JP2000352182A - Large tatami mat and surface material constituting its tatami mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a large tatami mat capable of being manufactured at a low cost. SOLUTION: The large tatami mat is composed of a surface material 1 having the same size as a room and a tatami mat floor 2 as a separate body laid on the floor of the room. The surface material 1 has a tatami mat facing 3 manufactured by joining a plurality of natural rushes together by using 'joining' technique and a rear protective layer 4 bonded with the rear of the tatami mat facing 3. The rear protective layer 4 is composed of a flexible material comprising the single layer or laminate of a natural or synthetic rubber or a synthetic resin material or felt or the composite foam of calcium carbonate and polyethylene, which is not inconvenient for rounding and carrying the surface material 1 as a carpet and has proper thickness of approximately 2-5 mm. A resin foam and a resin board or a woody board which have been known may be contained as main bodies as the tatami mat facing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a large tatami mat using natural rush as a material of a tatami mat surface and a surface material constituting the large tatami mat.

[0002]

2. Description of the Related Art Tatami is a traditional flooring of a Japanese house, but due to the recent westernization, the number of occupied rooms in the house has been increasing, and a part of the floor space between the occupied floors has been increased. Various uses have been proposed, such as laying tatami and using it as a carpet.

Under such circumstances, tatami mats use a synthetic resin product such as polypropylene instead of rush as a material for the tatami mat (see JP-A-9-60260).
As the material for the tatami floor, a material mainly comprising a foam such as expanded polystyrene instead of a straw (see JP-A-7-189463 and JP-A-8-151774) has begun to appear. Traditionally, tatami mats are sewn with rim bands extending along both side edges, but industrialized tatami mats without such rim bands have also been proposed (Japanese Patent Laid-Open No. Hei 7-189463).
The industrialized tatami teaches that a traditional tatami mat is provided with a separate band from the tatami mat as a separate part, and that the tatami mat is laid before the band mat material is installed.

[0004] Incidentally, a method of making a traditional tatami mat with a marginal band will be described according to the steps as follows. (1) Put the tatami mat on the tatami floor; (2) fold both ends of the tatami mat to the back side of the longitudinal ends of the tatami mat, that is, to the back of the frame; (4) Put the turned upside down band on both sides of the tatami mat and sew the tatami mat on the tatami mat through the tatami mat; And sewn on the side of the tatami floor.

[0005] In addition, the traditional method of making tatami without borders is
It is basically the same as a tatami mat with a margin band except for the step of sewing the margin band. That is, (1) put the tatami mat on the tatami floor; (2) fold both ends of the tatami mat to the back side of the longitudinal end of the tatami mat, that is, to the back of the frame; And sew on the side of this tatami floor.

Next, the work of laying the tatami mats will be described.
Traditionally, the following approaches have been adopted. First step: A tatami craftsman goes to the site and measures the size of the room; Second step: For example, if it is between six tatami mats, the size of each of the six tatami mats is determined based on the measured data. Third step: bringing the completed tatami mat to the site and laying each tatami mat in a predetermined position.

The laying of the tatami mat in the previously measured room is completed by the above first to third steps. For example, the tatami mat is laid as scheduled due to an error in the measurement performed in the first step. When the tatami mat cannot be inserted, the tatami mats need to be reworked. Therefore, it is a traditional method that the tatami maker goes to the site and lays out the third step. On the other hand, the industrialized tatami disclosed in Japanese Patent Application Laid-Open No. 7-189463 is a proposal from the viewpoint of construction management in which the tatami craftsman does not need to go to the site in the third step.

[0008]

As described above, the use and materials of tatami mats have been diversified, but the size of tatami mats is limited to two types, one tatami mats and half tatami mats. The idea of embedding has basically not changed at all since ancient times. However, the current trend of cost competition is not unrelated to this industry, and it is necessary to realize tatami mats that can reduce costs. Therefore, an object of the present invention is to
An object of the present invention is to provide a large tatami mat that can be manufactured at low cost and a surface material constituting the large tatami mat.

[0009]

SUMMARY OF THE INVENTION According to one aspect of the present invention, there is provided a tatami floor and a surface material laid on the tatami floor member after the tatami floor is laid in a room. Achieved by providing a large tatami mat, wherein the surface material comprises a tatami mat made by joining natural rushes and a back protective layer fixed to the back of the tatami mat Is done. According to another aspect of the present invention, a surface material for making a large tatami mat laid on a tatami floor laid in a room, the tatami mat being made by joining natural rushes, This is achieved by providing a surface material comprising a back surface protective layer fixed to the back surface of the tatami mat.

