JP5399049B2 - Tatami core and tatami - Google Patents

Tatami core and tatami Download PDF

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JP5399049B2
JP5399049B2 JP2008293351A JP2008293351A JP5399049B2 JP 5399049 B2 JP5399049 B2 JP 5399049B2 JP 2008293351 A JP2008293351 A JP 2008293351A JP 2008293351 A JP2008293351 A JP 2008293351A JP 5399049 B2 JP5399049 B2 JP 5399049B2
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nonwoven fabric
tatami
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俊也 横谷
栄一 中山
裕 大桃
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ダウ化工株式会社
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本発明は、合成樹脂発泡体を断熱性基材とする畳用芯材、及び該芯材を畳表材で覆った畳に関する。   The present invention relates to a tatami mat core material using a synthetic resin foam as a heat insulating base material, and a tatami mat covering the core material with a tatami mat surface material.

天然い草等の畳材料の不足や住環境の変化などに伴って、ポリスチレン発泡体などの合成樹脂発泡体を断熱性基材とした畳が多用されている。この合成樹脂発泡体を断熱性基材とした畳は、畳床の断熱性を向上させるだけでなく、畳自体の軽量化が図れ、また防虫及び防カビ加工を施し易いという長所を有する。その反面、合成樹脂発泡体は剛性に劣ることから、剛性を有する材料で合成樹脂発泡体製の断熱性基材を補強する種々の構造的な工夫がなされている。   With the shortage of tatami mat materials such as natural grass and changes in the living environment, tatami mats using a synthetic resin foam such as polystyrene foam as a heat insulating base material are frequently used. The tatami mat using the synthetic resin foam as a heat-insulating base material has the advantages that not only the heat-insulating property of the tatami floor is improved, but also the tatami mat itself can be reduced in weight, and insect-proofing and mold-proofing can be easily performed. On the other hand, since the synthetic resin foam is inferior in rigidity, various structural devices for reinforcing the heat insulating base material made of the synthetic resin foam with a material having rigidity have been made.

例えば、補強材としてベニヤ合板を用いた技術として、硬質ポリスチレン発泡体と軟質ポリスチレン発泡体を交互に重ねた断熱性基材とし、その上にさらに薄いベニヤ合板を重ね、これを縫着した軽量畳床が提案されている（特許文献１参照）。   For example, as a technique using veneer plywood as a reinforcing material, a lightweight tatami mat with a heat-insulating base material in which hard polystyrene foam and soft polystyrene foam are alternately stacked, on which thin veneer plywood is stacked and sewn. A floor has been proposed (see Patent Document 1).

また、合成樹脂発泡板の中間部に弾性を有する合成樹脂発泡板を介挿した断熱性基材とすると共に、断熱性基材の上面にベニヤ合板を配置し、ベニヤ合板の上側面と断熱性基材の下側面に板状綿体をそれぞれ配置して畳表で被覆した畳も提案されている（特許文献２参照）。   Moreover, it is set as the heat insulation base material which inserted the synthetic resin foam board which has elasticity in the intermediate part of a synthetic resin foam board, and arrange | positions a veneer plywood on the upper surface of a heat insulation base material, and the upper side surface and heat insulation of a veneer plywood There has also been proposed a tatami mat in which a plate-like cotton body is disposed on the lower surface of the base material and covered with a tatami mat (see Patent Document 2).

さらに、断熱性基材として用いる合成樹脂発泡体の補強材として合成樹脂製の成型ボードを用いた畳床も提案されている（特許文献３参照）。   Furthermore, a tatami floor using a synthetic resin molded board as a reinforcing material for a synthetic resin foam used as a heat insulating base material has also been proposed (see Patent Document 3).

実開昭４９−４４１９号公報Japanese Utility Model Publication No. 49-4419 実開昭６２−９４２３１号公報Japanese Utility Model Publication No. 62-94231 特開２００３−３０７０２４号公報JP 2003-307024 A

ところで、特許文献１及び２の補強材としてベニヤ合板を用いる技術では、木材であるベニヤ合板が重いため、畳の充分な軽量化を図ることができず、畳表面のクッション性も悪いという問題がある。   By the way, in the technique using a veneer plywood as a reinforcing material of patent documents 1 and 2, since the veneer plywood which is wood is heavy, there is a problem that the weight of the tatami mat cannot be sufficiently reduced and the cushioning property of the tatami surface is poor. is there.

また、特許文献３の補強材として合成樹脂成型ボードを用いる技術では、合成樹脂成型ボードが気温変化の影響を受けて寸法変化しやすい問題がある。即ち、冬季は合成樹脂成型ボードが収縮するので畳間に隙間が生じ易く、夏季は合成樹脂成型ボードが膨張するので設置場所に畳が入り難くなるという問題がある。   Further, in the technique using a synthetic resin molded board as a reinforcing material of Patent Document 3, there is a problem that the synthetic resin molded board is easily changed in size due to the influence of temperature change. That is, since the synthetic resin molded board contracts in the winter, there is a problem that a gap is easily formed between the tatami mats, and in the summer, the synthetic resin molded board expands, so that the tatami mat is difficult to enter.

