JPH09137585A - Tatami carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To lay and construct a tatami carpet as a flooring mat excellent in cushion performance in a feeling of a carpet by combining an artificial tatami facing mainly composed of thermoplastic resin and a thermoplastic resin cushion layer or a natural fiber cushion layer. SOLUTION: A tatami facing 1 is formed by an artificial rush using a resin composition mainly composed of thermoplastic resin. In the case of artificial rush, the width of the tatami facing can be set to 1.2m, 2m or more, and 3m or more. A thermoplastic resin cushion layer is laminated on one side of the facing 1 by an adhesive agent layer 3. When the thermoplastic resin cushion layer 2 is laid on the flooring, closely contacting property to the floor surface is good to be effective for preventing shifting. This tatami carpet is excellent in flexibility so as to be worked to free shape and size in execution of works such as flooring or the like.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a new type of tatami, that is, a tatami carpet, which can be laid and constructed like a carpet.

[0002]

[Prior Art] Tatami, which can be said to be the backbone of Japanese living space,
Traditionally it was made from natural rush. In recent years, it has been proposed to manufacture such rushes from a polypropylene resin foam or to make the polypropylene resin into a straw. However, the rug products using these rush and artificial rush were mainly composed of a single composition such as flower buds. However, the floor area of flooring is increasing in recent homes, and as a result, a tatami mat made of a combination of a tatami mat and a flooring made of insulation board or foamed styrene has been put to practical use as a tatami mat for flooring. ing.

[0003]

DISCLOSURE OF THE INVENTION The present invention is different from a classical tatami structure, that is, a new type of tatami, which has excellent cushioning properties and can be laid and constructed like a carpet, that is, as a flooring rug. The purpose is to provide tatami mat carpets.

[0004]

The present invention adopts the following means in order to achieve such an object. That is, the tatami mat of the present invention is characterized by comprising a tatami mat made of artificial grass having a thermoplastic resin as a main component and at least a cushion layer made of a thermoplastic resin or a cushion layer made of a natural fiber. Is.

[0005]

DETAILED DESCRIPTION OF THE INVENTION The present invention has been earnestly studied to provide a tatami with a new sensation that matches the flooring of recent homes, and as a result of the combination of a tatami mat and a thermoplastic resin cushion layer, the carpet is surprising. It was clarified that we can provide tatami mats that can be laid and constructed with a sense.

With the recent increase in the flooring area of a house, the present invention provides a more comfortable rug on the flooring, that is, a cushioning property, a flexible size setting suitable for the living space, and a highly flexible design. It is possible, especially when laid on a floor, a seamless carpet-like rug design is possible, and the quality is constant, and
It has all the features that enable low cost supply by industrial production. Further, it has a feature that a cut size can be freely set according to the application such as efficient production of tile carpets.

The invention will be further described with reference to the drawings.

FIG. 1 shows an example of the appearance of a tatami mat provided with a sheet-like layer formed by connecting cells of foamed resin as a cushion layer made of a thermoplastic resin on one surface of a tatami mat. The tatami mat 1 of the present invention has a limit of about 1 m width in the case of natural grass, but preferably at least 1.2 in artificial grass.
A tatami mat having a width of m, further 2 m or more, and particularly 3 m or more can be arbitrarily set. FIG. 2 shows examples of various sheet-like materials formed by connecting cells of foamed resin.

Such artificial rushes can be produced by heat treatment such as polypropylene, polyethylene, copolymers of propylene and ethylene and their mixtures, polyamide resins, polyester resins, acrylic resins, their mixtures and copolymers. The resin composition is mainly composed of a plastic resin.

A woven fabric in which the warp pitch of the tatami mat is changed and a woven fabric such as a jacquard weave such as a flower bud can be appropriately used depending on the purpose.

