JP2003125902A - Cushioning material and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fire retardant cushioning material which is excellent in cushioning properties and is relieved from a bottom response feeling underneath the cushion. SOLUTION: After an assembly body is formed with a plurality of paved carbon fiber chops with a binder resin adhered, at least the surface of the assembly body is covered with a carbon fiber web, and the cushioning material 1 is manufactured through a curing process of the binder resin. In the cushioning material, the assembly body can also be structured in a way the plurality of carbon fiber chops are paved in the carbon fiber directions oriented in the random directions. The fiber web can also be composed of a laminated body of the carbon fiber webs. The cushioning material is composed of a surface layer 3 formed of the fiber web and a backing layer 2 formed of the fiber assembly body. The ratio (weight ratio) of the assembly body/the fiber web ranges approximately from 100/0 to 20/80. The binder resin can also be a soft polyurethane resin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushioning material used for chairs, beds, etc. of vehicles such as airplanes, railway vehicles, and automobiles, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, various members have been used as cushioning materials for chairs, futons, beds and the like. As a cushion material for a chair, for example, a polyurethane foam, a member in which a plurality of urethane foams having different densities are combined, or a polyester foam is often used. Also,
Cotton, feathers, and the like are often used for the futon, and members such as futon cotton and chemical fibers (for example, polyester fiber, polyurethane fiber, etc.) and mechanical springs are often used for the bed.

However, with these cushion materials, fatigue occurs when a load is repeatedly applied after a long time of use, and the cushioning property deteriorates at a relatively early stage. Further, most of these cushion materials are flammable, and when burned, generate toxic gas.

On the other hand, the cushioning material made of carbon fiber is flame-retardant, suffers only a few percent of fatigue even after repeated compression of 1,000,000 times, and has excellent long-term stability. For example, in Japanese Patent Laid-Open No. 9-294649,
A cushioning material for a chair, which is composed of a three-dimensional mesh structure formed of carbon fibers and a binder resin, is disclosed. However, unless the cushion material made of carbon fiber has a high density, a feeling of bottoming (feeling of an object at the bottom of the cushion) remains, and the cushioning property is poorly balanced.
Further, Japanese Patent Application Laid-Open No. 9-273059 discloses a laminate in which a phenol resin solution is adhered to a cotton-like carbon fiber sheet, and the sheets are folded and superposed. However, the cushion material composed of this laminated body does not have sufficient compression recovery, and the balance between the cushioning property and the feeling of bottoming is poor.

Further, in Japanese Patent Laid-Open No. 2000-253958, a carbon fiber body impregnated with a binder resin is divided into a predetermined size to prepare a cushion piece, and the cushion piece is laid and cured. , A method of molding a cushion material is disclosed. According to this method, the cushion material can be manufactured by a simple method, but the obtained cushion material has a poor balance between cushioning properties and a feeling of bottoming, like the cushion material.

[0006]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a flame-retardant cushioning material which has excellent cushioning properties and eliminates the feeling of bottoming, and a chair including the cushioning material.

[0007] Another object of the present invention is to provide a cushioning material having less fatigue over a long period of time and a chair including the cushioning material.

Still another object of the present invention is to provide a method for easily producing a flame-retardant cushioning material which is excellent in cushioning property and has a bottomed feeling eliminated.

[0009]

Means for Solving the Problems The inventors of the present invention have conducted extensive studies in order to solve the above problems, and as a result, have found that the surface of a fiber assembly composed of carbon fiber chops in which carbon fibers are randomly oriented. By covering and integrating with a carbon fiber web, it is possible to enhance cushioning properties even when stress is applied to the seat surface from various angles,
It has been found that a flame-retardant cushioning material having a reduced bottoming feeling can be obtained.