本発明は、上記の事情に鑑みて創案されたものであり、合成樹脂発泡体製の断熱性基材を補強しうる剛性を有しながら畳の軽量化を促進することができ、気温変化による寸法変化が少なく、上面側に程度なクッション性を備えた畳用芯材及び畳を提供することを目的とする。   The present invention was devised in view of the above circumstances, and can reduce the weight of a tatami mat while having rigidity capable of reinforcing a heat insulating base material made of a synthetic resin foam. An object of the present invention is to provide a tatami core and a tatami mat that have little change in dimensions and have a cushioning property on the upper surface side.

上記目的のため、本発明の第一は、合成樹脂発泡体からなる断熱性基材の上面に、合成繊維を三次元に交絡させて成形した繊維密度の異なる２枚の不織布板が上下に重ねられており、前記断熱性基材に接する下側の不織布板の繊維密度が０．１５ｇ／ｃｍ 3 以上０．５ｇ／ｃｍ 3 以下、上側の不織布板の繊維密度が０．０５ｇ／ｃｍ 3 以上０．１５ｇ／ｃｍ 3 未満で、下側の不織布板の繊維密度が上側の不織布板の繊維密度よりも高く、しかも下側及び上側の不織布板を構成する合成繊維が、直状の合成繊維であることを特徴とする畳用芯材を提供するものである。 For the above purpose, the first aspect of the present invention is that two non-woven fabric plates having different fiber densities formed by three-dimensionally entangled synthetic fibers are stacked on the upper surface of a heat insulating substrate made of a synthetic resin foam. The fiber density of the lower nonwoven fabric plate in contact with the heat insulating substrate is 0.15 g / cm 3 or more and 0.5 g / cm 3 or less, and the fiber density of the upper nonwoven fabric plate is 0.05 g / cm 3 or more. Less than 0.15 g / cm 3 , the fiber density of the lower nonwoven fabric plate is higher than that of the upper nonwoven fabric plate, and the synthetic fibers constituting the lower and upper nonwoven fabric plates are straight synthetic fibers. There is provided a core material for tatami mats characterized by being.

上記本発明の第一は、下側及び上側の不織布板の両者が、湿熱接着性を有する繊維単独、又は湿熱接着性を有する繊維とその他の繊維とを用い、繊維同士が交絡した状態で圧縮し、加熱蒸気と接触させて相互に接着した板状体であること、
湿熱接着性を有する繊維が、ポリエチレンテレフタレートの芯層の表面をエチレン−ビニルアルコール共重合体の鞘層で覆った芯鞘型複合ステープル繊維、その他の繊維がポリエチレンテレフタレート繊維であること、
を好ましい態様として含むものである。 In the first aspect of the present invention, both the lower and upper nonwoven fabric plates are compressed in a state where the fibers are entangled using fibers having wet heat adhesion alone or fibers having wet heat adhesion and other fibers. And plate-like bodies adhered to each other by contacting with heated steam,
The fiber having wet heat adhesion is a core-sheath type composite staple fiber in which the surface of the polyethylene terephthalate core layer is covered with a sheath layer of ethylene-vinyl alcohol copolymer, and the other fibers are polyethylene terephthalate fibers,
Is included as a preferred embodiment.

また、本発明の第二は、上記本発明の第一に係る畳用芯材の下面に裏面材を宛がい、該裏面材ごと前記芯材の表面、側面及び裏面の周縁を包み込んで畳表材で覆って一体化したことを特徴とする畳を提供するものである。   The second aspect of the present invention is that the back surface material is assigned to the lower surface of the core material for tatami mats according to the first aspect of the present invention, and the surface material, the side surface and the peripheral edge of the back surface are wrapped together with the back surface material. The tatami mat is characterized by being covered and integrated.

上記本発明の第二は、裏面材が、少なくとも露出面側に防水面を有するシート材であることを好ましい態様として含むものである。   The second aspect of the present invention includes as a preferable aspect that the back material is a sheet material having a waterproof surface at least on the exposed surface side.

本発明によれば、合成樹脂発泡体製の断熱性基材の上面に重ね合わせた２枚の不織布板のうち、断熱性基材に接する下側の不織布板の繊維密度が上側の不織布板の繊維密度よりも高く設定されている。これらの不織布板は、繊維を三次元に交絡させて板状に成形された圧縮構造体であるので、繊維密度を高くすれば、軽量であるにもかかわらず合成樹脂発泡体を補強しうる剛性を有する。従って、必要な断熱性基材の補強効果を得ることができる。   According to the present invention, the fiber density of the lower nonwoven fabric plate in contact with the heat insulating substrate is the upper nonwoven fabric plate out of the two nonwoven fabric plates superimposed on the upper surface of the heat insulating substrate made of synthetic resin foam. It is set higher than the fiber density. These non-woven boards are compressed structures that are formed into a plate shape with three-dimensionally entangled fibers, so if the fiber density is increased, the rigidity that can reinforce the synthetic resin foam despite its light weight Have Therefore, the necessary reinforcing effect of the heat insulating substrate can be obtained.