Cushion layer made of thermoplastic resin provided on one side of the tatami mat 1 (foamed resin sheet layer or nonwoven sheet layer)
When No. 2 is laid on a flooring, it has good adhesion to the floor surface and is particularly effective in preventing slippage. The thermoplastic resin cushion layer (foamed resin sheet layer or non-woven sheet layer) 2
Thickness C is required to be at least 0.5 mm or more in terms of the adhesion to the floor surface and the adhesion to the tatami mat. Considering the door contact when opening and closing the door of the flooring room, the total thickness of the tatami carpet is Is preferably 15 mm or less, more preferably 8 mm or less. However, this thickness is
The thickness can be adjusted freely by adjusting the thickness of the cushion layer, although it may fluctuate somewhat depending on the space between the laid floor and the door. In particular, when punching into a tile carpet or when processing into a carpet size, FIG.
The rug form composed of the tatami mat 1 and the cushion layer 2 shown in (1) is suitable because the weft does not come off and the end surface treatment is unnecessary.

The thermoplastic resin cushion layer 2 is composed of at least one resin selected from olefin resins, styrene resins, urethane resins, ester resins, amide resins and vinyl chloride resins. Sheet-like materials can be used. As such a sheet-like material, a sheet-like material comprising the thermoplastic resin, particularly the above-mentioned resin-based elastomer is preferably used. Further, a sheet-shaped material made of the thermoplastic resin foam, a sheet-shaped material made of the foamed material and a non-woven fabric, a sheet-shaped material made of only the non-woven fabric, and the like. It is possible to use a combination of the above.

Among such thermoplastic resin cushion layers, various sheet-like materials made of ethylene copolymer are preferably used in terms of cushioning property and flexibility. As such an ethylene copolymer, for example, at least one selected from an ethylene-vinyl acetate copolymer and an ethylene-acrylate copolymer can be used. Specific examples thereof include copolymers of ethylene-vinyl acetate, ethylene-methyl methacrylate, ethylene-ethyl acrylate, ethylene-methyl acrylate, ethylene-acrylate, and the like, and among these, those having elastomer properties are preferably used. To be done.

Among these various sheet-like materials, a sheet-like material composed of two kinds of materials, a non-woven fabric and a foam resin, is preferably used. For example, the foam resin layer is made of a material selected from a sheet-shaped material and a linear material. For example, as the foam resin sheet material, a perforated sheet, preferably one formed by laying out the circular and polygonal foam resin, can be used. Also,
As the foam resin linear material, a material having a cushion layer arranged in at least one direction, preferably a sheet arranged in a lattice or net shape is used. As the foamed resin linear body, a thick and thin continuous linear body, a continuous linear body in which the thick and thin shape has a granular and / or beaded shape, and the like can be used. As another example, a sheet-like material in which a foamed resin is covered around each woven yarn or mesh yarn of the open base fabric can be preferably used. It is preferable that the gap A between the open base cloths has an interval of at least 0.5 mm or more. A sheet obtained by dipping the open base cloth into a liquid thermoplastic resin kneaded with a foaming agent and then foaming by heat treatment or the like to form a foam resin sheet can be used.
By using such a foamed resin sheet, it is possible to structurally increase the anchoring effect between the floor surface and the adhesive when bonding to the floor surface. In addition, as a material that can be applied to the opening base fabric, a thermoplastic resin fiber, a natural fiber, or the like described below can be appropriately used. It is important that this base cloth has a perforated structure, and it does not matter what processing method such as weaving, knitting or injection molding is concerned. By setting the expansion ratio of the foam resin to at least 1.5 times or more, irregularities on the floor surface will not be picked up, and the rug will have excellent smoothness when laying and will not slip. Further, the perforated structure of the foamed resin sheet greatly contributes to weight reduction.

Next, as long as the non-woven fabric is entangled with fibers, various types of non-woven fabrics such as short fibers, melt blown, spun bond, etc., for example, those made of fiber waste can be applied. The softness and low apparent specific gravity of the non-woven fabric and the low anisotropy when made into a sheet constitute a comfortable carpet that does not damage the flooring surface and provides adequate cushioning when walking on a rug. This is an extremely important point.

The basis weight of the nonwoven fabric is preferably 1000
g / m ² or less, more preferably 300 to 800 g / m
^When those in the range of ² are made into carpets, they are lightweight and excellent in handling such as laying work.