According to the present invention, the size of a tatami has been limited to two types, one tatami or a half tatami, but if one breaks away from the conventional concept of binding and, for example, creates a tatami to the same size as a room, It was devised based on the advantages obtained, especially from the viewpoint that relatively short rushes, which had been disposed of until now, can be connected and used, so that the cost of tatami mats can be significantly reduced. It is.

[0011] In other words, to explain the usage of rushes so far, tatami mats generally use a single real rush in the width direction, and the used portion is the tip of the rush and the root of the rush. It is the part sandwiched between the parts. In other words, since the tip of the rush and the root are cut and used,
In fact, trade in rushes was limited to 1 m or more, and shorter rushes were discarded because they could not be used. By the way, the width of the tatami mats and the tatami mats is 880 cm or 955 cm. In the case of high-class tatami, use only the best part of long rush,
Two rushes are used in the width direction of the tatami mat. In the industry, this tying technique is called “medium tying”.

According to the present invention, since the size of the surface material is not limited to one tatami mat or half tatami mat, a plurality of natural rushes can be joined together to form a tatami mat for a large tatami mat. It is possible to use relatively short rushes.

In addition, a completely different method from that of the related art is employed in which a tatami mat is formed by combining a surface material constituting a tatami surface and a tatami floor on site, and the surface material is different from a so-called goza. Since it has a backside protective layer, it is basically sufficient to spread the work on the tatami floor, so that the work by the so-called tatami craftsman can be eliminated, and the cost can be reduced in terms of labor costs. . The above and other objects and features of the present invention will be apparent from the following description of preferred embodiments of the present invention.

[0014]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings. In FIG. 1, reference numeral 1 indicates a surface material of a tatami mat according to the present invention. The surface material 1 is used in combination with a separate tatami floor 2 at the site. The tatami floor 2 is first laid in a room, and then the surface material 1 is placed on the tatami floor 2. Designed. That is, unlike conventional tatami mats, the combination of the tatami floor 2 and the surface material 1 at the site creates a so-called large tatami mat with a plurality of tatami mats laid.

The surface material 1 of the tatami mat is made, for example, for a size between six tatami mats so as to fit between the six tatami mats. The surface material 1 has a tatami table 3 manufactured by joining a plurality of natural rushes using a “medium joining” technique, and a back surface protective layer 4 adhered to the back surface of the tatami table 3. The back surface protective layer 4 is made of a natural or synthetic rubber or synthetic resin material having an appropriate thickness of, for example, about 2 mm to 5 mm, or a felt or calcium carbonate, which is not inconvenient for rolling and transporting the surface material 1 like, for example, a carpet. And a flexible material composed of a single layer or a laminate of a composite foam of polyethylene and polyethylene.

The tatami mat 3 has a peripheral portion 3a which is "edge-over".
Is preferred. “Overcasting” is also referred to as “overcasting” in the industry. However, since it is a technique conventionally known as a processing method of a goza width, detailed description thereof is omitted. Tatami table 3 is preferably made of hot pressed natural rush. Preferably, the press working has the advantage that wrinkles and uneven weaving are eliminated and the quality is stabilized, and chlorophyll is leached from the inside of the natural rush by the effect of the heating press. There is an advantage that the color unevenness can be reduced.

The tatami floor 2 may be mainly composed of a conventionally known resin foam, resin board or wood board, or may be composed mainly of a board made of natural or synthetic rubber. Or a combination thereof. Further, for example, a laminated structure in which rubber is adhered to the upper surface and / or the lower surface of the wooden board may be used. The size of the tatami floor 2 may be the same as that of a single tatami mat or a half tatami mat as in the related art, or may be larger. That is, the size of the tatami floor 2 is not particularly limited, but is a size that is not inconvenient to carry to the site, and the floor of the room is laid by laying one or more tatami floors 2. Any size is acceptable as long as it can be covered.

The tatami surface material 1 according to the present invention is manufactured and laid in a room in the following procedure. (1) Measure the size of the room; (2) Make the surface material 1 of the size that matches the size of the room that was measured; (3) Roll the finished surface material 1 and pack it, (4) Laying the tatami floor 2 on the floor of the room; (5) Spreading the surface material 1 on the laid floor 2; (6) Spreading the surface material 1 is, if necessary, fixed to the tatami floor 2 using a simple adhesive means such as a double-sided adhesive tape.