また、不織布板は、繊維が絡み合って内部に微細な空隙を形成しているので、断熱性を有し、また各繊維の温度変化に伴う伸縮が吸収されるので、気温変化による寸法変化を抑制することができる。   In addition, the nonwoven fabric board is intertwined with fibers and forms fine voids inside, so it has heat insulation and the expansion and contraction associated with the temperature change of each fiber is absorbed, thus suppressing dimensional changes due to temperature changes. can do.

さらに、上側の不織布板の繊維密度は低く設定されているので、上面側に適度なクッション性を付与することができる。   Furthermore, since the fiber density of the upper nonwoven fabric plate is set low, an appropriate cushioning property can be imparted to the upper surface side.

以下、図面を参照して、本発明の一例を説明する。   Hereinafter, an example of the present invention will be described with reference to the drawings.

図１は本発明の一例に係る畳の構造を模式的に示す断面図、図２は図１に示される畳に用いる畳用芯材の構造を模式的に示す断面図である。なお、図１及び図２では、本発明に係る畳及び畳用芯材の断面構造を明確にするため、各構成部材の長さ寸法もしくは幅寸法に対する厚みの比率を実際よりも厚く表現している。   FIG. 1 is a cross-sectional view schematically showing the structure of a tatami mat according to an example of the present invention, and FIG. 2 is a cross-sectional view schematically showing the structure of a tatami mat core used in the tatami mat shown in FIG. In addition, in FIG.1 and FIG.2, in order to clarify the cross-sectional structure of the tatami mat and tatami mat core material according to the present invention, the ratio of the thickness to the length dimension or the width dimension of each component member is expressed thicker than actual. Yes.

図１及び図２に示すように、本例に係る畳１は、畳用芯材１０と、この畳用芯材１０の下面に宛われた裏面材２０と、この裏面材２０ごと上記畳用芯材１０の表面、側面及び裏面の周縁を覆う畳表材３０とで構成されている。畳１の総厚みは、通常２０〜６０ｍｍ程度である。   As shown in FIG. 1 and FIG. 2, the tatami mat 1 according to this example includes a tatami core material 10, a back material 20 addressed to the lower surface of the tatami core material 10, and the back material 20 together with the tatami mat. It is comprised with the tatami surface material 30 which covers the periphery of the surface of the core material 10, a side surface, and a back surface. The total thickness of the tatami mat 1 is usually about 20 to 60 mm.

畳用芯材１０は、合成樹脂発泡体からなる断熱性基材１１の上面に、２枚の不織布板を１２，１３重ね合わせたものとなっている。   The core material 10 for tatami is made by superimposing 12 and 13 non-woven fabric plates on the upper surface of a heat insulating base material 11 made of a synthetic resin foam.

断熱性基材１１を構成する合成樹脂発泡体としては、例えば、ポリスチレン系樹脂発泡体、ポリエチレン系樹脂発泡体、ポリプロピレン系樹脂発泡体、ポリウレタン系樹脂発泡体、フェノール系樹脂発泡体などを用いることができるが、吸水性が低く、断熱性に優れることからポリスチレンの発泡体が好ましい。また、ビーズ発泡成形体でも押出発泡成形体でもよいが、耐圧性に優れることから、押出発泡成形体が好ましい。断熱性基材１１を構成する合成樹脂発泡体は、適度な剛性と断熱性を得る上で、密度が２０〜５０ｋｇ／ｍ3、発泡倍率が２０〜５０倍であることが好ましい。断熱性基材１１は、通常、１０〜５０ｍｍ程度の厚みで、畳の平面寸法（例えば、９００ｍｍ×１８００ｍｍ）に裁断した平板状をなしている。 As the synthetic resin foam constituting the heat insulating substrate 11, for example, a polystyrene resin foam, a polyethylene resin foam, a polypropylene resin foam, a polyurethane resin foam, a phenol resin foam, or the like is used. However, a polystyrene foam is preferred because of its low water absorption and excellent heat insulation. Moreover, although a bead foam molded body or an extrusion foam molded body may be sufficient, since it is excellent in pressure resistance, an extrusion foam molded body is preferable. The synthetic resin foam constituting the heat insulating base material 11 preferably has a density of 20 to 50 kg / m 3 and a foaming ratio of 20 to 50 times in order to obtain appropriate rigidity and heat insulating properties. The heat-insulating base material 11 has a thickness of about 10 to 50 mm and has a flat plate shape that is cut into a tatami mat plane (for example, 900 mm × 1800 mm).

基材１１の上面に重ね合わせる２枚の不織布板１２、１３は、合成繊維を三次元に交絡させて成形したもので、断熱性基材１１に接する下側の不織布板１２の繊維密度が上側の不織布板１３の繊維密度よりも高くなっている。   The two nonwoven fabric plates 12 and 13 to be superposed on the upper surface of the base material 11 are formed by three-dimensionally intermingling synthetic fibers, and the fiber density of the lower nonwoven fabric plate 12 in contact with the heat insulating base material 11 is higher. It is higher than the fiber density of the nonwoven fabric plate 13.