That is, the cushioning material of the present invention comprises a fiber assembly and a fiber web covering at least the surface of the assembly, and the fibers of the assembly and the web are respectively bonded with a binder resin, A cushioning material in which the aggregate and the web are joined by a binder resin, the aggregate is composed of a plurality of carbon fiber chops, and the web is composed of a carbon fiber web. In the fiber assembly, a plurality of carbon fiber chops may be laid with the carbon fibers oriented in random directions. The carbon fiber chop has an average length of 3 to 100 m.
It may be a tetragonal shape of m. The web may be composed of a laminate of carbon fiber webs. The cushion material may be composed of a surface layer formed of a fibrous web and a support layer formed of a fiber aggregate and supporting the surface layer. The basis weight of the fiber aggregate and the fiber web is about 125 to 1000 g / m ² . The ratio (weight ratio) of the aggregate to the web is aggregate / web = 100/0 to 20/80, preferably 80/20 to.
It is about 30/70. The binder resin may be a soft polyurethane resin. The ratio of the binder resin in the aggregate is about 0.5 to 30 parts by weight with respect to 100 parts by weight of the carbon fibers, and the ratio of the binder resin in the web is 1 to 50 parts by weight with respect to 100 parts by weight of the carbon fibers. It is about a part. The average density of the cushion material is about 10 to 50 kg / m ³ .

The present invention also includes a chair in which the cushion material is arranged at least at a portion of the seat surface on which a load acts.

Further, according to the present invention, a step of laying a plurality of carbon fiber chops to which a binder resin is attached to form an aggregate, and at least the surface of the aggregate is covered with a carbon fiber web to which the binder resin is attached. A manufacturing method including a step and a step of curing the binder resin while pressing the carbon fiber web is also included. Further, the present invention includes
It also includes a manufacturing method including a step of laying a plurality of carbon fiber chops to which a binder resin is attached to form an aggregate, and a step of curing the binder resin while pressing the fiber aggregate. In the step of forming the aggregate, a plurality of carbon fiber chops may be laid with the carbon fibers oriented in random directions.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below in detail with reference to the accompanying drawings as needed.

[Cushion Material] FIG. 1 is a schematic perspective view showing an example of the cushion material of the present invention. Cushion material 1
As shown in FIG. 1, is composed of a support layer (or a support buffer layer) 2 formed of a fiber assembly and a surface layer 3 formed of a laminate of fiber webs covering at least the surface of the support layer. ing.

(Fiber Assembly) The fiber assembly is composed of a plurality of carbon fiber chops (cut mats) 2 in which carbon fibers are randomly oriented, and the carbon fibers of the chops are joined by a binder resin. In addition, a plurality of adjacent chops are also joined with a binder resin. Furthermore, the plurality of carbon fiber chops 2 are laid with the carbon fibers oriented in random directions to form an aggregate. More specifically, the plurality of carbon fiber chops 2 adjacent to each other are formed by applying a binder resin solution and curing and curing the same.
They are joined together at their contact points to form an aggregate. Therefore, even when stress is applied from various directions, uniform impact resilience can be obtained, and buckling and settling can be prevented.

The shape of the chop is not particularly limited, and is not limited to a cubic shape, and may be a tetragonal shape such as a rectangular parallelepiped, a polygonal rectangular shape, or a cylindrical shape. Of these shapes,
From the viewpoint of simplicity, a tetragonal shape, particularly a cubic shape is preferable.

The average chop length (or cut width) is
For example, 3 to 100 mm, preferably 5 to 70 mm, more preferably 10 to 50 mm (especially 20 to 40 mm).
It is a degree. The average length is, for example, an average diameter of height, width, and height.

The shape of the aggregate is not particularly limited, but is generally a block shape or a thick plate block shape as a whole.

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

The average fiber diameter of the carbon fibers is, for example, 0.5.
-30 μm, preferably 1-25 μm (for example, 5-2
5 μm), and carbon fibers having an average fiber diameter of 1 to 20 μm (for example, 10 to 20 μm) are often used. As the carbon fibers, short fibers (discontinuous fibers) are usually used. The fiber length of the short fibers is, for example, 1 to 200 m.
m, preferably 1-150 mm (e.g. 1-100 m
m), and more preferably about 3 to 50 mm.