In the case of, for example, a saloon, the size of the surface material 1 of the tatami mat may be designed so that the saloon can be covered with a plurality of surface materials 1. Further, even in a room of a normal size such as a half-square room, a six-story room, or a eight-story room, individual sizes may be set so that a plurality of surface materials 1 can be spread. Good. In addition, the shape of the surface material 1 is not limited to a rectangle, and may be a geometric shape such as a triangle. The shape and size of the surface material 1 are variously combined so as to be used. May be designed.

In the tatami mat according to the present invention, the size of the surface material 1 is not limited to the standard of the conventional tatami mats and semi-tatami mats. Therefore, it is possible to use relatively short rushes which have been discarded until now. As a result, the cost of purchasing rush can be significantly reduced. In addition, since the surface material 1 and the tatami floor 2 are separate structures, the conventional techniques of tatami mats are substantially unnecessary, so that it is possible to reduce costs in terms of labor costs.

FIGS. 2 and 3 show the surface material of the tatami mat of the second embodiment. This surface material 10 constitutes a so-called tatami for the first time by being used in combination with a separate tatami floor 2 on site, as in the first embodiment described above. The surface material 10 of the second embodiment is the same as the first embodiment except for the following points.
Since it is the same as the surface material 1 of the embodiment, only the characteristic portions will be described below, and the same elements as those of the first embodiment will be denoted by the same reference numerals and description thereof will be omitted.

The front surface material 10 has a tatami surface 11 and a back surface protective layer 4, and the tatami surface 11 and the back surface protective layer 4 are fixed on the entire surface thereof using an adhesive applied in a streak shape at a pitch of, for example, 10 mm. I have. The adhesive used here may be a commercially available adhesive having appropriate durability, but it does not generate harmful substances such as formaldehyde, has flexibility, and has a strong adhesive force. It is preferable to use a hot melt adhesive, and most preferably, a hot melt agent having heat resistance. The tatami table 11 is formed by joining a plurality of natural rushes using the “medium joining” technique, similarly to the tatami table 3 of the first embodiment. Further, as the tatami table 11, similarly to the tatami table 3 of the first embodiment, it is preferable to use natural rush that has been hot-pressed. There is an advantage that the flatness of the borderless tatami mat 1 can be improved by using the hot-pressed rush.

The tatami table 11 can be understood from FIG.
The edge is chamfered over the entire circumference, and the chamfered portion 13
The peripheral surface of the back surface protective layer 4 including at least the chamfered portion 1
3 is covered with a peripheral protective film or a peripheral protective film 14. This peripheral protective film 14 is applied to at least the chamfered portion 13 of the peripheral surface of the surface material 10 by, for example, a natural rubber-based or latex-based resin which permeates the tatami surface 11 to some extent and solidifies, and retains appropriate flexibility. It is good to form by. The surface material 10 may be left uncut, but it is preferable to improve the appearance when the surface material 10 is laid by chamfering the periphery of the tatami mat 11 over the entire circumference. In addition, on the entire periphery of the surface material 10,
By covering at least the portion of the tatami table 11 with the peripheral edge protective film 14, "fraying", "fuzz" or "peeling" of the tatami table 11 can be prevented.

In the surface material 10 according to the second embodiment, since the tatami surface 11 and the back surface protective layer 4 are stuck together at a 1 mm pitch on the entire surface, an arbitrary portion of the surface material 10 can be cut. it can. The newly exposed cut surface obtained by cutting the surface material 10 may be covered with a back surface protective layer or a protective film 14 which can be formed by applying a suitable adhesive after chamfering the cut edge of the tatami mat 11. Good. Such a series of operations can be sufficiently performed by an amateur without being a tatami craftsman. Therefore, it is not necessary to measure the size of the room in advance and manufacture the surface material 10 having a size suitable for the measured value, and manufacture and stock the surface material 10 slightly larger than the normal room size. After taking it to the site, it can be cut into a size corresponding to the size of the room, and then can be laid in the room after forming the peripheral protective film 14. You don't need to be a tatami craftsman to do this.

Further, the tatami mat according to the second embodiment can be provided to the general public by a different route as described below. That is, a large number of surface materials 10 standardized to an arbitrary size are manufactured, and separately, for example, a tatami floor 2 having a size of, for example, a tatami mat or a semi-tatami mat is manufactured and sold to a general public. The purchaser can cut the surface material 10 and the tatami floor 2 into a desired shape and size, for example, to make a part of the flooring between the tatami floors.