下側の不織布板１２は、合成繊維が三次元に交絡した構造で、各繊維の熱伸縮が吸収され得る構造となっていることから、温度変化による全体としての寸法変化が抑制されている。また繊維密度が相対的に高いことで剛性が高められ、断熱性基材１１の補強材としての役割をなすものとなっている。   Since the lower nonwoven fabric plate 12 has a structure in which synthetic fibers are entangled three-dimensionally and has a structure capable of absorbing thermal expansion and contraction of each fiber, the overall dimensional change due to temperature change is suppressed. Moreover, since the fiber density is relatively high, the rigidity is increased, and it serves as a reinforcing material for the heat insulating base material 11.

下側の不織布板１２は、熱伸縮を抑制すると共に、補強材としての必要な剛性を付与する上で、繊維密度が０．１５以上０．５ｇ／ｃｍ3以下である。下側の不織布板１２の密度が０．５ｇ／ｃｍ3より大きくなると、温度変化に伴う各構成繊維の伸縮を吸収しにくくなり、温度変化に伴う寸法変化が大きくなる。また、下側の不織布板１２の密度が０．１５ｇ／ｃｍ3より小さくなると、剛性が低下し、断熱性基材１１の変形を生じやすくなる。さらに具体的には、下側の不織布板１２は、線膨張係数が１〜３×１０-5（Ｋ-1）、圧縮弾性率が１００〜４００Ｎ／ｃｍ2、曲げ強度が１００〜３００Ｎ／ｍｍ2であることが好ましく、繊維密度を調整することでこれらの物性を満たすことができる。下側の不織布板１２の厚さは、通常２〜６ｍｍである。 Nonwoven sheet 12 and the lower, suppresses the thermal expansion and contraction, in order to impart the necessary rigidity as the reinforcing material, fiber density Ru der 0.15 or 0.5 g / cm 3 or less. When the density of the lower nonwoven fabric plate 12 is larger than 0.5 g / cm 3 , it becomes difficult to absorb the expansion and contraction of each constituent fiber accompanying the temperature change, and the dimensional change accompanying the temperature change becomes large. Moreover, when the density of the lower nonwoven fabric plate 12 is smaller than 0.15 g / cm 3 , the rigidity is lowered and the heat insulating base material 11 is easily deformed. More specifically, the lower nonwoven fabric plate 12 has a linear expansion coefficient of 1 to 3 × 10 −5 (K −1 ), a compression modulus of 100 to 400 N / cm 2 , and a bending strength of 100 to 300 N / mm. It is preferably 2 , and these physical properties can be satisfied by adjusting the fiber density. The thickness of the lower nonwoven fabric plate 12 is usually 2 to 6 mm.

上側の不織布板１３は、繊維密度が下側の不織布板１２より小さいので、線膨張係数は下側の不織布板１２より小さいもので、主にクッション性を付与する役割をなす。   Since the upper nonwoven fabric plate 13 has a fiber density smaller than that of the lower nonwoven fabric plate 12, the linear expansion coefficient is smaller than that of the lower nonwoven fabric plate 12, and mainly serves to impart cushioning properties.

上側の不織布板１３は、適度なクッション性を得る上で、繊維密度が０．０５ｇ／ｃｍ3以上〜０．１５ｇ／ｃｍ3未満である。上側の不織布板１３の繊維密度が０．１５ｇ／ｃｍ3以上となっても０．０５ｇ／ｃｍ3より小さくなっても、クッション性が不足しやすくなる。また、上側の不織布板１３は、圧縮弾性率が３０〜２００Ｎ／ｃｍ2、曲げ強度が長さ方向で５０〜２００Ｎ／ｃｍ2、幅方向で３０〜１００Ｎ／ｃｍ2あることが好ましく、繊維密度を調整することでこれらの物性を満たすことができる。上側の不織布板１３の厚さは、通常２〜４ｍｍである。 Upper nonwoven plate 13, in order to obtain a moderate cushioning property, fiber density Ru der less than 0.05 g / cm 3 or more ~0.15g / cm 3. Even if the fiber density of the upper non-woven fabric sheet 13 is smaller than even 0.05 g / cm 3 becomes 0.15 g / cm 3 or more, cushioning tends to lack. Further, the upper nonwoven fabric sheet 13, the compression modulus 30~200N / cm 2, bending 50 to 200 / cm 2 intensity in the longitudinal direction, is preferably in 30~100N / cm 2 in the width direction, the fiber density These physical properties can be satisfied by adjusting. The thickness of the upper nonwoven fabric plate 13 is usually 2 to 4 mm.