The thermoplastic resin cushion layer may be made of, for example, polyethylene, polypropylene, a copolymer of propylene and ethylene and a mixture thereof, polyamide,
Polyester, polyacrylonitrile, copolymers and mixtures thereof, polyurethane, polystyrene, polyvinyl chloride and mixtures thereof can be used.
However, as the material forming the non-woven fabric, a mixture with a natural fiber can be used in addition to the above thermoplastic resin material. Examples of such natural fibers include wool and
Cotton, hemp, rayon, pulp and fiber wastes thereof and mixtures thereof can be used. Of course, the effect of the present invention can be achieved even in combination with a cushion layer composed only of such natural fibers.

For laminating the tatami mat and the cushion layer, an appropriate method such as sewing, fusing or an adhesive is used. For example, as the adhesive, a rubber-based, epoxy-based, urethane-based, or silicon-based adhesive can be appropriately selected according to its material. Further, it is also possible to perform heat fusion using a low melting point polymer powder or the like, or directly heat fusion by heating the tatami surface and the nonwoven fabric surface.

The tatami mat carpet thus obtained has a difference in softness from ordinary tatami mats, that is,
The bending resistance in the longitudinal direction of the tatami mat is preferably 1000 to 6000 mg, more preferably 2000 to 6000 mg, as measured by JIS L-1096 A method (Gurley method) as the bending resistance from the front side to the back side of the tatami mat. It has the flexibility of being in the range of 5000 mg. Further, the bending resistance in the longitudinal direction of the tatami carpet is opposite to the above-mentioned direction, and is preferably 1 when measured by the Gurley method as the bending resistance from the back side of the tatami to the front side of the tatami mat.
0000 to 17,000 mg, more preferably 11,000
It is characterized by being in the range of ˜16000 mg. That is, the tatami carpet is measured by the measuring direction, that is,
The bending resistance differs between the front and back surfaces, and the bending resistance from the tatami mat side to the back side is smaller than that from the tatami mat side to the tatami mat side, preferably 2 to 6 times, Preferably 3
It is characterized by a difference of ~ 4.5 times.

Since the tatami mat carpet has such flexibility, it has a characteristic that it is easy to wind on a roll because the bending resistance from the tatami side to the back side is particularly small.
It has the feature that it can be transported to the construction site in large quantities and easily.

[0021]

【Example】

Example 1 0.3 parts of azodicarbonamide was mixed with 60 parts of a polypropylene chip containing 100 parts of polypropylene and 60% by weight of calcium carbonate, and the mixture was extruded at 210 ° C.
And the molten polymer was discharged from the die at a speed of 4 m / min.

The discharged molten polymer is foamed and introduced into a cooling water tank having a water surface 30 cm immediately below the base. After cooling the polymer temperature to the water temperature, the obtained unstretched hollow foam is guided to a heated stretching zone heated to 180 ° C. Here, it is heated and stretched 7 times.

The stretched linear hollow foam is drawn into the can and guided to the weaving process. The obtained linear hollow foam had an outer diameter of 1.25 mm and a hollow portion having a diameter of 0.5 mm.
And had a cross-sectional shape having eight large irregularities in the axial direction, and the irregularities had many streaky irregularities extending in the axial direction. The artificial rush thus obtained was very similar in appearance and texture to natural rush.

Next, using a weaving machine in which the weft insertion device of the artificial mat grass loom was changed to a single rapier mechanism, the artificial grass prepared by pulling down the can was set and manufactured using manila hemp for the warp. Weaved on loom. As a result, the weft is 1200mm
The weave was woven with a mat weight of 1.8 kg / tatami.

Next, a perforated cloth made of polyester and having a pitch of 5 mm was dipped in a vinyl chloride sol mixed with a foaming agent and then cured at a temperature of 170 ° C. to prepare a foamed vinyl chloride sheet having a perforated foam. The expansion ratio of foamed PVC of this sheet was 5 times, the sheet thickness was 1 mm, and the pitch of the gaps in the sheet was 5 mm.

This woven PVC sheet was woven 1200
A tatami mat was prepared by adhering it to one side of a tatami mat having a width of mm with a rubber-based solvent type adhesive.

