JP2006183171A - Preliminarily compressed three dimensional structural material, method for producing the same and cushion for vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a preliminarily compressed three dimensional structural material improved so that the reduction in hardness hardly occurs even on receiving compression repeatedly. <P>SOLUTION: This three dimensional structural material obtained by bonding the crossing points of a fiber with another fiber by a binder resin is prepared. The hardening is performed against the three dimensional structural material 1 so that the hardness of the thickness part 1a is averaged over the whole of the thickness part. The thickness part of the three dimensional structural material 1 is compressed in the thickness direction. In a state of compressing the thickness part 1a of the three dimensional structural material 1, the thickness part 1a of the three dimensional structural material 1 is covered with a covering member 2 to obtain the preliminary compressed three dimensional structural material. Since the preliminarily compressed three dimensional structural material is compressed in the thickness direction in advance, and since the relatively easily detachable bonded points are detached in advance, the reduction of the hardness hardly occurs even on receiving repeated compression in the thickness direction further afterwards. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates generally to a three-dimensional structure of fibers, and more particularly, a pre-compressed three-dimensional structure that has been improved to be less susceptible to reduced hardness even after repeated compression. About. The invention also relates to a method for producing such a pre-compressed three-dimensional structure. The invention further relates to a vehicle cushion using such a pre-compressed three-dimensional structure.

  The three-dimensional structure of fibers is used as a cushion member for a seat. The conventional elastic fiber made of natural materials such as cotton, wool, feathers, and artificial fibers such as acrylic, polyester, glass fiber, and carbon fiber is poor in compression resilience, There has been a problem in that the fibers move and become unevenly distributed due to repeated use, and are easy to sag. Patent Document 1 discloses a fiber elastic body that solves this problem.

  With reference to FIG. 7, the fiber elastic body 51 disclosed in Patent Document 1 includes a fiber assembly 52, a front fabric 53 as a protective sheet that wraps the fiber assembly 52, and the front fabric 53 of the fiber assembly 52. It is composed of an adhesive 54 that adheres to the seating surface, and the fiber assembly 52 and the front fabric 53 are collectively quilted (stitched) with a quilting thread 55. According to this configuration, since the fiber assembly 52 is fixed to the front fabric 53 with the adhesive and is divided by the quilting yarn 55, the phenomenon that the fibers of the fiber assembly 52 move and become unevenly distributed is alleviated. Can be reduced. Further, the quilting yarn 55 increases the compression repulsion force of the fiber elastic body 51 to improve the sitting comfort, and the front fabric 53 has an effect of regulating the air supply / discharge speed of the fiber assembly 52 at the time of sitting / separating. .

JP-A-10-155602

  When configured as described above, the phenomenon in which the fibers of the fiber assembly 52 move and become unevenly distributed can be alleviated. However, particularly in a fiber elastic body obtained by adding a binder resin to carbon fibers, it was not possible to prevent a decrease in hardness due to repeated compression. Such a decrease in hardness due to repeated compression causes a feeling of bottoming during use of the cushion when the fiber elastic body is used for a seat cushion or the like, and makes sitting comfort worse.

  Such a change in the properties of the fiber elastic body due to repeated compression is considered to occur because the binding point (binding) where the fibers are bound to each other is released. The fiber elastic body tends to approach the fiber raw material (web) when the binding point is removed. At that time, the hardness decreases.

  SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a pre-compressed three-dimensional structure which is improved so that the hardness is not easily lowered even after repeated compression.

  Another object of the present invention is to provide a method for producing such a pre-compressed three-dimensional structure.

  Yet another object of the present invention is to provide a vehicle cushion using such a pre-compressed three-dimensional structure.

  The pre-compressed three-dimensional structure according to the present invention includes a three-dimensional structure having a binding point in which the intersections of fibers are bound with a binder resin (including heat-fusible fibers). The thickness portion of the three-dimensional structure is compressed in the thickness direction, and the hardness of the thickness portion is averaged over the entire thickness portion. Furthermore, the expansion in the thickness direction of the thick portion is restricted.

  According to the present invention, the thickness portion of the three-dimensional structure is compressed in the thickness direction in advance, and the hardness of the thickness portion is averaged over the entire thickness portion, so that it is relatively easy to come off. The landing points have been removed beforehand. Therefore, even if it receives compression repeatedly further in the thickness direction after that, a fall of hardness becomes difficult to occur.