下側及び上側の不織布板１２，１３は、上記物性を得る上で、直状の合成繊維を三次元に交絡させて構成したものとなっている。直状の合成繊維とはクリンプのない合成繊維をいう。クリンプした合成繊維の場合、繊維密度を高めても柔軟で、上記圧縮強度や曲げ強度を満たしにくい。 Lower and upper nonwoven plates 12 and 13, in order to obtain the physical properties, and is obtained by configuration are entangled in a three dimensional straight synthetic fibers. A straight synthetic fiber means a synthetic fiber without a crimp. In the case of a crimped synthetic fiber, it is flexible even if the fiber density is increased, and it is difficult to satisfy the compressive strength and bending strength.

下側及び上側の不織布板１２，１３は、上記諸物性が得やすいことから、湿熱接着性を有する繊維単独、又は湿熱接着性を有する繊維とその他の繊維との混合繊維を用い、繊維同士が交絡した状態で圧縮し、加熱蒸気と接触させて相互に接着した板状体であることが好ましい。湿熱接着性繊維とは、加熱蒸気との接触により接着性を発揮する繊維で、ポリエチレンテレフタレートの芯層の表面をエチレン−ビニルアルコール共重合体の鞘層で覆った芯鞘型複合ステープル繊維が好ましい。芯鞘質量比は、４０〜６０：６０〜４０程度が好ましい。その他の繊維としてはポリエチレンテレフタレート（ＰＥＴ）繊維が好ましい。両者の混合比は、重量比で、上記芯鞘型複合ステープル繊維７０〜９５重量％に対してＰＥＴ繊維が５〜３０重量％であることが好ましい。   Since the lower and upper nonwoven fabric plates 12 and 13 are easy to obtain the above-mentioned physical properties, fibers using wet heat adhesiveness alone or mixed fibers of fibers having wet heat adhesiveness and other fibers are used, and the fibers are separated from each other. It is preferably a plate-like body that is compressed in an entangled state and is bonded to each other by contacting with heated steam. The wet heat adhesive fiber is a fiber that exhibits adhesiveness by contact with heated steam, and is preferably a core-sheath type composite staple fiber in which the surface of the polyethylene terephthalate core layer is covered with a sheath layer of an ethylene-vinyl alcohol copolymer. . The core-sheath mass ratio is preferably about 40-60: 60-40. Other fibers are preferably polyethylene terephthalate (PET) fibers. The mixing ratio between the two is preferably 5 to 30% by weight of PET fiber with respect to 70 to 95% by weight of the core-sheath type composite staple fiber.

下側及び上側の不織布板１２，１３は、上記湿熱性接着性繊維単独、又は上記湿熱性接着性繊維とその他の繊維との混合繊維を用い、ポリカーボネート製エンドレスネットを装備したベルトコンベアに移送し、表裏両面に対して加熱蒸気処理を施すことにより、交絡した繊維同士を相互に接着した板状体とすることで得ることができる。   The lower and upper nonwoven fabric plates 12 and 13 are transferred to a belt conveyor equipped with a polycarbonate endless net using the wet heat adhesive fiber alone or a mixed fiber of the wet heat adhesive fiber and other fibers. It can be obtained by forming a plate-like body in which entangled fibers are bonded to each other by subjecting the front and back surfaces to heat steam treatment.

下側及び上側不織布板１２，１３は、断熱性基材１１の上面に単に重ね合わせて配置してもよいが、予め両者を重ねて加熱蒸気を接触させて接着しておくことが好ましい。このようにすることにより、畳１の製造時の作業性を向上させることができる。   The lower and upper nonwoven fabric plates 12 and 13 may be simply superimposed on the upper surface of the heat-insulating substrate 11, but it is preferable that they are previously stacked and brought into contact with each other by heating steam. By doing in this way, the workability | operativity at the time of manufacture of the tatami 1 can be improved.

裏面材２０としては、少なくとも露出面側に防水面を有するシート材が好ましい。具体的には、合成樹脂シートや、布と合成樹脂の積層シート、紙と合成樹脂の積層シートなどを用いることができ、合成樹脂面を露出面側（下面側）として上記基材１１の下面に宛がわれる。   The back material 20 is preferably a sheet material having a waterproof surface at least on the exposed surface side. Specifically, a synthetic resin sheet, a laminated sheet of cloth and synthetic resin, a laminated sheet of paper and synthetic resin, or the like can be used, and the lower surface of the substrate 11 with the synthetic resin surface as an exposed surface side (lower surface side). Addressed to.

このように上記断熱性基材１１の下面に裏面材２０を宛がって、この裏面材２０ごと畳用芯材１０の表面、側面及び裏面の周縁を包み込むように畳表材３０で覆い、裏面の周縁を縫着糸もしくは止着針によって止着することにより、各構成部材が一体化されて畳１となる。   In this way, the back surface material 20 is applied to the lower surface of the heat insulating base material 11, and the back surface material 20 is covered with the tatami mat surface material 30 so as to wrap around the front surface, the side surface and the periphery of the back surface of the tatami core material 10. Each of the constituent members is integrated to form the tatami mat 1 by fastening the peripheral edge thereof with a sewing thread or a fastening needle.

