JP2002209680A - Cushion member and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fire retardant cushion member excellent in cushion performance, and eliminating a bottom touching feeling. SOLUTION: A plurality of molded blocks 2 composed of a laminated body of a carbon fiber web are joined randomly in the laminating direction of the carbon fiber web with a binder resin to manufacture the cushion member. The cushion member may be composed of a central core body 3 composed of a plurality of molded blocks and a fiber web 4 covering this central core body. The cushion member is arranged in a part of seat surface where at least a load acts so that a plurality of molded blocks are positioned to manufacture a chair.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion member used for a chair or a bed of a vehicle such as an aircraft, a railway car, an automobile, and the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, various members have been used as cushion members for chairs, futons, beds and the like. As a cushion member of a chair, for example, a polyurethane foam, a member obtained by combining a plurality of urethane foams having different densities, a polyester foam, and the like are widely used. In addition, cotton, feathers, and the like are commonly used for futons, and members made of a combination of futon cotton and chemical fibers (for example, polyester fibers, polyurethane fibers, and the like) and mechanical springs are commonly used for beds.

[0003] However, in these cushion members, when a load is repeatedly applied over a long period of time, settling occurs, and the cushioning properties deteriorate at a relatively early stage. Most of these cushion members are flammable, and generate toxic gas when burned.

On the other hand, a cushion member made of carbon fiber is not only flame-retardant, but also suffers only a few percent set from repeated compression of one million times, and has excellent long-term stability. For example, Japanese Patent Application Laid-Open No. 9-294649 discloses a cushion member for a chair constituted by a three-dimensional network structure formed of carbon fibers and a binder resin. However, if the cushion member made of carbon fiber is not dense, the feeling of bottoming (feeling of the object under the cushion) remains, and the balance with the cushioning property is poor.

Further, Japanese Patent Application Laid-Open No. 2000-253958 discloses a method in which a carbon fiber body impregnated with a binder resin is divided into predetermined sizes to produce cushion pieces, and these cushion pieces are laid and cured. A method of forming a cushion member is disclosed. In this method, the cushion member can be manufactured by a simple method, but the obtained cushion member has a poor balance between the cushioning property and the feeling of bottoming, similarly to the cushion member.

[0006]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a flame-retardant cushion member which is excellent in cushioning property and in which the feeling of bottoming is eliminated, and a chair including the cushion member.

[0007] Another object of the present invention is to provide a cushion member which does not drip over a long period of time and a chair including the cushion member.

It is still another object of the present invention to provide a method for easily producing a flame-retardant cushion member which is excellent in cushioning property and has a feeling of bottoming out.

[0009]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to solve the above-mentioned problems, and as a result, have formed a plurality of molding blocks each composed of a laminate of carbon fiber webs. By bonding with the stacking direction oriented in a random direction, the cushioning properties can be improved even when stress acts on the seating surface from various angles, and the flame-retardant cushion with the feeling of bottoming is eliminated. It has been found that a member can be obtained.

That is, the cushion member of the present invention is a cushion member composed of a plurality of molding blocks, wherein the molding block is composed of a laminate of carbon fiber webs in which carbon fibers are joined with a binder resin. A plurality of molding blocks are arranged with the laminating direction of the carbon fiber web oriented in a random direction. The molded block may be compressed in the laminating direction. Further, the molded block is a tetrahedral block, particularly having an average diameter of 3 to 10.
It may be a cubic block of about 0 mm. The cushion member may be composed of a core formed of a plurality of molding blocks, and a fiber (particularly carbon fiber) web covering the core. The ratio of the binder resin in the molding block is about 1 to 50 parts by weight based on 100 parts by weight of the carbon fiber. Even if the cushion member has a relatively low density, it has excellent cushioning properties,
Sag does not occur, and the density may be, for example, about 10 to 50 kg / m ³ .

[0011] The present invention also includes a chair in which the cushion member is disposed at least on a portion of a seat surface on which a load acts.