  The fibers that make up the three-dimensional structure include a wide range of natural fibers and man-made fibers (including semi-synthetic fibers), mixtures of these, and ordinary natural fibers and man-made fibers with physical and chemical treatments added. Fiber can be used. Specifically, cotton, hemp, wool, etc. can be used as natural fibers, and acrylic fibers, aramid fibers, polyester fibers, glass fibers, carbon fibers, etc. can be used as artificial fibers. The three-dimensional structure may be composed of one type of fiber or may be composed of a mixture of two or more types.

  However, the fiber constituting the three-dimensional structure is preferably a fiber having a strong elastic repulsion, and preferably a flame-retardant or non-flammable fiber excellent in disaster prevention. Examples of such fibers include aramid fibers, polyester fibers, glass fibers, and carbon fibers. When compression resilience (cushioning), repeated use (sagging resistance), and disaster prevention are required, polyester fiber or carbon fiber is used as the three-dimensional structure, and the intersection of the fibers is a binder. It is preferable to form a three-dimensional network structure by binding with a resin (binder), etc. Among these, carbon fiber is the main fiber (50% by weight or more of the fiber material is carbon fiber) 3D structure (hereinafter referred to as a carbon fiber three-dimensional structure) can be suitably used. Although a three-dimensional structure may be formed using only a carbon fiber three-dimensional structure, a three-dimensional structure and / or other linear fiber aggregate composed of the carbon fiber three-dimensional structure and other materials. May be combined to form a three-dimensional structure. Moreover, what laminated | stacked the three-dimensional structure from which a kind differs may be sufficient.

  The three-dimensional structure has a compression hardness LC of 0.7 to 0.8 and a compression recovery rate RC of 65 when the bulk density is 20 to 40 Kg / m3 and the maximum load is 100 gf / cm2 (9.8 kPa). More than 10%, when the ratio of 65% compression stress to 25% compression stress is 10 or more, the residual strain ratio after compression of 10% is 10% or less, and the residual strain ratio after compression of 80,000 times is 10% or less. Therefore, it is possible to obtain a compression repulsion suitable for the resin, and it is possible to secure sufficient lightness and excellent repeated use.

  These physical property values are defined as follows. That is, in the compression hardness LC, the load-strain curve is changed linearly (straight line) to the work energy required for compression to a maximum load of 100 gf / cm 2 (9.8 kPa), with the thickness at no load being the initial thickness. The value divided by the work energy required for the case. The compression recovery rate RC is the energy required to compress the maximum load to 100 gf / cm 2 (9.8 kPa), and divides the amount of energy in the recovery process from the compression state to return to the no-load state. The multiplied value. The compressive stress ratio is a value obtained by dividing the stress when compressed by 65% by the stress when compressed by 25%. The single-time compression residual strain was compressed to 50% of the initial thickness M0 at room temperature, held in this state for 40 hours and then unloaded, and the thickness M1 after 30 minutes was measured. (1-M1 / M0) A value calculated from x100. The residual strain ratio after compression 80,000 times is obtained by calculating a displacement amount (M∞) after 80,000 times by repeating a cycle of restoring to 50% of the initial thickness M0 at room temperature and then restoring 80%. -M∞ / M0) × 100. However, among the above physical property values, LC and RC use 10 cm 2 circular samples, and the compression stress ratio, single compression residual strain ratio, and residual strain ratio after 80,000 compression use a 50 mm × 50 mm square sample. It is measured.

  The kind of carbon fiber is not limited. For example, carbon fiber carbonized or graphitized using a raw material such as polyacrylonitrile, a polymer such as phenol resin, rayon, or a pitch such as petroleum pitch or coal pitch can be used. In particular, pitch-based carbon fibers have low toxicity of generated gas under forced heating. Further, when the carbon fiber is a crimped fiber (preferably 50 to 100% by weight of the whole fiber is a crimped fiber), the elasticity of the carbon fiber itself is used to obtain a strong rebound compression force with a small bulk density (light weight). It is easy to be done. The fiber length of the crimped fiber is preferably 0.1 cm to 10 cm.

