JPH07158237A - Rush mat using artificial plastic rush - Google Patents

Abstract

PURPOSE:To prevent the outer surface of a rush mat from floating up due to thermal expansion in the summer season, by cutting the rush mat surface in the longitudinal direction of rush by a length which is greater than the width of a rush mat base by a predetermined length, but less than the width of the edge, and by bonding the cut rush mat surface to the base. CONSTITUTION:A rush mat surface formed of plastic rush-like strands is cut so as to have a length which is greater than the width of the mat base (a) by 0.5mm, but less than the width of an edge (d), and are fixed to the base (b). Further, the rush mat surface (b) is formed of a tape-like material longitudinally drawn and led through heating members form forming thin pares so as to be randomly converged, and a fused film is formed on the outer surface thereof. Further, gaps for allowing the rush itself to expand are present, and accordingly, it is possible to prevent the mat surface from swelling due to a temperature rise.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tatami mat using a plastic igsa.

[0002]

2. Description of the Related Art Traditionally, tatami mats have been manufactured by sewing a tatami mat woven from natural rush on a floor made of straw or the like. This is a highly skilled task and not easy. It has been mechanized recently, but it is not cheap.

Further, the conventional tatami mats using natural rush or straw are a medium for breeding mites and other bacteria, and cause asthma and skin diseases.

Therefore, the production of plastic tatami mats and floors has begun to appear. Of course, you don't have to worry about mites and bacteria. Further, since it is a factory-produced product, its price and supply are stable, it hardly fades or deteriorates, and it has a very long life.

[0005]

However, the plastic tatami mat has the following major drawbacks. That is, since it is made of plastic as compared with natural rush, the imitation rush itself has a very large coefficient of thermal expansion, and in summer, it may extend by 0.5 to 10 mm per 1 m compared with winter. Of course, this extension itself also depends on the type of plastic and the type and amount of filler.

[0006] When the tatami mat is extended in this manner, the tatami mat cannot be pushed out of the tatami mat because the tatami mat is fixed by the edges at both ends in the lengthwise direction of the rush. Therefore, it will swell in the middle part of the tatami mat. In severe cases, the height is 5-10 mm
It may swell.

When such a part appears, it is of a detrimental effect on its appearance, and it causes a tripping or catching on other things. Therefore, the part is frayed or cut.

[0008]

In view of the above-mentioned circumstances, the present inventor has completed the tatami mat of the present invention as a result of earnest research, and is characterized by using a tatami mat of a plastic igusa. A tatami mat, in the length direction of the rush,
The point is that the tatami mat is cut to a length shorter than the width of the tatami mat by 0.5 mm or more and less than the width of the edge and fixed to the tatami mat.

[0009] The plastic rush is a plastic rug that is formed into a string-like body such as rush, and it is a mere cylindrical or rod-shaped imitation rug that is manufactured through a more complicated manufacturing process. Good. In short, it just needs to be made of plastic.

The tatami mat is woven from the above-mentioned rush as weft, and not only the appearance like a tatami mat woven from normal natural igusa, but also a so-called PP flower basket may be used. What is necessary is just to woven the above-mentioned plastic rush like natural rush into a sheet.
Further, it may be a woven material which cannot be obtained by natural rush.

The tatami floor is usually a straw portion to which a tatami mat is sewn, but a plastic floor or a thinner plate-like member may be used here.

Conventionally, the width of this floor is the same as the width of the tatami mat. In other words, the tatami craftsman either cuts the tatami mat to the same width and sew it, or cuts the tatami mat to some extent and cuts the tatami mat to some extent, and finally cuts it. In the present invention, it is a gist at this time to cut the tatami mat by 0.5 mm or more shorter than the floor. Of course, the width cannot exceed the width of the edge because it cannot extend beyond the edge. And this short tatami mat is sewn on the floor. That is, both ends of the rush are not in contact with the vertical part of the tatami edge. Of course, only one may be in contact.