なお、断熱性基材１１止着部位には裏面補強材４０を取り付けて補強しておくことができる。   In addition, the back surface reinforcement material 40 can be attached and reinforced to the heat insulation base material 11 fixation site | part.

このように、本発明の畳用芯材１０及び畳１においては、合成樹脂発泡体の断熱性基材１１の上面に重ね合わせた下側及び上側不織布板１２，１３のうち、補強材として機能する下側の不織布板１２の繊維密度を、クッション材として機能する上側の不織布板１３の繊維密度よりも高く設定している。下側及び上側不織布板１２，１３は、合成樹脂繊維を三次元に交絡させて板状に成形された構造体であるので、繊維密度を調整することで、軽量化を図りながら、断熱性基材１１を補強しうる剛性やクッション性をもたせることができる。また、下側及び上側不織布板１２，１３、内部に微細な空隙を有するであるので、断熱性を有し、気温変化による影響が少なく、畳の寸法変化が少ない。また、本発明の畳用芯材１０は、その構成部材が合成樹脂発泡体及び不織布板であるので、裁断が容易である。加えて、不織布板は表面摩擦強度が強くて発塵が少なく、合成樹脂発泡体との密着性もよいので、畳表材３０で覆う際の作業性もよい。   Thus, in the core material 10 for tatami and the tatami 1 of this invention, it functions as a reinforcing material among the lower side and upper side nonwoven fabric boards 12 and 13 superimposed on the upper surface of the heat insulating base material 11 of a synthetic resin foam. The fiber density of the lower nonwoven fabric plate 12 is set higher than the fiber density of the upper nonwoven fabric plate 13 functioning as a cushioning material. Since the lower and upper nonwoven fabric plates 12 and 13 are structures formed by three-dimensionally interlacing synthetic resin fibers and formed into a plate shape, adjusting the fiber density can reduce the weight while reducing the weight of the insulating base. Rigidity and cushioning properties that can reinforce the material 11 can be provided. Moreover, since it has a fine space | gap inside the lower side and upper side nonwoven fabric boards 12 and 13, it has heat insulation, there is little influence by a temperature change, and there are few dimensional changes of a tatami. Moreover, since the structural member of the core material 10 for tatami mat | matte of this invention is a synthetic resin foam and a nonwoven fabric board, it is easy to cut | judge. In addition, the nonwoven fabric plate has high surface friction strength, little dust generation, and good adhesion to the synthetic resin foam, so that the workability when covering with the tatami mat 30 is also good.

以下、本発明に係る畳の実施例及び比較例を挙げて、本発明をさらに詳しく説明する。 Hereinafter, the present invention will be described in more detail with reference to examples and comparative examples of tatami mats according to the present invention.

〔実施例〕
図１に示した構造を有する畳１を作製した。 〔Example〕
A tatami mat 1 having the structure shown in FIG. 1 was produced.

基材１１の合成樹脂発泡体として、厚さ４５ｍｍで発泡倍率が３３倍の押出発泡ポリスチレンフォーム（商品名：スタイロフォーム、ダウ化工株式会社製）を用いた。   As the synthetic resin foam of the base material 11, an extruded expanded polystyrene foam (trade name: Styrofoam, manufactured by Dow Chemical Co., Ltd.) having a thickness of 45 mm and an expansion ratio of 33 times was used.

断熱性基材１１の上面に接し、補強材として機能する下側の不織布板１２として、厚さが２ｍｍ、繊維密度が０．２ｇ／ｃｍ3であり、曲げ強度が長さ方向で約３００Ｎ／ｃｍ2、幅方向で約１５０Ｎ／ｃｍ2、線膨張係数が２×１０-5（ｋ-1）の不織布板を用いた。 The lower nonwoven fabric plate 12 that is in contact with the upper surface of the heat insulating substrate 11 and functions as a reinforcing material has a thickness of 2 mm, a fiber density of 0.2 g / cm 3 , and a bending strength of about 300 N / long in the length direction. A non-woven fabric board having a cm 2 width of about 150 N / cm 2 and a linear expansion coefficient of 2 × 10 −5 (k −1 ) was used.

また、緩衝材として機能する上側の不織布板１３として、厚さが３ｍｍ、繊維密度が０．１ｇ／ｃｍ3であり、曲げ強度が長さ方向で約１５０Ｎ／ｃｍ2、幅方向で約８０Ｎ／ｃｍ2、線膨張係数が２×１０-5（ｋ-1）の不織布板を用いた。 The upper nonwoven fabric plate 13 functioning as a buffer material has a thickness of 3 mm, a fiber density of 0.1 g / cm 3 , a bending strength of about 150 N / cm 2 in the length direction, and about 80 N / width in the width direction. A nonwoven fabric plate having a cm 2 and a linear expansion coefficient of 2 × 10 −5 (k −1 ) was used.