[0012] The present invention also includes a step of manufacturing a core by joining a plurality of molding blocks each formed of a laminate of carbon fiber webs in which carbon fibers are joined by a binder resin; A method of manufacturing a cushion member including a step of covering with a fiber web and a step of curing a binder resin, wherein the core is formed by orienting a lamination direction of the carbon fiber web of the molding block in a random direction. The manufacturing method of the cushion member to be used is also included. In the above-mentioned manufacturing method, a core resin may be formed by adhering a binder resin to a molding block in an air stream and orienting the resin at random.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings as necessary.

[Cushion Member] FIG. 1 is a schematic perspective view showing an example of the cushion member of the present invention, FIG. 2 is a schematic perspective view showing an example of a molding block constituting the cushion member, and FIG. FIG. 4 is a schematic perspective view showing another example of the cushion member of FIG.
FIG. 4 is a schematic cross-sectional view taken along a line A.

As shown in FIG. 1, the cushion member of the present invention comprises a plurality of molding blocks 2. The molding block 2 is a cubic block, and the molding blocks are joined to each other with a binder resin.

(Molding Block) As shown in FIG. 2, each molding block 2 is a laminate of a carbon fiber web (carbon fiber web layer) 2a in which carbon fibers are joined with a binder resin and the fibers are randomly entangled. It is configured.
In this laminate, the carbon fiber web (carbon fiber web layer) is laminated (orientated) in the thickness direction (vertical direction), and molded (compression molded) into a cubic block. Since the molding block (laminate) 2 is compressed and molded in the laminating direction (thickness direction) of the carbon fiber web 2a, it is more perpendicular to the laminating direction than the degree of compressive deformation (compression strain) in the laminating direction. (In the drawing, the horizontal direction) is smaller. That is, the carbon fibers are in a denser state on the surface (the side surface in FIG. 2) in the direction orthogonal to the lamination direction than on the surface in the lamination direction (the upper surface in FIG. 2). Then, the carbon fiber webs are entangled irregularly on the lamination surface, and the carbon fiber webs 2a are arranged in a substantially layered manner in the laminating direction.

The carbon fiber web only needs to be in a state in which the fibers are intertwined with each other irregularly, and this state includes crimping, curving, and the like. Further, the sheet-like web may be formed by carding means such as a card machine.

The shape of the molding block is not limited to a cube, but may be a tetragon such as a rectangular parallelepiped, a polygonal cube, a column, or the like. Among these shapes, a tetrahedral shape, particularly a cubic shape, is preferable from the viewpoint of simplicity and strength.

The average diameter of the molded block is, for example, 3 to 1
00 mm, preferably 5 to 50 mm (for example, 5 to 40
mm), more preferably 10 to 30 mm (especially 10 to 30 mm).
20 mm). Note that the average diameter is, for example, in the case of a tetrahedral block, the sum of the vertical, horizontal, and height average diameters.

Examples of the carbon fiber include pitch-based carbon fiber, polyacrylonitrile (PAN) -based carbon fiber, phenol resin-based carbon fiber, regenerated cellulose-based carbon fiber (eg, rayon-based carbon fiber, polynosic-based carbon fiber, etc.), cellulose Carbon fiber and polyvinyl alcohol-based carbon fiber. These carbon fibers can be used alone or in combination of two or more.

The average fiber diameter of the carbon fibers is, for example, 5 to 3
0 μm, preferably about 6 to 25 μm, and carbon fibers having an average fiber diameter of about 10 to 20 μm are often used.
Usually, short fibers (non-continuous fibers) are used as the carbon fibers. The fiber length of the short fiber is, for example, 0.1 to 200 m.
m, preferably 1 to 100 mm, more preferably 3 to
It is about 50 mm.

As the binder resin, an adhesive such as a thermoplastic resin (for example, a vinyl resin, an acrylic resin, a styrene resin, a polyester resin, a thermoplastic polyurethane resin, a polyamide resin, etc.), a thermosetting resin, etc. Can be used. Among these binder resins, a thermosetting resin adhesive can be preferably used.

Examples of the thermosetting resin include polyurethane resins, amino resins, phenol resins, epoxy resins, unsaturated polyester resins, thermosetting acrylic resins, and polyimide resins. Among these thermosetting resins, polyurethane-based resins, epoxy-based resins and the like, particularly polyurethane-based resins, are preferred. As a polyurethane resin, a solution type, an emulsion type, a two-part type,
Moisture (steam) -curable polyurethane resin or the like can be used.