  As the binder resin, a hard thermoplastic resin (such as a styrene resin) or a hard thermosetting resin (such as an amino resin, a phenol resin, an epoxy resin, or an unsaturated polyester resin) may be used. However, soft thermoplastic resins (eg, vinyl resins, acrylic resins, polyester resins, thermoplastic polyurethane resins, polyamide resins, etc.) and soft thermosetting resins (polyurethane resins, thermosetting acrylics, etc.) Resin, polyimide resin, etc.) can be preferably used. Of these binder resins, soft thermosetting resins, particularly polyurethane resins are preferred. As the polyurethane resin, a solution type, an emulsion type, a two-component curable type, a moisture (water vapor) curable type polyurethane resin, or the like can be used.

  For flexible polyurethane resins, polyether polyol (poly C2-4 alkylene glycol such as polyethylene glycol, polypropylene glycol, ethylene-propylene block copolymer, polytetramethylene ether glycol) or C4-12 polybasic acid (polyol) is used as a polyol component. Examples include polyurethane resins using polyester polyols obtained from C6-12 alkanedicarboxylic acids such as adipic acid) and polyol components (C2-10 alkylene glycols such as ethylene glycol, butanediol, hexanediol, etc.). Isocyanate components include general-purpose aromatic diisocyanates (such as diphenylmethane diisocyanate and tolylene diisocyanate), araliphatic diisocyanates (such as xylylene diisocyanate), alicyclic diisocyanates (such as isophorone diisocyanate), and aliphatic diisocyanates (such as hexamethylene diisocyanate). Etc. can be exemplified. The polyurethane resin is a composition of a polyurethane prepolymer having an isocyanate group at the terminal and a curing agent (short chain ol, polyhydric alcohol, alkylene diamine such as hexamethylene diamine, polyamines such as alkanolamine, etc.). May be.

  The elongation percentage (JIS-K-6301) of the flexible polyurethane resin is about 50% or more, preferably about 100% or more (for example, 100 to 500%), more preferably about 150% or more (for example, 150 to 400%). is there.

  According to a preferred embodiment of the present invention, the expansion in the thickness direction is restricted by covering at least the thickness portion of the three-dimensional structure with a covering member.

  The covering member is preferably one whose dimensions do not easily change. The material is not limited to a specific raw material, and examples thereof include cloth, leather, synthetic resin sheets, composite material sheets thereof, and the like, including a net-like sheet, a mesh, and stringing at fine intervals. As the fabric, natural fibers and man-made fibers (including semi-synthetic fibers), or a mixture thereof, woven or non-woven fabrics composed of a wide range of fibers such as ordinary natural fibers and man-made fibers with physical and chemical treatments added. Can be used. The covering member is preferably provided with a flexibility that does not make the seating comfort too strong. Specifically, a novoloid fiber (phenolic resin is made into a fiber and then cross-linked to make the molecular structure three-dimensional) Examples thereof include felt-like woven fabrics or nonwoven fabrics, cotton woven fabrics such as gold widths, wool woven fabrics, felt-like nonwoven fabrics made of carbon fibers, and the like. The thickness of the covering member can be appropriately selected in consideration of the durability, the material of the covering member, etc., depending on the use of the pre-compressed three-dimensional structure. The degree is good. If it exceeds 10 mm, it gives a strong feel.

When the three-dimensional structure is compared under a 25% strain condition, the three-dimensional structure is preferably compressed so that the improvement in hardness reduction represented by the following formula is 10 to 100%.

  Thereby, a durable three-dimensional structure is obtained. The degree of compression is preferably changed as appropriate according to the service life. More specifically, when the thickness of the three-dimensional structure before compression is T and the thickness of the three-dimensional structure after compression is t, the ratio of t / T is 0.85 to 0.95. It is preferred that

  In the method for producing a pre-compressed three-dimensional structure according to another aspect of the present invention, first, a three-dimensional structure having a binding point in which the intersections of fibers are bound with a binder resin is prepared. The three-dimensional structure is hardened so that the thickness of the thickness portion is averaged over the entire thickness portion. The thickness portion of the three-dimensional structure is compressed in the thickness direction. Expansion in the thickness direction is constrained in a state where the thickness portion of the three-dimensional structure is compressed. Hardness removal is performed by removing a binding point that is relatively easy to come off.

