, the present invention is not limited thereto. For example, in the above embodiment, the mounting table 16, floor retainer 20, etc., were made common to the left folding unit 14a and the right folding unit 14b, but these may be provided individually to the left folding unit 14a and the right folding unit 14b.

[0487] Furthermore, the mounting table 16 is configured to lower when the other side 202 of the tatami surface 200 is folded inward relative to the other side 208 of the tatami base 206 and fixed to the other side 208 of the tatami base 206. However, the mounting table 16 may be fixed and the folding member 24 may be configured to move up and down so that the other side 202 of the tatami surface 200 is folded inward and fixed to the other side 208 of the tatami base 206.

[0488] Furthermore, although the above embodiment uses a single mounting table 16, the left folding unit 14a and the right folding unit 14b may each be equipped with their own independently driven mounting tables for placing the tatami mat surface and tatami base in predetermined positions.

[0489] Furthermore, in the above embodiment, the upper floor bending device 32, which is operated by the upper floor bending drive mechanism 36, and the lower floor bending device 34, which is operated by the lower floor bending drive mechanism 38, are configured in common for the left bending unit 14a and the right bending unit 14b.

[0490] However, it is also possible to individually provide the upper floor bending device 32 and the lower floor bending drive mechanism 38, which are operated by the upper floor bending drive mechanism 36, to the left bending unit 14a and the right bending unit 14b.

[0491] In this case, when handling a tatami mat the size of one tatami mat, bending only half of it will affect the finished product, so it is essential to operate both simultaneously.

[0492] Furthermore, although the tatami mat folding device of the present invention has been described in the case where the side of the tatami mat 200 to be folded (side 202 of the tatami mat 200) is folded in a direction perpendicular to the weave direction of the rush grass (direction of the rush grass), various modifications are possible without departing from the objective of the present invention, such as the application to the side of the tatami mat 200 on the frame 206c side. [Industrial applicability]

[0493] The present invention can be applied to a tatami mat folding device for folding the other sides of the tatami mat inward and fixing them to the other sides of the tatami mat (the upper front side and the lower front side, hereinafter simply referred to as "the other sides"), in a state where the side of the tatami mat facing the frame direction is fixed to the side of the tatami mat facing the frame direction of a tatami mat cut to a predetermined size (the so-called "frame-first method"). [Explanation of symbols]

[0494] 10 Tatami Mat Folding Device 11. Mounting Table Drive Mechanism 12. Mounting frame 13a Left positioning plate drive mechanism 13b Right-side positioning plate drive mechanism 14a Left-side folding unit 14b Right-side folding unit 15 Floor-holding drive mechanism 16 Mounting Table 17a Left side movement assist mechanism 17b Right side movement assist mechanism 18 Positioning plate 18a Left positioning plate 18b Right side positioning plate 19. Rear-side folding plate drive mechanism 19a Left rear folding plate drive mechanism 19b Right rear folding plate drive mechanism 20 Floor holding 21a Left floor edge retaining drive mechanism 21b Right-side floor edge retaining drive mechanism 22a Folded end 23 Surface covering device drive mechanism 23a Left side front covering device drive mechanism 23b Right-side front tensioning device drive mechanism 24 Bending member 24a Left-side folding member 24b Right-side folding member 25a Left side movement mechanism 25b Right side movement mechanism 25c Mobility aid mechanism 26a Left side back folded plate 26b Right side back folded plate 28a Left side floor edge retainer 28b Right-side floor edge retainer 29 Frame Member Drive Mechanism 30 Surface covering device 30a Left side surface covering device 30b Right-side surface covering device 31 Temporary holding drive mechanism 32 Upward floor bending device 33 Temporary reservation 34 Downward floor bending device 35 Frame members 36 Upward floor bending drive mechanism 38 Downward floor bending drive mechanism 40 Control device 42 Control Panel 44a Left-side operating switch 44b Right-side operating switch 46 Automatic / Manual Switch 48 Circuit breaker 50 Circuit breaker lamp 52. Origin return switch 56 Heater temperature setting display unit 58 Up switch 60 Down switch 200 tatami mats 201 tatami mats 202 Side 204 Side 206 Tatami floor 206a Side 206b Side 206c stile 208 Side 210 Side 212 Back side 214 Side 216 side 300 Tatami Mat Folding Device 312 Positioning member 312a First positioning plate 312b Second positioning plate 316c Rotary shaft 316d Swivel shaft hole 346 Bending member 400 Tatami floor 400a end face 402 Mounting Table 404 Positioning plate 406 End face 408 Bending member 410 Folding section 412 Tatami mat surface B Arrow P Virtual central axis Q approach position R Retract position