These binder resins can be used alone or in combination of two or more. The ratio of the binder resin is 1 to 50 parts by weight (for example, 2 to 50 parts by weight), preferably 2 to 30 parts by weight (for example, 5 to 30 parts by weight), and more preferably 5 to 100 parts by weight of carbon fiber. ~ 2
It is about 0 parts by weight.

The carbon fiber web constituting the molded block includes organic fibers (for example, polyolefin fibers, polyester fibers, nylon fibers, polyvinyl alcohol fibers, vinylon fibers, polyvinyl chloride fibers, acrylic fibers, rayon). Fibers, acetate fibers, synthetic fibers such as polyurethane fibers, natural fibers, etc.), and inorganic fibers (eg, glass fibers, aluminosilicate fibers, aluminum oxide fibers, silicon carbide fibers, boron fibers, metal fibers, etc.). Good. In order to form a three-dimensional entangled structure, a heat-adhesive fiber that exhibits adhesiveness to carbon fibers by heating may be used. Of these fibers, flame-retardant organic fibers and inorganic fibers are preferred. These fibers can be used alone or in combination of two or more.

(Cushion Member) In the cushion member of the present invention, as shown in FIG. 1, the laminating directions of the carbon fiber webs in the plurality of molding blocks 2 constituting the cushion member 1 are oriented in random directions, respectively. And adjacent molding blocks are joined to each other. In the present invention,
Even if stress (pressure) acts from various directions on the seating surface by joining and joining randomly anisotropic molded blocks that are biased in the degree of compressive deformation depending on the direction,
A cushion member having excellent cushioning properties and having a feeling of bottoming is eliminated. Furthermore, since the molding blocks are joined in a random combination, an appropriate gap is formed inside the cushion member, and a member having a high cushion back can be obtained even if the weight is small.

The binder resin that joins a plurality of molding blocks usually only needs to adhere to at least the surface of the molding blocks. From the viewpoint of simplicity of production, it is preferable that the binder resin is substantially uniformly attached to the surface of the molding block. As the kind of the binder resin, the same resin as the binder resin used for bonding the carbon fiber web can be used. The ratio of the binder resin is 0.1 to 50 parts by weight, preferably 1 to 40 parts by weight, and more preferably about 5 to 30 parts by weight based on 100 parts by weight of the molding block.

The shape of the cushion member is not particularly limited and can be selected according to the purpose of use, but is usually a plate shape such as a flat plate shape or a disk shape. The number of the molding blocks constituting the cushion member is not particularly limited, and the size may be a desired size by combining the molding blocks according to the application. In the case of a cushion member for a chair, for example, 10 to 20,000 pieces, preferably 100 to 5000 pieces
, More preferably 300 to 3000 (particularly 500
〜1500). The thickness of the cushion member is not particularly limited, either, and the desired thickness may be obtained by combining the molding blocks having the average diameter. In the case of a cushion member for a chair, 5 to 150 mm (for example, 5 to 100 mm), preferably 5 to 50 mm, more preferably 10 to 40 m
m.

FIGS. 3 and 4 show the cushion member of the present invention.
As shown in (1), a core body 3 composed of a plurality of molding blocks 2 and a fiber web 4 covering the core body 3 may be used. As in the cushion member shown in FIG. 1, a plurality of molded blocks 2 are joined to the core 3 in a random direction. The fiber web 4 is formed of a carbon fiber web, is disposed so as to cover the entire plurality of molding blocks 2, and is formed into a predetermined shape. The chair cushion member 5 has a structure in which the core body 3 is reinforced by the fiber web 4, and a plurality of molding blocks 2 forming the core body 3.
Is firmly fixed, so that the cushioning property and strength are excellent, and the cushioning property and strength are maintained for a long time without sagging. Further, a plurality of molding blocks 2
By covering the uneven surface of the core body 3 formed by the above with the fiber web 4, the sitting comfort is also improved. The cushion member 5 has high durability and is in a form suitable as a cushion member used for a chair of an aircraft, a railway car or the like. In addition,
The chair cushion member 5 is arranged on the seat surface of the chair.