  Thereby, the hardness of the thickness portion is averaged over the entire thickness portion, and even after repeated compression, the thickness is reduced and the hardness is not easily reduced. The body is obtained. Thereafter, expansion in the thickness direction is constrained in a state where the thickness portion of the three-dimensional structure is compressed.

  In the method for producing a pre-compressed three-dimensional structure according to still another aspect of the present invention, a three-dimensional structure having a binding point in which the intersections of fibers are bound with a binder resin is prepared. The thickness portion of the three-dimensional structure is compressed in the thickness direction. Expansion in the thickness direction is constrained in a state where the thickness portion of the three-dimensional structure is compressed. In a state where the expansion in the thickness direction is constrained, the three-dimensional structure is hardened so that the thickness of the thickness portion is averaged over the entire thickness portion.

  Thus, even if the order of the hardness removing step and the pre-compression step is changed, the hardness of the thickness portion is averaged over the entire thickness portion, and the hardness is reduced even if it is repeatedly subjected to repeated compression thereafter. A pre-compressed three-dimensional structure is obtained that is less likely to occur.

  According to a preferred embodiment of the present invention, the step of constraining expansion in the thickness direction in a state where the three-dimensional structure is compressed covers at least the thickness portion of the three-dimensional structure in a compressed state. A step of covering with a member. The process of covering with the covering member here includes binding with a string at a fine interval.

  The use of the pre-compressed three-dimensional structure obtained in this way is not particularly limited, but seats for various vehicles such as aircraft, high-speed rail vehicles, subway vehicles, buses, surface ships, spacecrafts, Examples of cushion members placed on seats of various seats such as theaters, movie theaters, offices, home chairs, etc., and spring cover members for hiding the presence of springs felt on the buttocks when sitting on the seats it can. In particular, when a carbon fiber three-dimensional structure is used and applied to a cushion for a vehicle such as an aircraft, the weight is reduced as compared with a cushion formed of a conventional polyurethane, and the operating fuel consumption of a vehicle such as an aircraft can be remarkably reduced. Carbon fiber has the property of not burning and clean (good environmental properties).

  According to the present invention, even when subjected to repeated compression, a pre-compressed three-dimensional structure is obtained in which the hardness is unlikely to decrease, and as a result, a feeling of bottoming is prevented, and long-term sitting comfort is good. A cushion or the like that can maintain the state is obtained.

  The purpose of obtaining a pre-compressed three-dimensional structure that has been improved so that the decrease in hardness is less likely to occur even when subjected to repeated compression. This was realized by compressing in the thickness direction and restraining the expansion in the thickness direction of the three-dimensional structure in the compressed state. Embodiments of the present invention will be described below with reference to the accompanying drawings.

  With reference to FIG. 1, the manufacturing method of the three-dimensional structure before preliminary compression is demonstrated first. A fiber material (web) 5 containing a binder resin is laminated on the lower (receiving) mold 6 of the mold. Then, while pressing with the upper mold 7 of the mold, for example, the binder resin is thermoset by heating means such as water vapor to join the fibers and demold to obtain the three-dimensional structure 1. The obtained three-dimensional structure 1 has a three-dimensional network structure having binding points in which the intersections of fibers are bound with a binder resin.

  Next, a method for producing a pre-compressed three-dimensional structure according to the present invention will be described. FIG. 2 is a process diagram of the method for manufacturing the pre-compressed three-dimensional structure according to the first embodiment. 2B to 2E are cross-sectional views taken along line XX in FIG.

  Referring to FIGS. 2A and 2B, the thickness t1 after demolding obtained by the method shown in FIG. 1 has a binding point where the intersection of the fibers is bound with a binder resin. The three-dimensional structure 1 is prepared. With reference to FIG. 2 (C), an applied load of a repeated compression test (described later) is applied to the three-dimensional structure 1 so that the hardness of the thickness portion 1a is averaged over the entire thickness portion 1a. For example, in the case of a seat cushion, the compression treatment is performed several times to several tens of times with a load equal to or higher than 100 kgf) to reduce the hardness (hardness removal). As a result, a three-dimensional structure having a thickness t2 is obtained.