Even with the sewing method as described above, the deviation (lacking portion) from the floor is actually hidden from the edge and cannot be seen from above. However, if it is separated from the end of the floor more than necessary, that is, if it is separated by 15 to 20 mm on one side,
When I step on it with my feet, I find that there is no rush on that part, which is uncomfortable. From this point of view, in the experiment of the inventor, the length to be shortened was preferably 2 mm or less. actually,
1 to 5 mm was optimal from the viewpoint of safety of expansion and feeling of foot.

Furthermore, when the length is shortened to the extent that it can be felt by the feet,
There is a method of fixing an auxiliary material to that portion. this is,
It doesn't have to be very special, like a piece of the same rush. It is sufficient if the thickness is the same. If this is fixed side by side with the edge of the tatami floor, the edge of the edge can be sharpened. Of course, in consideration of expansion of the rush, it is natural to provide a gap between the auxiliary material and the rush.

The tatami mats and edges are not only fixed by sewing,
It may be fixed by adhesion or the like. Especially because the igusa itself is made of plastic, if the floor is made of plastic,
Easy to fuse and bond.

The present invention is also suitable for a tatami table using an imitation rush filed by the applicant. The imitation rush will be briefly described below. This tatami mat is formed by passing a tape-shaped body made of a thermoplastic resin stretched in the longitudinal direction through a heating member forming a narrow void to irregularly converge and form a fusion coating on the surface. It is made of woven plastic rush.

The term "thermoplastic resin" as used herein refers to a resin whose viscosity is reduced by heating so that it can be molded. Polyolefins such as polypropylene are representative, but other resins may be used. Also, a mixture of a plurality of resins may be used. The resin may be mixed with weathering agents, pigments, matting agents and the like, which are usually mixed.

Stretching may be carried out by an ordinary method, and the magnification is about 2 to 7 times.

The tape-shaped body may be manufactured by any method, but it is preferable that a tubular shape obtained by inflation processing is folded as it is to form two pieces, which are cut into an appropriate width and used. . It is preferable that not only the upper and lower two tapes of this appropriate width but also a plurality of sets are combined and passed through the heating section to form one imitation igza. The thickness of the tape is
About 0.005 to 0.05 mm is preferable. Further, the width to be cut is about 20 to 50 mm (width after stretching), but neither is limited to this.

Although not essential, this tape-shaped body is preferably provided with a large number of uneven wrinkles. The uneven wrinkles are wrinkles such as waves existing in parallel to the longitudinal direction of the tape-shaped body, and do not need to be regular. With such wrinkles, the imitation rush can absorb water because it has a so-called strength and can absorb water and the like therebetween.

The narrow gap means that it is narrower than a state in which the tape-like body is simply converged, and is usually about 1.0 to 1.5 mm. This value is determined by the diameter of the finished imitation rush, and is about 1 mm when manufacturing a product close to a natural rush.

The heating member may be such that the narrow space itself is electrically heated like a heater, or the heating member may exist around the narrow space.

The irregular convergence means that the tape-shaped body is not folded or rolled up regularly, but is wrinkled at random to form a tubular body having the tape-shaped body therein. The reason why the fusion film is formed on the surface is to give a certain shape-retaining property, and the surface is not completely uniform. The plastic rush is a tubular or rod-shaped product manufactured in this manner. These productions may be performed continuously in one step, or may be divided into several steps. When the processing speed is different, the division method is preferable. It goes without saying that steps and treatments other than the above essential requirements may be performed.

[0024]

The present invention will be described in more detail with reference to the embodiments shown in the drawings. FIG. 1 is a schematic perspective view showing a tatami mat b bonded to a floor a. This figure also shows that the width of the tatami mat is smaller than that of the floor. In this example, 5m at both ends
It is shortened by m. The expanded plastic rush advances into the blank portion c that appears after shortening. The plastic igusa of this example was produced simply by extrusion. However, even if the igusa is changed to the imitation igusa described above, the drawings are almost the same.

FIG. 2 is a sectional view of the structure of FIG. 1 with an edge d. A margin c is visible between the edge d and the plastic rush.