When the cushion member is composed of a core and a fibrous web covering the core, the ratio of the molding block is 10 to 80% by weight, preferably 20 to 70% by weight based on the whole cushion. % By weight, more preferably 3%
It is about 0 to 60% by weight (particularly 40 to 50% by weight).

The type of the fibrous web may be a fibrous web composed of the above-mentioned organic fibers, inorganic fibers and the like, in addition to carbon fibers. The fibrous web may be arranged in a thickness direction opposite to the molding block.

The average density of the cushion member is, for example, 1
It is about 0 to 50 kg / m ³ , preferably about 20 to 40 kg / m ³ . Since the cushion member of the present invention combines an anisotropic molding block having a bias in the degree of compressive deformation,
Even if the density is relatively low, the strength is excellent. Therefore, as compared with a cushion member made of a conventional carbon fiber, even if the density is low, the cushioning property is excellent, the feeling of bottoming is eliminated, and no sagging occurs.

[Method of Manufacturing Cushion Member] FIG. 5 is a schematic diagram for explaining a method of manufacturing the molded block 2 of FIG. 2, and FIG. 6 is a schematic diagram for explaining a method of manufacturing the cushion member of FIG. FIG.

As shown in FIG. 5, for example, the molding block 2 is made of a carbon fiber web 6 impregnated with a binder resin.
Are stacked in a fixed mold (not shown), and pressure is applied in the stacking direction so as to have a predetermined density. Then, the laminate is thermally cured with a heating means such as steam to bond the carbon fiber web to obtain a laminate 7. Furthermore, the molded block 2 can be obtained by cutting the laminate 7 in a predetermined shape and size in the thickness direction and the horizontal direction.

For lamination, the carbon fiber web may be continuously laminated while being folded from a carding machine, or a plurality of carbon fiber webs may be laminated.

The number of layers of the carbon fiber web varies depending on the size of the molding block.
Preferably, the number is about 20 to 100.

The pressure applied to the laminated carbon fiber web can be selected according to the desired density. Usually 0-10
00 Pa, preferably about 100 to 500 Pa.

The method of cutting the laminated body is not limited to the method of cutting the molded block into a cube, but may be a method of cutting into a tetragonal shape such as a rectangular parallelepiped shape, a polygonal rectangular shape, or a column shape. However, from the viewpoints of simplicity and strength, a method of cutting into a tetragonal shape, particularly a cubic shape is preferable.

The cushion member 1 is formed by, for example, spraying (spraying) a binder resin solution onto the molding block suspended in an air flow, thereby adhering the binder resin to the surface of the molding block, and then laminating the carbon fiber web. It can be manufactured by combining a plurality of molding blocks in a mold or the like so that the directions are oriented in random directions, and then thermosetting. In particular, since the size of the molding block is small and lightweight, it is preferable to spray the binder resin while floating a plurality of molding blocks in an air stream. In this manufacturing method, the binder resin can be easily attached to the molding block, and the molding blocks need only be arranged at random, so that the cushion member can be efficiently produced. Moreover, the obtained cushion member exhibits excellent cushioning properties and strength by a combination of anisotropic molded blocks. Further, since the molding is easy, the type of the carbon fiber is not limited, and for example, a recycled product can be easily produced. Therefore, it is possible to recycle the carbon fiber, and it is excellent in economical efficiency and is preferable in terms of resource environment.

Examples of a method of applying the binder resin to the molding block include a method of impregnating the binder resin solution, and a method of directly applying or spraying the binder resin. From the viewpoint of simplicity, the binder resin solution is sprayed. The method is particularly preferred. In addition, the binder resin may be attached to at least a portion to be joined, but is preferably attached to the surface of the molded block substantially uniformly from the viewpoint of simplicity.

The concentration of the binder resin solution is 100
1 to 100 parts by weight of binder resin, preferably 10 to 50 parts by weight, more preferably 20 to 4 parts by weight with respect to parts by weight.
It is about 0 parts by weight.