  The concept of hardness removal is shown in FIG. In FIG. 3, the direction perpendicular to the paper surface is the thickness direction. With reference to FIG. 3 (A), before the process of removing the hardness, out of the binding points 4 that connect the fibers CF and the fibers CF, the binding points that are relatively easy to disconnect (incomplete binding points, There is a portion indicated by a white circle), and the hardness is not uniform as a whole. By applying hardness removal, referring to FIG. 3B, a binding point that is relatively easy to come off is removed, and the hardness becomes uniform. Thereby, it returns to FIG.2 (C) and the hardness of the thickness part 1a is averaged over the whole thickness part 1a. That is, the thickness portion 1a at any location in the horizontal direction is set to substantially the same hardness. In addition, the remaining binding point 4 is a strong binding point that is hard to come off in this hardness removing operation, and even if it is repeatedly compressed later, this binding point 4 is not easily removed.

  In this operation of removing the hardness, the binding point is partially removed, so that the hardness decreases and the thickness tries to return to the web (will increase in bulk), but usually the number of fibers that come off is tertiary. Since the total number of fibers constituting the original structure is overwhelmingly small, the detached fibers move to the voids in the three-dimensional structure due to friction during repeated compression, and the change in thickness is apparent. There is little or no tendency to decrease (this is also evident from the fact that the carbon fiber felt is reduced in thickness by repeated compression).

  Referring to FIG. 2D, the thickness portion 1a of the three-dimensional structure 1 is compressed in the thickness direction (hereinafter referred to as pre-compression). As a result, the three-dimensional structure 1 having a thickness t3 is obtained (t3 <t1). The degree of preliminary compression will be described later.

  Referring to FIG. 2 (E), in a state in which the thickness portion 1a of the three-dimensional structure 1 is pre-compressed, it is covered with a covering member (gold width) 2 whose dimension is difficult to change, and the thickness portion 1a in the thickness direction is covered. Restrain the expansion. At this time, the hardness once dropped at the stage of removing the hardness is recovered at that time. Thereby, the pre-compressed three-dimensional structure 3 is obtained.

The pre-compression is performed so that the ratio of improvement in hardness reduction represented by the following formula becomes 10 to 100% when compared under a 25% strain condition.

  That is, the rate of improvement in hardness reduction (%) is obtained from the evaluation results of each separate specimen. For example, a block of a three-dimensional structure is made first, and is divided into two (MN). First, M is coated with a suitable covering member, the initial hardness is measured, and then the compression is repeated 100,000 times, then the hardness is measured again, and the rate of decrease in hardness (%) using the formula described below. Ask for. On the other hand, N is first covered with the same covering member in a pre-compressed state, and the initial hardness is measured in that state. Then, after repeating 100,000 compressions, the hardness is measured again to determine the rate of reduction in hardness (%). From these values, the improvement ratio (%) is obtained using the above formula.

The repeated compression test was performed by attaching the covering member to each three-dimensional structure (M and N) as described above. A load is applied from a direction perpendicular to the plane of the three-dimensional structure so that the major axis direction of the ellipse is parallel to the width direction of the three-dimensional structure using an elliptical plate having an area of 616 cm ² and 100 kgf 100,000 times Was repeated (cycle) test. The repetition (cycle) speed at that time is appropriately selected from 0.1 to 10 times per second, preferably 0.5 to 2 times.

  In addition, the hardness is measured by leaving the three-dimensional structure at a thickness of 3/4 (25% compression) of the original thickness for 20 seconds. The stress was measured and the value was taken as the hardness. FIG. 4 shows the relationship (initial) between the strain and hardness immediately before the 100,000 times compression test and the relationship between the strain and hardness after the 100,000 times compression test of the pre-compressed three-dimensional structure. It was street.

The ratio (%) of reduction in hardness when compared under 25% strain condition was calculated using the following formula.

  Here, the initial hardness (A) is a stress value (hardness value) under a 25% strain condition measured in the state immediately before the 100,000 times repeated compression test. The comparison under the 25% strain condition assumes that a person is sitting on the cushion, for example.

  The pre-compression is performed in order to meet the expected improvement in hardness reduction. More specifically, referring to FIG. 2 again, the thickness of the three-dimensional structure before compression is t1, and after compression, When the thickness of the three-dimensional structure is t3, the ratio of t3 / t1 is set to 0.85 to 0.95. If this ratio is greater than 0.95, no significant effect will appear, and if this ratio is less than 0.85, the sitting comfort will be greatly different from the conventional one, while maintaining the conventional sitting comfort, The object of the present invention, which is to obtain a three-dimensional structure in which the hardness is hardly reduced even when repeatedly compressed, is not satisfied.