As the binder resin, a hard thermoplastic resin (styrene resin or the like), a hard thermosetting resin (amino resin, phenol resin, epoxy resin,
Unsaturated polyester resin, etc.) may be used, but soft thermoplastic resin (for example, vinyl resin, acrylic resin, polyester resin, thermoplastic polyurethane resin, polyamide resin, etc.) or soft resin Thermosetting resins (polyurethane resin, thermosetting acrylic resin, polyimide resin, etc.) can be preferably used. Among these binder resins, a soft thermosetting resin, particularly a polyurethane resin is preferable. As the polyurethane resin, solution type, emulsion type, two-component curing type, moisture (water vapor) curing type polyurethane resin and the like can be used.

Polyether polyol (poly C _2-4 alkylene glycol such as polyethylene glycol, polypropylene glycol, ethylene-propylene block copolymer and polytetramethylene ether glycol) is used as a polyol component in the soft polyurethane resin.
Or a polyester polyol obtained from a C _4-12 polybasic acid (C _6-12 alkanedicarboxylic acid such as adipic acid) and a polyol component (C _2-10 alkylene glycol such as ethylene glycol, butanediol, hexanediol) Polyurethane-based resins using the above are included. As the isocyanate component, general-purpose aromatic diisocyanates (diphenylmethane diisocyanate, tolylene diisocyanate, etc.), araliphatic diisocyanates (xylylene diisocyanate, etc.), alicyclic diisocyanates (isophorone diisocyanate, etc.), aliphatic diisocyanates (hexamethylene diisocyanate, etc.) Etc. can be illustrated. In addition, polyurethane resin,
It may be a composition of a polyurethane prepolymer having an isocyanate group at the terminal and a curing agent (short chain oats, polyhydric alcohols, alkylenediamines such as hexamethylenediamine, polyamines such as alkanolamines).

Elongation of flexible polyurethane resin (JIS
-K-6301) is 50% or more, preferably 100%
It is above (for example, 100 to 500%), and more preferably above 150% (for example, 150 to 400%).

These binder resins may be used alone or in combination of two or more. The ratio of the binder resin is, in terms of solid content, 0.1% based on 100 parts by weight of carbon fiber.
1 to 30 parts by weight, preferably 0.3 to 20 parts by weight, more preferably 0.5 to 10 parts by weight (particularly 1 to 5 parts by weight)
It is a degree.

The carbon fiber chops include organic fibers (for example, polyolefin fibers, polyester fibers, nylon fibers, polyvinyl alcohol fibers, vinylon fibers, polyvinyl chloride fibers, acrylic fibers,
Synthetic fibers such as rayon fibers, acetate fibers, polyurethane fibers and natural fibers), and inorganic fibers (for example, 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 the carbon fiber when heated may be used. Of these fibers, flame retardant organic fibers,
Inorganic fibers are preferred. These fibers can be used alone or in combination of two or more.

The basis weight of the fiber assembly is 125 to 1000 g.
/ M ² , preferably about 250 to 1000 g / m ² . The average density of the fiber assembly is 10 to 50 kg / m ³ , preferably about 15 to 45 kg / m ³ .

(Fiber web) The fiber web is composed of a carbon fiber web (carbon fiber web layer) in which fibers are entangled with each other, and not only the carbon fibers of the web but also adjacent webs are joined with a binder resin. The carbon fiber web may be in a state where fibers are randomly entangled with each other. As the carbon fibers, crimped fibers, non-linear fibers such as looped fibers may be used. The fibrous web may be a laminate. The number of laminated carbon fiber webs is usually 10 to 10.
It is about 500 sheets, preferably about 20 to 100 sheets. The fibrous web is preferably laminated in terms of cushioning properties and strength.

As the fibers and binder resin constituting the fibrous web, the same fibers and binder resin as those of the above aggregate can be exemplified.