上記断熱性基材１１の下面に、合成樹脂をラミネートした紙を裏面材２０として宛がって、この裏面材２０ごと、畳用芯材１０の表面、側面及び裏面の周縁を包み込むように畳表材３０で覆い、裏面の周縁を止着針によって止着して畳１を作製した。   A paper having a synthetic resin laminated on the lower surface of the heat insulating base material 11 is addressed as a back surface material 20, and the back surface material 20, the surface of the tatami mat core material 10, the side surface, and the periphery of the back surface are wrapped. The tatami mat 1 was produced by covering with a material 30 and fastening the peripheral edge of the back surface with a fastening needle.

本実施例で作製した畳１の総重量は６ｋｇであった。また、ＪＩＳ Ａ ５９１４に規定する局部圧縮試験による変位量測定したところ２ｍｍであり、充分な剛性を示した。さらに、２５℃／９０％湿度の雰囲気下と５℃／３０％湿度の雰囲気下で寸法を測定したところ、寸法変化量（高温時の寸法に対する低温時の寸法の変化量）は長さ方向及び幅方向ともに−１ｍｍであった。   The total weight of the tatami mat 1 produced in this example was 6 kg. Further, the displacement measured by a local compression test specified in JIS A 5914 was 2 mm, which showed a sufficient rigidity. Furthermore, when the dimensions were measured under an atmosphere of 25 ° C./90% humidity and an atmosphere of 5 ° C./30% humidity, the dimensional change amount (the change amount of the dimension at low temperature relative to the dimension at high temperature) was The width direction was -1 mm.

本実施例で作製した畳１について、床性能研究会が定める「身体を押しつける時の痛さからみた床の評価方法」に基づき測定したところ、−０．９５であり、十分なクッション性を有している結果であった。ここで、測定値の−（マイナス）数値が大きくなるほど畳として硬いことを示す。   The tatami mat 1 produced in this example was measured based on the “method for evaluating the floor from the viewpoint of pain when pressing against the body” established by the Floor Performance Study Group, and found to be −0.95 and had sufficient cushioning properties. It was a result. Here, it shows that it is so hard that it is tatami mat, so that the-(minus) numerical value of a measured value becomes large.

〔比較例１〕
断熱性基材１１の上面に補強材として機能する厚さ２．３ｍｍのベニヤ合板及び２ｍｍの発泡ポリエチレンクッション材を配置した以外は、実施例と同様の構成で畳を作製した。 [Comparative Example 1]
A tatami mat was prepared in the same manner as in the example except that a 2.3 mm thick veneer plywood and a 2 mm foamed polyethylene cushion material functioning as a reinforcing material were disposed on the upper surface of the heat insulating base material 11.

本比較例で作製した畳の総重量は７ｋｇであった。また、ＪＩＳ Ａ ５９１４に規定する局部圧縮試験による変位量測定したところ２ｍｍであった。さらに、２５℃／９０％湿度の雰囲気下と５℃／３０％湿度の雰囲気下で寸法を測定したところ、寸法変化量は長さ方向が−１．５ｍｍ、幅方向が−１ｍｍであった。   The total weight of the tatami mat produced in this comparative example was 7 kg. The displacement measured by the local compression test specified in JIS A 5914 was 2 mm. Furthermore, when the dimensions were measured in an atmosphere of 25 ° C./90% humidity and an atmosphere of 5 ° C./30% humidity, the dimensional change was −1.5 mm in the length direction and −1 mm in the width direction.

本比較例で作製した畳について、床性能研究会が定める「身体を押しつける時の痛さからみた床の評価方法」に基づき測定したところ、−２．４１であり、クッション性がやや劣る結果となった。   The tatami mat produced in this comparative example was measured on the basis of the “method of evaluating the floor from the pain when pressing against the body” established by the Floor Performance Study Group, and it was −2.41, and the cushioning property was slightly inferior. became.

〔比較例２〕
断熱性基材１１の上面に補強材として機能する厚さ１０ｍｍのポリオレフィン再生樹脂板（合成樹脂ボード）を配置した以外は、実施例と同様の構成で畳１を作製した。 [Comparative Example 2]
A tatami mat 1 was produced with the same configuration as in the example except that a polyolefin recycled resin plate (synthetic resin board) having a thickness of 10 mm functioning as a reinforcing material was disposed on the upper surface of the heat insulating substrate 11.

本比較例で作製した畳の総重量は９ｋｇであった。また、ＪＩＳ Ａ ５９１４に規定する局部圧縮試験による変位量測定したところ２ｍｍであった。さらに、２５℃／９０％湿度の雰囲気下と５℃／３０％湿度の雰囲気下で寸法を測定したところ、寸法変化量は長さ方向及び幅方向が−３ｍｍであった。   The total weight of the tatami mat produced in this comparative example was 9 kg. The displacement measured by the local compression test specified in JIS A 5914 was 2 mm. Furthermore, when the dimensions were measured under an atmosphere of 25 ° C./90% humidity and an atmosphere of 5 ° C./30% humidity, the dimensional change was −3 mm in the length direction and the width direction.