  Depending on the strength of the precompression, it is possible to make the elastic body harder than the initial hardness.

  Further, after the step of FIG. 2 (E), sewing such as fold stitching may be performed if necessary. This sewing is performed in order to make it difficult to come off from the pre-compressed three-dimensional structure 3 when using a hook-and-loop fastener (for example, Velcro tape (registered trademark), Velcro tape (registered trademark)).

  With reference to FIG. 5, since the precompressed three-dimensional structure obtained as described above has already been removed from the binding point that is relatively easy to come off, and precompression is applied in the thickness direction, When it is incorporated in the cushion 30 of the stool 11, even if it is further subjected to repeated compression in the thickness direction, the hardness is unlikely to decrease. Therefore, even when subjected to repeated compression, a feeling of bottoming does not occur and the cushion 30 is comfortable to sit on. In FIG. 4, 12 is a base of the seat, 13 is a hook-and-loop fastener, 14 is a backrest, and 15 is an upholstery.

  The hook-and-loop fastener 13 is used for locking with the hook-and-loop fastener disposed on the upper cover 15, and when the pre-compressed three-dimensional structure is attached as a cushioning agent on the base of the seat, 12 is attached to the cushion 30 so as to correspond to each position for the purpose of locking with the hook-and-loop fastener arranged on the top.

  FIG. 6 is a process diagram of the method for manufacturing the pre-compressed three-dimensional structure according to the second embodiment.

  In Example 1, the case of manufacturing in the order of demolding → hardening → coating / sewing in a pre-compressed state → pre-compressed three-dimensional structure was illustrated, but demolding → pre-compression as shown below It may be manufactured in the order of covering and sewing in the state → hardness removal → pre-compressed three-dimensional structure.

  That is, referring to FIG. 6A, a three-dimensional structure 1 having a thickness t4 is prepared, which has a binding point in which the intersection of the fibers is bound with a binder resin.

With reference to FIG. 6B, the thickness portion 1a of the three-dimensional structure 1 is preliminarily compressed in the thickness direction. The pre-compression is performed so that the ratio of improvement in hardness reduction represented by the following formula is 10 to 100% when compared under a 25% strain condition.

  The details are as described above. Here, the three-dimensional structure 1 having a thickness t5 is obtained (t4> t5).

  Referring to FIG. 6C, the thickness portion 1a of the three-dimensional structure 1 is covered with a covering member (gold width) 2 in a pre-compressed state, and the thickness portion 1a of the three-dimensional structure is expanded in the thickness direction. Is restrained. Here, the thickness is t6 (t5 = t6).

  With reference to FIG. 6 (D), in a state where the three-dimensional structure 1 is covered with a gold width, the applied load of the repeated compression test is averaged over the entire thickness portion 1a so that the hardness of the thickness portion 1a is averaged. (For example, 100 kgf in the case of a seat cushion application) A compression treatment is performed several times to several tens of times with a load equal to or higher than that to reduce the hardness. By this hardness removal, a binding point that is relatively easy to come off is removed in advance. As a result, the pre-compressed three-dimensional structure 3 in which the thickness t6 of the three-dimensional structure 1 is t6 <t4 is obtained.

  If necessary, perform sewing such as folding. Even if the pre-compressed three-dimensional structure is formed in this order, the obtained pre-compressed three-dimensional structure 3 is removed in advance from the binding points that are relatively easy to come off, and pre-compressed. Therefore, when it is used as a cushion for a stool, even if it is repeatedly subjected to subsequent compression, the hardness is unlikely to decrease. Therefore, even when subjected to repeated compression, a feeling of bottoming does not occur, and the cushion is comfortable to sit on.

  In the above embodiment, as a method for restraining the thickness portion 1a of the three-dimensional structure in a compressed state in the thickness direction, the case where the entire three-dimensional structure 1 is covered with the covering member 2 is exemplified. Instead of coating, only the thickness portion 1a may be covered to restrain the expansion of the thickness portion 1a in the thickness direction.