The ratio of the binder resin is 100 carbon fibers.
0.5 to 50 parts by weight, preferably 1 to 3 parts by weight
0 parts by weight, more preferably 3 to 20 parts by weight (especially 5 to
10 parts by weight).

The basis weight of the single or laminated fibrous web is 125-1000 g / m ² , preferably 200-8.
00 g / m ² , more preferably 300 to 700 g / m ^2.
It is a degree. The average density of the fibrous web is 10 to 50 kg /
m ³ , preferably about 15 to 45 kg / m ³ .

The binder resin is also bonded between the fiber assembly and the fiber web. The ratio (weight ratio) of the fiber aggregate and the fiber web is as follows: fiber aggregate / fiber web = 100/0 to 20/80, preferably 80/20 to 3
It is 0/70, more preferably about 60/40 to 40/60.

In the cushion material of the present invention, the fiber web may cover at least the surface of the fiber assembly. Therefore, as shown in FIG. 1, in addition to the form in which the surface layer of the support layer is covered with the fiber web, the entire support layer may be covered with the fiber web, or the surface layer and the lower layer of the support layer may be covered with the fiber web.

Since the fibrous web is superior in smoothness and unity (continuity) to the fibrous aggregate, it is preferable to cover at least the portion (usually the surface layer) on which the load acts as a cushioning material with the fibrous web. Since the fiber assembly is composed of a plurality of carbon fiber chops in which carbon fibers are oriented in random directions, by covering the uneven surface of the fiber assembly with a fiber web, sitting comfort is improved.

The shape of the cushion material is not limited to a flat plate shape and can be selected according to the purpose for which it is used, but it is usually a flat plate shape, a disk shape or the like.

The thickness of the cushion material is not particularly limited, and in the case of a chair cushion material, it is 5 to 150 mm (for example,
5 to 100 mm), preferably about 20 to 80 mm.

According to the present invention, by covering the surface of the carbon fiber aggregate with the carbon fiber web, even if stress (pressure) is applied to the seat surface from various directions, the cushioning property is excellent and the feeling of bottoming is obtained. A cushion material in which is eliminated is obtained. Further, since the carbon fiber aggregate is formed of a plurality of carbon fiber chops, an appropriate void is formed inside the cushion material, and a member having high cushioning property can be obtained even if the weight is small.

Further, since the cushion material of the present invention has the above-mentioned structure, it has excellent strength even if the density is relatively low.
Therefore, compared with the conventional cushioning material made of carbon fiber, even if the density is low, the cushioning property is excellent, the feeling of bottoming is eliminated, and sagging does not occur. further,
Since the aggregate composed of the carbon fiber chops is used, the cushioning property and the strength are maintained for a long time without any fatigue.

[Cushion Material Manufacturing Method] FIG.
FIG. 6 is a schematic view for explaining the method for manufacturing the cushion material of FIG.

In this method, as shown in FIG. 2, a plurality of carbon fiber chops (or cut mats) 3 impregnated with a binder resin are placed on the lower (reception) die 6 of the mold in the direction of the carbon fibers. Lay in random directions. further,
A carbon fiber web 5 impregnated with a binder resin is laminated on the laid carbon fiber chop 4. Then, while pressing with the upper mold 7 of the mold, by heating means such as steam,
The binder resin is heat-cured to bond the carbon fibers to obtain the cushion material 1.

The carbon fiber chop (cut mat) 3 is
It may be laid in parallel or non-parallel in the vertical and horizontal directions, but it is preferable to lay it in a random direction in order to facilitate and cope with stress from each direction. Carbon fiber chop 3
Can be produced, for example, by cutting a carbon fiber mat.

The number of carbon fiber chops is not particularly limited and may be adjusted according to the application. In the case of a cushion material for a chair, for example, the number may be about 50 to 20000, preferably about 200 to 2000.

The carbon fiber webs may be laminated continuously while folding the carbon fiber web from a carding machine, or may be laminated with a plurality of carbon fiber webs.
The carbon fiber web may be covered with the monolithic carbon fiber web without being laminated.