The bending resistance in the longitudinal direction of this tatami carpet is
As the bending resistance from the tatami mat side to the back surface is 3635 mg when measured by JIS L-1096 A method (Gurley method), the bending resistance on the opposite side, that is, from the tatami mat side to the tatami mat side is 1328 mg.
Met.

When this tatami mat carpet was laid on a flooring, it was a rug which was excellent in softness, light weight and extremely less slippery.

Example 2 The rug made in Example 1 was punched with a 50 cm square Thomson blade to make a tile carpet-like rug. Became a rug.

Example 3 In Example 1, as a cushion layer made of a thermoplastic resin, a 2 mm-thick sheet made of an ethylene-vinyl acetate copolymer elastomer was bonded to one side of a tatami mat with a rubber-based solvent type adhesive. I made a tatami mat carpet.

The bending resistance in the longitudinal direction of this tatami carpet is
The bending resistance from the tatami mat side to the back side is 3000 mg as measured by JIS L-1096 A method (Gurley method), and the bending resistance on the opposite side, that is, from the tatami mat back side to the tatami mat side is 1100 mg.
Met.

When this tatami mat carpet was laid on a flooring, it was a rug which was excellent in softness, light weight and completely non-slip.

Example 4 In Example 2, as a cushion layer made of a thermoplastic resin, a sheet of ethylene-vinyl acetate copolymer elastomer having a thickness of 2 mm was used, and a polyester sheet having a thickness of 5 mm and a basis weight of 500 g / m ² was formed on one side of a tatami mat. Tatami carpets were prepared by bonding with a rubber-based solvent-type adhesive through a needle-punched nonwoven fabric of short fibers.

The bending resistance in the longitudinal direction of this tatami carpet is
The bending resistance from the tatami mat side to the back side is 3200 mg as measured by JIS L-1096 A method (Gurley method), and the bending resistance on the opposite side, that is, from the tatami mat back side to the tatami mat side is 1210 mg.
Met.

When this tatami mat carpet was laid on the flooring, it was a rug which was excellent in softness, light weight and completely non-slip, and moreover superior in hygroscopicity to that of Example 3. .

EXAMPLE 5 100 parts of polypropylene and 60 parts of polypropylene chips containing 60% by weight of calcium carbonate were mixed with 0.3 part of azodicarbonamide, and the mixture was heated at 210 ° C. in an extruder.
And the molten polymer was discharged from the die at a speed of 4 m / min.

The molten polymer discharged is foamed and introduced into a cooling water tank having a water surface 30 cm directly below the mouthpiece. After cooling the polymer temperature to the water temperature, the obtained unstretched hollow foam is guided to a heated stretching zone heated to 180 ° C. Here, it is heated and stretched 7 times.

The stretched linear hollow foam is drawn into the can and guided to the weaving process. The obtained linear hollow foam had an outer diameter of 1.25 mm and a hollow portion having a diameter of 0.5 mm.
And had a cross-sectional shape having eight large irregularities in the axial direction, and the irregularities had many streaky irregularities extending in the axial direction. The artificial rush thus obtained was very similar in appearance and texture to natural rush.

[0039] Next, using a weaving machine in which the weft inserting device of the artificial grass weeding machine is changed to a single rapier mechanism, the artificial grass that has been drawn down is set in the can, and the hemp is made using Manila hemp. I laid it on the loom. As a result, the weft is 1200mm
The weave was woven with a mat weight of 1.8 kg / tatami.

Further, a needle-punched nonwoven fabric of polyester short fibers having a weight of 5 mm and a basis weight of 500 g / m ² was bonded to one side of a woven 1200 mm wide tatami mat with a rubber-based solvent type adhesive to form a tatami carpet. Created.

The bending resistance in the longitudinal direction of this tatami carpet is
The bending resistance from the tatami mat side to the back side is 4900 mg when measured by JIS L-1096 A method (Gurley method), and the bending resistance on the opposite side, that is, from the tatami mat back side to the tatami mat side is 15808.
mg.

When this tatami mat carpet was laid on a flooring, it was a rug which was excellent in softness, light weight and extremely less slippery.

Example 6 The rug made in Example 1 was punched out with a 50 cm square Thomson blade to make a tile carpet-like rug. Became a rug.