The solvent varies depending on the type of the binder resin used, but a conventional solvent can be used.
For example, water, alcohols (eg, ethanol, isopropanol, etc.), halogenated hydrocarbons (eg, methylene chloride, etc.), ketones (eg, acetone, methyl ethyl ketone, etc.), esters (eg, ethyl acetate),
Ethers (eg, diethyl ether, tetrahydrofuran, etc.), cellosolves (eg, methyl cellosolve, ethyl cellosolve, etc.), aromatic hydrocarbons (eg, toluene), aliphatic hydrocarbons (eg, hexane), alicyclic hydrocarbons (Such as cyclohexane).

The temperature for thermally curing the binder resin varies depending on the type of the binder resin.
0 to 150 ° C, preferably about 70 to 120 ° C, and the curing time is usually 0.1 to 24 hours, preferably 0.1 to 24 hours.
It is about 12 hours.

The chair cushion member 5 is, for example, as shown in FIG.
As shown in FIG. 6, a carbon fiber web 6 to which a binder resin (polyurethane-based adhesive or the like) is adhered is placed in a mold receiving die 8 (FIG. 6A). The core body 3 is disposed (FIG. 6 (b)), and a carbon fiber web 6 to which a binder resin is adhered is also disposed around (upper and side surfaces) of the core body 3. Is covered with a carbon fiber web 6 (FIG. 6 (c)), and an upper mold 9 of a metal mold is put thereon (FIG. 6 (d)). Then, the mold is heated in a heat treatment furnace, and the binder resin is thermally cured to obtain the chair cushion member 5. The core body 3 can be manufactured by the same manufacturing method as that of the cushion member 1.

The method of manufacturing the cushion member for a chair is not limited to the above-described manufacturing method.
Alternatively, a plurality of molded blocks having a binder resin adhered to the surface may be randomly arranged on the carbon fiber web 6 and then heat-set together with the surrounding fiber web to produce a core body. When the core is prepared in advance, the periphery of the core may be covered with a carbon fiber web and housed in a mold to be molded.

The method of applying the binder resin to the carbon fiber web is not limited to the method of impregnating the binder resin solution,
A method of spraying a binder resin solution, a method of directly applying or spraying a binder resin, and the like can be given.

The concentration of the binder resin solution is 100
0.1 to 30 parts by weight of binder resin based on parts by weight,
Preferably 1 to 20 parts by weight, more preferably 1 to 10 parts by weight
It is about parts by weight. As the solvent, the solvents exemplified above can be used, and the same resin as described above can be used as the binder resin.

[Chair] In the chair of the present invention, a cushion member is arranged so that a plurality of molded blocks are located at least on a portion of a seat surface on which a load acts. The cushion member is also excellent in flame retardancy and durability, in various fields,
For example, it can be used as a chair for vehicles such as aircraft, ships, railway vehicles, and automobiles, chairs for general households, parks, offices, and the like, and cushions for beds and the like. In addition, since the cushion member is a cushion member that eliminates cushioning properties and a feeling of bottoming, among these uses, it is required to have safety such as flame retardancy and a sitting comfort for alleviating a feeling of fatigue. It is useful for applications (chairs of vehicles such as aircraft, ships, railway vehicles, and automobiles, particularly cushions used for chairs of aircraft).

[0049]

According to the present invention, it is possible to obtain a flame-retardant cushion member which is lightweight, has excellent cushioning properties, and has a feeling of bottoming. In addition, a cushion member with little settling over a long period of time can be obtained. Further, in the present invention, a cushion member having such excellent performances can be easily manufactured. This cushion member is used for aircraft, railway vehicles,
It is useful as a cushion used for a chair or a bed of a vehicle such as an automobile.

[0050]

EXAMPLES The present invention will be described in detail below with reference to examples and comparative examples, but the present invention is not limited to these examples. In this example, the performance of the cushion member was measured by the following method.

(Compression hardness) JIS K 6400: 19
It measured according to 97. The higher the number, the harder.

(Compression recovery rate) JIS K 6400: 1
According to 997, a test piece (length 450 mm × width 450 mm × thickness 50) was formed using a pressure plate (JIS E 7104).
mm or 100 mm), the thickness when a load of 4.9 N is applied is defined as the original thickness, and after compressing to 75% of the original thickness at a constant speed, the load is removed at the same speed as during compression. From the obtained load-deflection diagram, it is represented by the ratio of the work at compression to the work at compression recovery. The higher this value, the better the elasticity is obtained.