Examples of the method of applying the binder resin to the fiber aggregate and the web include a method of impregnating the binder resin solution, a method of spraying the binder resin solution, and a method of directly applying or spraying the binder resin. Among these methods, the impregnation method and the spray method are preferable from the viewpoint of simplicity.

The concentration of the binder resin solution is 100
The amount is 1 to 100 parts by weight, preferably 5 to 50 parts by weight, and more preferably 5 to 40 parts by weight (particularly 10 to 20 parts by weight) with respect to parts by weight.

As the solvent, a commonly used solvent can be used, although it depends on the kind of binder resin used.
For example, water, alcohols (eg ethanol, isopropanol etc.), halogenated hydrocarbons (eg methylene chloride etc.), ketones (eg acetone, methyl ethyl ketone etc.), esters (ethyl acetate etc.),
Ethers (eg diethyl ether, tetrahydrofuran etc.), cellosolves (eg methyl cellosolve, ethyl cellosolve etc.), aromatic hydrocarbons (toluene etc.), aliphatic hydrocarbons (hexane etc.), alicyclic hydrocarbons Examples thereof include cyclohexane and the like.

The temperature for thermosetting the binder resin varies depending on the kind of the binder resin, but is usually 5
0 to 150 ° C, preferably about 70 to 120 ° C,
The curing time is usually 10 seconds to 24 hours, preferably 30 seconds.
Second to 5 hours, more preferably 1 minute to 1 hour (particularly 3 to
10 minutes).

The pressure exerted on the fibrous mass and fibrous web can be selected depending on the desired density. Usually 10
The pressure is 1000 Pa (for example, 50 to 500 Pa), preferably about 100 to 800 Pa.

The method for manufacturing the cushioning material is not limited to the above-mentioned manufacturing method. For example, a fiber chop may be laid on the laminated fiber web, or a fiber web may be laid on the chop. Good.

[Chair] In the chair of the present invention, a cushion material is arranged at least at a portion of the seat surface on which a load acts. In particular, it is preferable to cover the surface of the portion where the load is applied with a fibrous web. The cushion material is also excellent in flame retardancy and durability, and is used in various fields, for example, railway vehicles, aircraft,
It can be used as a chair for ships, vehicles for automobiles, chairs for general households, parks, offices, etc., and cushions for beds, etc. Further, since the cushion material is a cushion material that eliminates the cushioning property and the feeling of bottoming out, among these applications, safety such as flame retardancy is required and sitting comfort for alleviating the feeling of fatigue is required. Applications (rail vehicles,
It is useful for chairs of vehicles such as aircrafts, ships, and automobiles, especially cushions used for chairs of rail cars and aircrafts.

[0050]

According to the present invention, it is possible to obtain a flame-retardant cushioning material which is light in weight and excellent in cushioning property, and in which the feeling of bottoming is eliminated. In addition, a cushioning material with less fatigue over a long period of time can be obtained. Further, according to the present invention, the cushioning material having such excellent performances can be easily manufactured. This cushion material is useful as a cushion used for a chair of a vehicle such as an aircraft, a rail car, an automobile, a bed, and the like.

[0051]

EXAMPLES The present invention is described in detail below by showing Examples and Comparative Examples, but the present invention is not limited to these Examples. In this example, the performance of the cushion material was measured by the method described below.

(Compression recovery) Pressure plate (JIS E 71
04), using a test body (length 450 mm × width 450 mm
X thickness 50 mm or 100 mm), the thickness when a load of 5 N is applied is the original thickness, and the original thickness is 7 at the constant speed.
After compressing to 5%, 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 amount during compression and the work amount during compression recovery. The higher this value, the better the elasticity.

(Compression durability) Pressure plate (JASO B40
77 kg of 7-87 for seat cushion JM type) is placed on a test body (length 450 mm x width 450 mm x thickness 100 mm), and after applying constant vibration, the thickness of a plurality of points contacted by the pressure plate is measured, Calculate the amount of sag from the original thickness. The smaller the amount, the higher the durability.