FIG. 3 is a partial sectional view of an example using the auxiliary material e. An auxiliary material e is fixed on the blank portion c, and there is a gap between the auxiliary material e and the tatami mat b. Edge d is the margin c
These parts are hidden from view because they cover all. Further, since the end portion of the auxiliary material e and the end portion of the floor a are aligned, the folded back end portion f of the edge d can be sharply and neatly finished.

Next, an example of a method of manufacturing the above imitation rush is shown. 3 and 4 show an example of an apparatus for implementing the method. In this example, two steps are performed separately. FIG. 3 shows the steps up to the irregular convergent formation, and FIG. 4 shows the subsequent steps.

In the tape-shaped body manufacturing process, the thermoplastic resin as a raw material is introduced into the feeder 2 of the inflation device 1, heated and extruded from the mold 3, and then bulged in a hollow state through the cooling device 4. In this example, the diameter in the hollow state is about 400 to 800 mm and the thickness is about 0.03 to 0.07 mm. After passing this between the rolls 5 to make a double film, it is cut by a cutter 6 in the longitudinal direction to have a slit width of about 30 to 80 mm. Then, it is stretched 2 to 7 times. Stretching may be performed by heating with a heating device 7 to around 100 to 150 ° C. and pulling with a roll 8. In order to anneal this, the heating device 9 is passed again. Then, it is wound around the winding roll 10.

In the convergent molding step, the tape-shaped body (cut) is introduced from the winding roll 10 into the space of the heating and converging device 11. The diameter of this void is about 1.0 mm. The heating temperature is about 300 to 400 ° C, and the passing speed is
40 to 100 m / min is sufficient. After passing, the film expands more than the diameter of the voids, so the diameter becomes about 1.5 mm.

Next, the imitation igusa delivered from the void is
Pass the cooling process. In this example, it is just blast cooling. That is, the blower 12 only blows the wind. When the cooling is completed, it is introduced into the heat treatment process. In this example,
Pass through hot water bath 13. Here, the outer shape of the imitation igsa which has been deformed or flattened during heat contraction is expanded and shaped by heat so that its cross section is approximately a perfect circle. Next, it passes through the cooling step 14 again, and finally is cut into a predetermined size (usually 1 to 2 m) by a cutter 15.
This completes the imitation rush 16.

[0031]

The present invention described in detail above has the following great effects. Since the plastic igsa itself has a margin (space) for expanding in the length direction, it does not expand upward due to temperature rise. Therefore, the aesthetic appearance is not impaired, and the swollen portion is not worn out quickly. The tatami mat of the present invention is fixed to the floor with a margin as compared with the conventional tatami mat, and the manufacturing method thereof is the same as that of the conventional mat and is very simple.

[Brief description of drawings]

FIG. 1 is a perspective view showing the process of manufacturing an example of a tatami mat of the present invention.

FIG. 2 is a cross-sectional view showing an example of the tatami mat of the present invention.

FIG. 3 is a partial cross-sectional view showing another example of the tatami mat of the present invention.

FIG. 4 is a schematic flow sheet showing an example of an apparatus for producing a plastic rush used in the tatami of the present invention.

FIG. 5 is a schematic flow sheet showing an example of an apparatus for producing a plastic rush used for the tatami of the present invention.

[Explanation of reference signs] a Floor b Tatami table c Margin part d Edge e Auxiliary material f Folding end part 1 Inflation device 2 Feeder 3 Mold 4 Cooling device 5 Roll 6 Cutter 7 Heating device 8 Roll 9 Heating device 10 Winding roll 11 Heating Converging device 12 Blower 13 Hot water bath 14 Cooling process 15 Cutter 16 Plastic rush

Claims (2)

[Claims] 1. A tatami mat using a tatami mat of a plastic igsa, wherein the tatami mat is 0.
Cut the tatami mat shorter by 5 mm or more and less than the width of the edge,
A tatami mat using a plastic rush that is fixed to the tatami mat floor. 2. The tatami mat is irregularly convergently formed by passing a tape-shaped body made of a thermoplastic resin stretched in a longitudinal direction through a heating member forming a narrow void, and melted on the surface. The tatami using a plastic rush according to claim 1, which is a woven plastic igsa having a coating film formed thereon.