(Repeated compression residual strain) JIS K
6400: 450 mm in length x 450 in width according to 1997
A load is applied to a test piece having a size of 50 mm or 50 mm or 100 mm at a constant speed with a pressing plate (JIS E 7104).
Compress to 50% of its original thickness, immediately reduce the load at the same speed, and return to its original thickness. This compression test was repeated 100,000 times, and the compression residual strain was determined. The lower the value, the better the distortion is small.

Example 1 A general-purpose carbon fiber (Donor Carbo S210, manufactured by Donac Co., Ltd.) was opened to produce a carbon fiber web, and this carbon fiber web was impregnated with a binder resin solution. As a binder resin solution, 3 parts by weight of a polyurethane resin (one-package / steam-curing type, content of isocyanate group: 6 to 7% by weight, viscosity at 25 ° C., 5000 cps, manufactured by Cemedine Co., Ltd.) are dissolved in 100 parts by weight of methylene chloride. The used solution was used.
Drop the binder resin attached to the carbon fiber web,
The mixture was lightly squeezed to obtain a fiber aggregate in which about 10 parts by weight of a binder resin was adhered to 100 parts by weight of a carbon fiber web. The semi-dried fiber aggregate was laminated on a fixed mold so as to have a fixed density. This laminate is heated at 80 ° C. under steam.
Heating for 2 hours to evaporate and cure the methylene chloride,
A block molded body was obtained. This block molded body was cut to obtain a cubic block molded body having an average diameter of about 15 mm. A solution obtained by dissolving 1 part by weight of the polyurethane resin in 3 parts by weight of methylene chloride is sprayed on the cubic block in a stream, and about 20 parts by weight of a binder resin adhered to 100 parts by weight of the cubic block. I got a body.

Next, as shown in FIG. 6, using this cubic block molded body and the same fiber assembly as described above,
A cushion member for a chair (density: 30 kg / m ³ ) was manufactured. The curing was performed by steam heating at a temperature of about 80 ° C. for 5 minutes. Table 1 shows various properties of the obtained cushion member.

Example 2 A cushion member for a chair was manufactured in the same manner as in Example 1 except that a commercially available carbon fiber laminate (Donacarbofelt S222, manufactured by Donac Inc.) was used as a block molded body. . Table 1 shows the results.

Example 3 A cushion member for a chair was produced in the same manner as in Example 1 except that a commercially available carbon fiber laminate (Donacarbomat S210, manufactured by Donac Inc.) was used as the block molded body. . Table 1 shows the results.

Example 4 As a block molded product, a commercially available carbon fiber laminate (a lightweight heat insulating material DLW made from Donacarbo S210) was used.
(Donack)
A cushion member for a chair was manufactured. Table 1 shows the results.

Example 5 As a block molded product, a commercially available carbon fiber laminate (simple needle punched on Donna Carbo S210, manufactured by
(Donack)
A cushion member for a chair was manufactured. Table 1 shows the results.

Comparative Example 1 A cushion member for a chair was produced in the same manner as in Example 1 except that only a fiber aggregate was used without using a cubic block molded body. Table 1 shows the results.

Comparative Example 2 Table 1 shows the results obtained using a chair cushion member formed of urethane resin.

[0062]

[Table 1]

From the results shown in Table 1, the cushion members of the examples show good results in all of the compression hardness, the compression recovery rate and the residual compression set. On the other hand, the cushion member of Comparative Example 1 has insufficient compression hardness. Further, the cushion member of Comparative Example 2 has a large residual compressive strain.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view showing an example of a cushion member of the present invention.

FIG. 2 is a schematic perspective view showing an example of a molding block constituting a cushion member.

FIG. 3 is a schematic perspective view showing another example of the cushion member of the present invention.