As described above, such an operation can be sufficiently performed even by an unskilled person. That is,
The cut surface newly exposed by cutting the surface material 10 may be, as necessary, a peripheral protective film 14 formed by chamfering the edge of the tatami mat 11 and then applying an appropriate adhesive.
What is necessary is just to cover with. If necessary, the cutting tool and the resin material for forming the peripheral edge protective film 14 may be sold as a set.

As a common problem of the first embodiment and the second embodiment, there is a problem of "warping" as a possibility of the tatami floor 2 after being laid in a room, particularly when the tatami floor 2 is made relatively thin. There is a problem of "warping" which is liable to occur in the tatami floor 2. For example, a double-sided adhesive tape provided with a release tape (not shown) is attached to an appropriate position on the bottom of the tatami floor 2 at the time of shipment from a factory. In addition, when the tatami floor 2 is laid, the release tape of the double-sided adhesive tape may be removed, and the tatami floor 2 may be adhered to the floor of the room. You may make it fix with a screw. When the tatami floor 2 is used in an environment in which the problem of "warping" of the tatami floor 2 is likely to be induced, a layer made of a material having relatively low elasticity, such as a PVC resin layer, is provided on the bottom of the tatami floor 2. They may be stacked.

The problem of the "warpage" of the tatami floor 2 can be solved from the viewpoint of the method of laying the tatami floor 2. That is, before the tatami floor 2 is laid, a sheet material such as a curing sheet as referred to in this industry is partially laid on the floor of the room, and the tatami floor 2 is placed on the double-sided adhesive tape ( (Not shown). According to this method, there is an advantage that "warping" can be prevented without damaging the floor of the room. Therefore, for example, even if a plurality of tatami floors 2 are laid on the whole or part of the flooring between the oceans, the tatami floors 2 are not directly fixed to the flooring. Even if the tatami mat according to the present invention is removed, there is no problem in restoring the room.

Tatami tables 3, 11 of the first and second embodiments
Heating press (Fig. 4) is performed as processing of the peripheral part of
The peripheral portions 3a, 11a of the tatami mats 3, 11 may be flattened. In this case, in the case of the tatami table 11 of the second embodiment, it is preferable that at least the flattened peripheral portion 11a is covered with the peripheral protective layer 14. Of course, the peripheral edge protection layer 14 may be provided also on the peripheral edge portion 3a of the tatami mat 3 of the first embodiment with the overhang.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a structure of a tatami mat according to a first embodiment of the present invention.

FIG. 2 is an explanatory diagram showing a structure of a tatami mat according to a second embodiment of the present invention.

FIG. 3 is a partial cross-sectional view illustrating an end of a surface material included in the tatami mat of FIG. 2;

FIG. 4 is an explanatory view of a step of forming a flat peripheral portion by applying a heat press to a peripheral portion of the tatami table surface, thereby forming a surface material, and (a) applying a hot press to a peripheral portion of the tatami table surface. (B) shows a process of bonding and integrating a back surface protective layer with a tatami mat having a flattened peripheral portion, and (c) shows a process of forming a peripheral protective layer on the peripheral surface of the surface material. Show.

[Explanation of symbols]

 1, 10 tatami mat surface material 2 tatami mat floor 3, 11 tatami mat table 4 back protective layer 13 chamfered part 14 peripheral protective layer

Claims (7)

[Claims] 1. A tatami floor and a surface material laid on the tatami floor member after the tatami floor is laid in a room, the surface material being made by joining natural rushes. A large tatami mat comprising a tatami surface and a back surface protective layer provided on the back surface of the tatami surface. 2. The large tatami mat according to claim 1, wherein the back surface protective layer is made of a flexible material capable of rolling the surface material. 3. The large tatami mat according to claim 1, wherein the surface material has the same size as a room. 4. A surface material for making a large tatami mat laid on a tatami floor laid in a room, wherein the tatami mat is made by joining natural rushes together.
A surface material for large tatami mats, comprising a back surface protective layer provided on the back surface of the tatami mat surface. 5. The surface material according to claim 4, wherein the tatami mat has the same size as a room. 6. The tatami mat is completely adhered to the back surface protective layer, the rim of the tatami mat is chamfered, and a peripheral surface of the surface material including a chamfered portion of the tatami mat is provided. The surface material according to claim 4, wherein at least the chamfered portion is covered with a peripheral protective film. 7. The tatami mat surface is entirely adhered to the back surface protective layer, a peripheral portion of the tatami mat surface is flattened by hot pressing, and of the peripheral surface of the surface material, The surface material according to claim 4, wherein at least a flattened peripheral portion of the tatami mat surface is covered with a peripheral protective film.