Claims

1. With the side of the tatami mat facing the frame fixed to the side of the tatami base facing the frame, A tatami mat folding device for folding the other side of the tatami mat surface inward relative to the other side of the tatami mat base and fixing it to the other side of the tatami mat base, In the front view of the aforementioned tatami mat folding device, the left folding unit is located on the left side, In the front view of the tatami mat folding device, the right-side folding unit is located on the right side, The system includes a placement table for placing the tatami mat surface and tatami base in predetermined positions, The left folding unit and the right folding unit are, respectively, To determine the folding position of the tatami mat surface and to position the other side of the tatami mat base at the folding position, a positioning plate configured to be vertically movable relative to the aforementioned table is provided. The system includes a folding member positioned opposite the folding end of the aforementioned mounting table, and configured to be detachable from the other side of the tatami mat base in order to fold the tatami surface that protrudes outward from the folding end of the aforementioned mounting table, The left-side folding unit and the right-side folding unit are configured to operate either individually or both simultaneously. When using the aforementioned tatami mat folding device for a single tatami mat with a slight crease in the middle, By activating either the left folding unit or the right folding unit, One side of the tatami mat surface of the tatami mat with the aforementioned curvature is folded inward relative to one side of the other side of the tatami mat base with the aforementioned curvature. After fixing it to one side of the other edge of the tatami mat base for a single tatami mat that has a slight irregularity throughout, By activating either the left-side folding unit or the right-side folding unit, The other side of the tatami mat surface of the tatami mat with the aforementioned curvature is folded inward relative to the other side of the other side of the tatami mat base of the tatami mat with the aforementioned curvature. A tatami mat folding device characterized by being configured to be fixed to the other side of the other edge of a tatami mat base for a single mat that has a slight curvature in the middle.

2. With the side of the tatami mat facing the frame fixed to the side of the tatami base facing the frame, A tatami mat folding device for folding the other side of the tatami mat surface inward relative to the other side of the tatami mat base and fixing it to the other side of the tatami mat base, In the front view of the aforementioned tatami mat folding device, the left folding unit is located on the left side, In the front view of the tatami mat folding device, the right-side folding unit is located on the right side, The system includes a placement table for placing the tatami mat surface and tatami base in predetermined positions, The left folding unit and the right folding unit are, respectively, To determine the folding position of the tatami mat surface and to position the other side of the tatami mat base at the folding position, a positioning plate configured to be vertically movable relative to the aforementioned table is provided. The system includes a folding member positioned opposite the folding end of the aforementioned mounting table, and configured to be detachable from the other side of the tatami mat base in order to fold the tatami surface that protrudes outward from the folding end of the aforementioned mounting table, The left-side folding unit and the right-side folding unit are configured to operate either individually or both simultaneously. The positioning plates of the left bending unit and the right bending unit are It is provided on a common frame member that moves up and down, A tatami mat folding device characterized in that the positioning plates of the left folding unit and the right folding unit are each configured to move up and down independently.

3. The left folding unit and the right folding unit are, respectively, In the case of a thin tatami mat, the other side of the tatami surface is folded inward and fixed to the other side and back of the tatami mat base. The tatami mat folding device according to any one of claims 1 to 2, further comprising a back surface folding plate configured to be detachable from the upper back surface of the other side of the tatami mat base.

4. The left folding unit and the right folding unit are, respectively, When the aforementioned folded back plate moves in a direction approaching the upper back surface of the other side of the tatami mat, The tatami mat folding device according to claim 3, characterized in that it is equipped with a vertically movable floor edge retainer for pressing the aforementioned back folding plate from above to fold the other side of the tatami mat surface inward and fix it to the other side and back of the tatami mat base.

5. When using the aforementioned tatami mat folding device for half-size tatami mats, The left folding unit and the right folding unit are operated simultaneously. The other side of the tatami mat surface for the half-size tatami mat is folded inward relative to the other side of the tatami mat base for the half-size tatami mat, The tatami mat folding device according to any one of claims 2 to 4, characterized in that it is configured to be fixed to the other side of a tatami mat base for half a mat.

6. When using the aforementioned tatami mat folding device for a single tatami mat without any creases, The left folding unit and the right folding unit are operated simultaneously. The other side of the tatami mat surface for a single tatami mat without any irregularities is folded inward and fixed to the other side of the tatami mat base for a single tatami mat without any irregularities, or By activating either the left folding unit or the right folding unit, The tatami mat folding device according to any one of claims 2 to 5, characterized in that, after folding one side of the other side of the tatami mat surface for a single tatami mat with a central crease inward relative to one side of the other side of the tatami mat base for a single tatami mat with a central crease and fixing it to one side of the other side of the tatami mat base for a single tatami mat with a central crease, the other side of the other side of the tatami mat surface for a single tatami mat with a central crease is operated to fold inward relative to the other side of the other side of the tatami mat surface for a single tatami mat with a central crease and fixing it to the other side of the other side of the tatami mat base for a single tatami mat with a central crease.

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