FIG. 4 is a schematic sectional view taken along line AA of the cushion member of FIG. 3;

FIG. 5 is a schematic diagram for explaining a method of manufacturing the molded block of FIG. 2;

FIG. 6 is a schematic view for explaining a method of manufacturing the cushion member of FIG. 3;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Cushion member 2 ... Molding block 2a ... Carbon fiber web layer 3 ... Core core 4 ... Fiber web 5 ... Cushion member 6 ... Carbon fiber web to which a binder resin solution is adhered 7 ... Laminated body 8 ... Die receiving Mold 9: Lower mold

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme court ゛ (Reference) D04H 1/42 D04H 1/42 E // A47C 7/00 A47C 7/00 C (72) Inventor Kimio Kitano Osaka Gas Co., Ltd. 4-1-2, Hirano-cho, Chuo-ku, Osaka-shi (72) Inventor Akira Nakamura 3-6-1, Bingo-cho, Chuo-ku, Osaka-shi Osaka Gas Chemical Company (72) Inventor Takuo Ishihara Osaka-shi Osaka Gas Co., Ltd. 4-1-2 Hirano-cho, Chuo-ku (72) Inventor Shigeru Tomita 2-4-131 Kutaro-cho, Chuo-ku, Osaka-shi Kurashiki Spinning Co., Ltd. (72) Inventor Kazuo Masuda Central in Osaka City 2-43, Kutaro-cho, Kurashiki Spinning Co., Ltd. F-term (reference) 3B096 AB00 AD04 4F100 AD11A AD11B AD11C AK01A AK01B AK01C AK12 AK25 AK41 AK51 BA02 BA03 BA04 BA05 BA10 A BA10C BA22 DA20 DG06A DG06B DG06C EJ17 GB33 JA13 JJ07 JK11 JL03 YY00A YY00B YY00C 4L047 AA03 BA15 BC09 BC12 BD01 CA02 CA05 CA19 CB01 CB02 CB05 CC09 CC16

Claims (14)

[Claims] 1. A cushion member comprising a plurality of molding blocks, wherein the molding block is composed of a laminate of carbon fiber webs in which carbon fibers are joined with a binder resin, and wherein the carbon fiber web is laminated. A cushion member in which a plurality of molding blocks are arranged in random directions. 2. The cushion member according to claim 1, wherein the molding block is compressed in a laminating direction. 3. The cushion member according to claim 1, wherein the molded block is a tetrahedral block. 4. The molding block has an average diameter of 3 to 100 mm.
The cushion member according to claim 1, which is a cubic block. 5. The cushion member according to claim 1, wherein the cushion member comprises a core formed of a plurality of molding blocks, and a fiber web covering the core. 6. The cushion member according to claim 5, wherein the ratio of the molding block is 10 to 80% by weight based on the whole cushion member. 7. The cushion member according to claim 1, wherein the ratio of the binder resin in the molding block is 1 to 50 parts by weight based on 100 parts by weight of the carbon fibers. 8. The cushion member according to claim 1, wherein the fibrous web is a carbon fiber web. 9. The cushion member according to claim 1, wherein the density is 10 to 50 kg / m ³ . 10. A cushion member comprising a core formed of a plurality of molding blocks, and a carbon fiber web covering the core, wherein the molding block is formed by binding carbon fibers with a binder resin. It is composed of a laminate of bonded carbon fiber webs and is compressed in the lamination direction, and has an average diameter of 5 to 5.
It is a cubic block of 50 mm, the ratio of the binder resin in the molded block is 5 to 30 parts by weight with respect to 100 parts by weight of the carbon fiber, and the ratio of the molded block is 20 to 70 parts with respect to the entire cushion member. weight%
And a cushion member in which a plurality of molding blocks are disposed with the laminating direction of the carbon fiber web in the molding blocks being oriented in a random direction. 11. A chair in which the cushion member according to claim 1 is disposed at least in a portion of a seat surface on which a load acts. 12. A step of bonding a plurality of molding blocks each formed of a laminate of carbon fiber webs in which carbon fibers are bonded with a binder resin to produce a core, and a step of covering the core with a fiber web. And a step of curing the binder resin, the method comprising manufacturing the cushioning member, wherein the core is formed by orienting the carbon fiber web of the molding block in a random direction. Method. 13. The production method according to claim 12, wherein a carbon fiber web having a binder resin adhered to the carbon fiber is laminated, and pressure is applied in the laminating direction to produce a molded block. 14. The production method according to claim 12, wherein a binder resin is adhered to the molding block in an air stream, and the molding block is randomly oriented to form a core.