(Compression hardness) JIS K 6400: 19
According to 97, using a pressure plate (JIS E 7104), a test body (length 450 mm × width 450 mm × thickness 50 m)
m or 100 mm), the thickness when a load of 5 N is applied is taken as the original thickness, and after compressing to 75% of the original thickness at a constant speed, the original thickness is restored. It is compressed to 25% of the original thickness again, and is expressed by the load when 20 seconds have passed after rest. The higher this number is, the harder it is.

(Repeated compressive residual strain) JIS K
6400: According to 1997, length 450 mm x width 450
mm × thickness of 50 mm or 100 mm, a pressure plate (JIS E 7104) is used to apply a load at a constant speed,
Load 100 kg, immediately reduce the load at the same speed,
Return to no load. This compression test was repeated 100,000 times, and the compression residual strain was obtained based on the following formula. The lower this value is, the less the distortion is and the better.

Repeated compressive residual strain (%) = (AB)
/ B × 100 (In the formula, A indicates the amount of compressive strain at 100,000 times, and B indicates the amount of compressive strain at the first time).

Example 1 Carbon fiber chops (manufactured by Donac Co., cubes with an average diameter of 30 mm obtained by cutting Dona Carbomat S210) were impregnated with a binder resin solution, and the excess liquid was treated with a centrifuge to obtain carbon fibers. A fiber assembly was obtained in which about 3 parts by weight of a binder resin was attached to 100 parts by weight of chop. As the binder resin solution, polyurethane resin (Meiwa Yuka Kogyo KK, MEIWASOL CX-360L, steam curing type, isocyanate group content 10.5 ± 0.5% by weight, viscosity at 25 ° C. 3500 ± 500 cps) A solution prepared by dissolving 7 parts by weight in 100 parts by weight of methylene chloride was used.
This fiber assembly was laid evenly in the mold so as to have a constant thickness.

Carbon fiber web (WE, manufactured by Donac Co., Ltd.)
B225) was impregnated with the binder resin solution. The binder resin attached to the carbon fiber web was dropped, and the excess liquid was treated with a centrifuge to obtain a carbon fiber web in which about 7 parts by weight of the binder resin was attached to 100 parts by weight of the carbon fiber web. Onto 40 parts by weight of the fiber aggregate, 60 parts by weight of this semi-dried carbon fiber web was laminated. This laminated body was heated in water vapor at about 80 ° C. for 5 minutes to be cured to obtain a cushion material having a density of 30 kg / m ³ . Table 1 shows various performances of the obtained cushioning material.

Comparative Example 1 Table 1 shows the results obtained by using a cushion material for chairs made of urethane resin.

Comparative Example 2 A chair cushion material was manufactured in the same manner as in Example 1 except that the carbon fiber chop was not used and only the carbon fiber web laminate was used. The results are shown in Table 1.

[0061]

[Table 1]

From the results shown in Table 1, the cushioning material of Example 1 shows good results in all of compression recovery, compression durability, compression hardness and repeated compression residual strain. On the other hand, the cushioning material of Comparative Example 1 has a large repetitive compressive residual strain. The cushion material of Comparative Example 2 is
Compression recovery and compression hardness are not sufficient.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing an example of a cushioning material of the present invention.

FIG. 2 is a schematic diagram for explaining a manufacturing method of the cushion material of FIG.