[0044]

According to the present invention, in the construction of flooring or the like, it is possible to carry out the construction with a free shape and size by fitting it into the laying area, and to carry it in large quantities easily.

[Brief description of the drawings]

FIG. 1 is an example of a schematic sectional view of a tatami mat of the present invention.

FIG. 2 is a schematic view of various foam sheets adhered to the tatami mat of the tatami mat of the present invention.

[Explanation of symbols]

 1: Artificial grass made of tatami mats 2: Thermoplastic resin cushion layer 3: Adhesive layer

Claims (25)

[Claims] 1. A tatami mat carpet comprising a tatami mat made of artificial grass having a thermoplastic resin as a main component and at least a cushion layer made of a thermoplastic resin. 2. The tatami mat according to claim 1, wherein the total thickness of the tatami mat is 15 mm or less. 3. The tatami mat according to claim 1, wherein the total thickness of the tatami mat is 8 mm or less. 4. The bending resistance in the longitudinal direction of the tatami carpet is in the range of 1000 to 6000 mg as the bending resistance from the front side to the back side of the tatami mat carpet, measured by Method A (Gurley method) of JIS L-1096. The tatami mat carpet according to claim 1. 5. The bending resistance in the longitudinal direction of the tatami carpet is JIS L-1096 A as the bending resistance from the back side of the tatami to the front side of the tatami mat.
Method 10000 when measured by the Gurley method
A tatami mat carpet according to claim 1 in the range of mg. 6. The thermoplastic resin cushion layer is composed of at least one resin selected from olefin resins, styrene resins, urethane resins, ester resins, amide resins and vinyl chloride resins. The tatami mat carpet according to claim 1, wherein 7. The tatami mat carpet according to claim 6, wherein the thermoplastic resin cushion layer is made of an elastomer. 8. The tatami carpet according to claim 6, wherein the thermoplastic resin cushion layer is an ethylene copolymer. 9. The tatami carpet according to claim 8, wherein the ethylene copolymer is at least one selected from an ethylene-vinyl acetate copolymer and an ethylene-acrylate copolymer. 10. A tatami mat according to claim 1, wherein the thermoplastic resin cushion layer is made of a material selected from a foam resin and a non-woven fabric. 11. The tatami carpet according to claim 1, wherein the thermoplastic resin cushion layer is composed of a laminate of both materials of a foam resin and a non-woven fabric. 12. The tatami carpet according to claim 10 or 11, wherein the foam resin has a foaming ratio of 1.5 times or more. 13. The tatami mat carpet according to claim 1, wherein the foam resin is made of a material selected from a sheet-like material and a linear material. 14. The tatami mat according to claim 13, wherein the foam resin sheet material is a perforated sheet. 15. The tatami mat according to claim 14, wherein the perforated sheet is constructed by spreading the circular and polygonal foam resins. 16. The foam resin linear members are arranged in at least one direction to form a cushion layer.
The tatami mat carpet described in 3. 17. The tatami carpet according to claim 16, wherein the foam resin linear body is a sheet arranged in a lattice or a net. 18. The tatami mat carpet according to claim 13, 16 or 17, wherein the foam resin linear body is a thick and thin continuous linear body. 19. The tatami mat carpet according to claim 18, wherein the thick and thin shape is a continuous linear body having a granular and / or beaded shape. 20. The tatami mat carpet according to claim 10 or 11, wherein the non-woven fabric is a sheet having a basis weight of 1000 g / m ² or less. 21. The tatami mat carpet according to claim 20, wherein the non-woven fabric is composed of fiber scraps. 22. A tatami mat carpet comprising a tatami mat made of artificial grass having a thermoplastic resin as a main component, and a cushion layer made of natural fibers. 23. The tatami carpet according to claim 1 or 22, wherein the artificial grass is made of an olefin resin. 24. The tatami carpet according to claim 1 or 22, wherein the artificial grass has a length of at least 1.2 m. 25. The artificial grass-made tatami mat containing the thermoplastic resin as a main component and the thermoplastic resin cushion layer are joined by an adhesive or fusion.
Tatami carpet as described.