  It should be understood that the embodiments disclosed herein are illustrative and non-restrictive in every respect. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  The pre-compressed three-dimensional structure according to the present invention is used for seats for various vehicles such as aircraft, high-speed rail vehicles, subway vehicles, buses, surface ships, spacecrafts, chairs for theaters, movie theaters, offices, homes, etc. It is used as a cushion member disposed on the seats of various seats such as, and a spring cover member for concealing the presence of a spring felt on the buttocks when sitting on the seat.

It is the schematic for demonstrating the manufacturing method of a three-dimensional structure. 6 is a process diagram of a method for producing a pre-compressed three-dimensional structure according to Example 1. FIG. It is a figure which shows the concept of hardness removal. It is a figure which shows the relationship between the distortion and hardness of the pre-compressed three-dimensional structure before and after the 100,000 times compression test. It is a side view of the seat which used the precompressed three-dimensional structure concerning Example 1 for the cushion. 6 is a process diagram of a method for producing a pre-compressed three-dimensional structure according to Example 2. FIG. It is a conceptual diagram of the conventional fiber elastic body.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Three-dimensional structure 1a Thickness part 2 Gold width 3 Pre-compressed three-dimensional structure 4 Binding point

Claims (11)

A three-dimensional structure having a binding point in which the intersections of fibers are bound with a binder resin,
The thickness portion of the three-dimensional structure is compressed in the thickness direction, and the hardness of the thickness portion is averaged over the entire thickness portion, and further, the expansion of the thickness portion in the thickness direction is restricted. Is a pre-compressed three-dimensional structure.   The precompressed three-dimensional structure according to claim 1, wherein the constraint of expansion in the thickness direction is performed by covering at least the thickness portion of the three-dimensional structure with a covering member.   The pre-compressed three-dimensional structure according to claim 1 or 2, wherein the three-dimensional structure includes carbon fiber as a main fiber (50% by weight or more of the fiber material is carbon fiber). The said three-dimensional structure is compressed so that the improvement rate of the hardness reduction | decrease shown to the following formula | equation may become 10 to 100% when compared on 25% strain conditions. A pre-compressed three-dimensional structure according to claim 1.

  The ratio of t / T is 0.85 to 0.95, where T is the thickness of the three-dimensional structure before compression and t is the thickness of the three-dimensional structure after compression. 4. The precompressed three-dimensional structure according to any one of items 3 to 3. A step of preparing a three-dimensional structure having a binding point in which intersections of fibers are bound with a binder resin;
For the three-dimensional structure, a process of removing hardness so that the hardness of the thickness portion is averaged over the entire thickness portion;
Compressing the thickness portion of the three-dimensional structure in the thickness direction;
A method for producing a pre-compressed three-dimensional structure, comprising a step of constraining expansion of the thickness portion in the thickness direction in a state where the thickness portion of the three-dimensional structure is compressed. A step of preparing a three-dimensional structure having a binding point in which intersections of fibers are bound with a binder resin;
Compressing the thickness portion of the three-dimensional structure in the thickness direction;
In a state where the thickness portion of the three-dimensional structure is compressed, restraining expansion in the thickness direction of the thickness portion;
And a step of removing the hardness of the three-dimensional structure so that the hardness of the thickness portion is averaged over the entire thickness portion in a state where the expansion in the thickness direction is constrained. A method for producing a pre-compressed three-dimensional structure.   The step of restraining expansion in the thickness direction in a state where the three-dimensional structure is compressed includes the step of covering the thickness portion with a covering member in a state where at least the thickness portion of the three-dimensional structure is compressed in the thickness direction. A method for producing a pre-compressed three-dimensional structure according to claim 6 or 7.   The method for producing a pre-compressed three-dimensional structure according to any one of claims 6 to 8, wherein the fibers include carbon fibers.   When the thickness of the three-dimensional structure before compression is T and the thickness of the three-dimensional structure after compression is t, the compression is performed so that the ratio of t / T is 0.85 to 0.95. The method for producing a pre-compressed three-dimensional structure according to any one of claims 6 to 9. A cushion for a vehicle disposed in a seat portion of a vehicle including an aircraft and a railway,
A three-dimensional structure having a binding point in which the intersections of fibers are bound with a binder resin,
The thickness portion of the three-dimensional structure is compressed in the thickness direction, and the hardness of the thickness portion is averaged over the entire thickness portion, and further, the expansion of the thickness portion in the thickness direction is restricted. The cushion for the vehicle that is.

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