[Explanation of symbols]

1 ... Cushion material 2 ... Support layer 3 ... Surface 4 ... Carbon fiber chop with binder resin solution attached 5 ... Carbon fiber web with binder resin solution attached 6 ... Mold bottom (receiving) mold 7 ... Upper mold

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Kimio Kitano             4-1-2 Hirano-cho, Chuo-ku, Osaka City, Osaka             Gas Co., Ltd. (72) Inventor Takuo Ishihara             4-1-2 Hirano-cho, Chuo-ku, Osaka City, Osaka             Gas Co., Ltd. (72) Inventor Akira Nakamura             3-6-14 Bingocho, Chuo-ku, Osaka             Gas Chemical Co., Ltd. (72) Inventor Tomoyuki Yoneda             2-43, Kutaro-cho, Chuo-ku, Osaka             Shiki Spinning Co., Ltd. F-term (reference) 3B096 AD04 BA01                 4F100 AD11A AD11B AD11C AD11D                       AD11E AK01A AK01B AK01C                       AK51A AK51B AK51C AK51D                       AK51E BA02 BA03 BA04                       BA05 BA10B BA10C DG03A                       DG03B DG03C DG06A DG06B                       DG06C DG06D DG06E GB33                       GB71 GB81 JA13A JA13B                       JA13C JA13D JA13E JJ07                       JK11 JL03 JL04 YY00A                       YY00B YY00C YY00D YY00E                 4L047 AA03 AB02 BA12 BC12 BD01                       CA02 CA05 CA19 CB01 CB05                       CC07 CC09

Claims (15)

[Claims] 1. A fiber assembly and a fiber web covering at least the surface of the assembly, wherein the fibers of the assembly and the web are bonded with a binder resin, respectively, and the assembly and the web are A cushion material joined by a binder resin, wherein the aggregate is composed of a plurality of carbon fiber chops, and the web is composed of a carbon fiber web. 2. The cushion material according to claim 1, wherein a plurality of carbon fiber chops are laid with the carbon fibers oriented in random directions to form an aggregate. 3. The carbon fiber chop has an average length of 3 to 100.
The cushion material according to claim 1, which has a rectangular shape of mm. 4. The cushioning material according to claim 1, wherein the fibrous web is composed of a laminated body of carbon fibrous webs. 5. The cushioning material according to claim 1, comprising a surface layer formed of a fibrous web and a support layer formed of a fiber assembly. 6. The weight per unit area of the fiber aggregate and the fiber web is 1.
The cushion material according to claim 1, which has a weight of 25 to 1000 g / m ² . 7. The ratio (weight ratio) of the fiber aggregate and the fiber web is such that fiber aggregate / fiber web = 100/0 to 20 /.
The cushion material according to claim 1, which is 80. 8. The cushion material according to claim 1, wherein the binder resin is a soft polyurethane resin. 9. The ratio of the binder resin in the fiber assembly is 0.1 to 30 parts by weight with respect to 100 parts by weight of the carbon fibers, and the ratio of the binder resin in the fiber web is 100 parts by weight of the carbon fibers. The cushion material according to claim 1, which is 0.5 to 50 parts by weight. 10. The cushioning material according to claim 1, which has an average density of 10 to 50 kg / m ³ . 11. A surface layer formed of a laminate of fibrous webs and a support layer formed of a fiber assembly and supporting the surface layer, wherein the fibers of the assembly and the web are made of a soft polyurethane. While being joined with resin,
A cushioning material in which the aggregate and the web are joined with a soft polyurethane resin, the aggregate is composed of carbon fiber chops, the web is composed of a carbon fiber web, and the aggregate and the web Ratio (weight ratio)
Is the aggregate / web = 80/20 to 30/70. 12. A chair in which the cushion material according to claim 1 is arranged at least at a portion of a seat surface on which a load acts. 13. A step of laying a plurality of carbon fiber chops to which a binder resin is attached to form an aggregate, a step of covering at least the surface of the aggregate with a carbon fiber web to which the binder resin is attached, and the carbon. Curing the binder resin while pressing the fibrous web. 14. A manufacturing method comprising: a step of laying a plurality of carbon fiber chops to which a binder resin is attached to form an aggregate, and a step of curing the binder resin while pressing the aggregate. 15. The manufacturing method according to claim 13, wherein in the step of forming the aggregate, a plurality of carbon fiber chops are laid with the carbon fibers oriented in random directions.