本比較例で作製した畳について、床性能研究会が定める「身体を押しつける時の痛さからみた床の評価方法」に基づき測定したところ、−３．１１であり、クッション性が劣る結果となった。   The tatami mat produced in this comparative example was measured based on the “method for evaluating the floor from the viewpoint of pain when pressing the body” established by the Floor Performance Study Group, and was found to be −3.11, resulting in poor cushioning properties. It was.

本発明の一例に係る畳の構造を模式的に示す断面図である。It is sectional drawing which shows typically the structure of the tatami concerning an example of this invention. 本発明の一例に係る畳用芯材の構造を模式的に示す断面図である。It is sectional drawing which shows typically the structure of the core material for tatami mats concerning an example of the present invention.

符号の説明Explanation of symbols

１ 畳
１０ 畳用芯材
１１ 基材
１２ 下側の不織布板
１３ 上側の不織布板
２０ 裏面材
３０ 畳表材 DESCRIPTION OF SYMBOLS 1 Tatami 10 Tatami core 11 Base material 12 Lower nonwoven fabric board 13 Upper nonwoven fabric board 20 Back surface material 30 Tatami surface material

Claims (5)

合成樹脂発泡体からなる断熱性基材の上面に、合成繊維を三次元に交絡させて成形した繊維密度の異なる２枚の不織布板が上下に重ねられており、前記断熱性基材に接する下側の不織布板の繊維密度が０．１５ｇ／ｃｍ 3 以上０．５ｇ／ｃｍ 3 以下、上側の不織布板の繊維密度が０．０５ｇ／ｃｍ 3 以上０．１５ｇ／ｃｍ 3 未満で、下側の不織布板の繊維密度が上側の不織布板の繊維密度よりも高く、しかも下側及び上側の不織布板を構成する合成繊維が、直状の合成繊維であることを特徴とする畳用芯材。 Two nonwoven fabric plates having different fiber densities formed by three-dimensionally entangled synthetic fibers are vertically stacked on the upper surface of a heat insulating base material made of a synthetic resin foam, and are in contact with the heat insulating base material. fiber density of the side of the nonwoven fabric sheet is 0.15 g / cm 3 or more 0.5 g / cm 3 or less, the fiber density of the upper nonwoven fabric sheet is less than 0.05 g / cm 3 or more 0.15 g / cm 3, the lower A core material for tatami mats, wherein the nonwoven fabric plate has a fiber density higher than that of the upper nonwoven fabric plate, and the synthetic fibers constituting the lower and upper nonwoven fabric plates are straight synthetic fibers . 下側及び上側の不織布板の両者が、湿熱接着性を有する繊維単独、又は湿熱接着性を有する繊維とその他の繊維との混合繊維を用い、繊維同士が交絡した状態で圧縮し、加熱蒸気と接触させて相互に接着した板状体であることを特徴とする請求項１に記載の畳用芯材。 Both the lower and upper nonwoven fabric plates use wet fibers alone or a mixed fiber of wet fibers and other fibers, compressed in a state where the fibers are entangled, and heated steam The core material for tatami mats according to claim 1 , wherein the tatami mat core materials are plate-like bodies that are brought into contact with each other and bonded to each other. 湿熱接着性を有する繊維が、ポリエチレンテレフタレートの芯層の表面をエチレン−ビニルアルコール共重合体の鞘層で覆った芯鞘型複合ステープル繊維、その他の繊維がポリエチレンテレフタレート繊維であることを特徴とする請求項２に記載の畳用芯材。 The fiber having wet heat adhesion is a core-sheath type composite staple fiber in which the surface of the polyethylene terephthalate core layer is covered with a sheath layer of ethylene-vinyl alcohol copolymer, and the other fibers are polyethylene terephthalate fibers. The core material for tatami mats according to claim 2 . 請求項１〜３いずれか１項に記載の畳用芯材の下面に裏面材を宛がい、該裏面材ごと前記芯材の表面、側面及び裏面の周縁を包み込んで畳表材で覆って一体化したことを特徴とする畳。 A back surface material is applied to the lower surface of the core material for tatami mats according to any one of claims 1 to 3 , and the front surface, side surfaces, and peripheral edges of the back surface of the core material are wrapped together and covered with a tatami surface material. A tatami mat characterized by that. 裏面材が、少なくとも露出面側に防水面を有するシート材であることを特徴とする請求項４に記載の畳。 The tatami mat according to claim 4 , wherein the back material is a sheet material having a waterproof surface at least on the exposed surface side.
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JP3026948U (en) * 1996-01-19 1996-07-30 玉井産業株式会社 tatami
JPH10131465A (en) * 1996-11-01 1998-05-19 Toray Ind Inc Frameless artificial 'tatami' mat
JPH10259657A (en) * 1997-03-17 1998-09-29 Toyobo Co Ltd Cushion material for tatami mat and tatami mat using it
JP3478789B2 (en) * 2000-08-30 2003-12-15 株式会社イケヒコ・コーポレーション tatami
WO2008108295A1 (en) * 2007-03-08 2008-09-12 Kuraray Kuraflex Co., Ltd. Nonwoven fabric

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