Carbon fiber multi-corrugated sheet and its manufacturing method, carbon fiber sofa using carbon fiber multi-corrugated sheet and its assembly method

Abstract

To provide a carbon fiber sofa using a carbon fiber multiple corrugated plate and a manufacturing method thereof.SOLUTION: A carbon fiber sofa using a carbon fiber multiple corrugated plate in which a carbon fiber composite material laminate is formed into a corrugated form at a pitch of 10-15 mm includes a base 52 consisting of a front base 52F and a rear base 52b, a back panel 56, a seat panel 58, and right and left side panels 54R(L). A front face of the front base is formed with a front panel 60F having an inclination of 90-120 degrees from a reference direction, and a rear face of the rear base is formed with a rear panel 60B having an inclination of 60-90 degrees from a reference direction. The right and left side panels are fixed to the side faces of the front base and the rear base. The seat panel is fixed above the front base so as to have an inclination of a positive angle of smaller than 30 degrees from the front panel and a reference direction. The back panel is fixed so as to have an inclination of 90-120 degrees from the rear end of the seat panel and the rear panel, and a reference direction.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a carbon fiber multi-corrugated sheet and a manufacturing method thereof, a carbon fiber sofa using a carbon fiber multi-corrugated sheet and a method for assembling the same. [Background technology]

[0002] In recent years, the use of molded products made from carbon fiber composite materials, which are made from carbon fiber reinforced resin, has expanded into fields such as civil engineering and construction, general industrial machinery, energy-related equipment, and transportation equipment.The application of carbon fiber, which began in sports applications in the 1970s, progressed to aerospace applications, and in the 2000s, demand for carbon fiber for industrial applications such as medical X-ray diagnostic equipment, compressed natural gas (CNG) tanks for automobiles, and seismic reinforcement for civil engineering and buildings surpassed demand for sports and aerospace applications.

[0003] Carbon fiber molded products are produced by laminating and curing multiple prepreg sheets, each of which is an intermediate substrate made of carbon fiber impregnated with a curable resin, as shown in Figure 24. When prepregs with reinforcing fibers oriented in one direction are used and multiple sheets are laminated so that the arrangement pattern of the reinforcing fibers after lamination is symmetrical, a quasi-isotropic laminate with nearly isotropic tensile elongation is obtained.

[0004] For example, Patent Document 1 discloses a composite material laminate comprising "a 0°-oriented layer containing carbon fibers oriented at 0° with respect to a reference direction and a resin, and one or more other-direction-oriented layers having a thickness of 0.044 mm or less and containing carbon fibers oriented in a direction other than 0° and a resin, wherein the carbon fibers contained in the 0°-oriented layer and the other-direction-oriented layer are fiber bundles having a maximum height difference on the surface of a single fiber of 30 to 70 nm, an average unevenness of 4 to 10 nm, a ratio of the long axis to the short axis of the cross section of a single fiber of 1.02 to 1.10, and a tensile elongation of 2.2% or more," and similar to the invention of Patent Document 2, provides a composite material laminate with increased tensile strength.

[0005] However, when used in applications where warping needs to be suppressed, such as chair backs, the rigidity of composite laminates may be insufficient, and there is a need for the development of composite laminates that have even higher rigidity than composite laminates that can be produced at low cost using conventional manufacturing methods.

[0006] [Patent Document 1] Patent No. 5821051 [Patent Document 2] Patent No. 5821052 Summary of the Invention [Problem to be solved by the invention]

[0007] Therefore, the present invention provides a carbon fiber multi-corrugated sheet that is more rigid than a flat plate (carbon fiber multi-layer flat plate) made by laminating carbon fiber composite material and has less distortion even at the same thickness, as well as a method for manufacturing the same.As an example of its use, the present invention also provides a carbon fiber sofa using a carbon fiber multi-corrugated sheet and a method for assembling the same. [Means for solving the problem]

[0008] The carbon fiber multi-corrugated plate according to the present invention is a carbon fiber composite laminate having a front surface and a back surface, which is formed by laminating a plurality of flexible sheet-like prepregs containing a plurality of carbon fibers having flexibility and resin permeability and a matrix resin impregnating the carbon fibers, The carbon fiber composite laminate is characterized in that it is formed into a wave shape with a pitch of 10 mm to 15 mm.

[0009] In the following description, a laminate formed by stacking multiple carbon fiber composite materials will be referred to as a "carbon fiber composite laminate," and this "carbon fiber composite laminate" includes a flat carbon fiber multilayer flat plate and a corrugated carbon fiber multilayer corrugated plate formed by stacking carbon fiber composite materials.

[0010] The carbon fiber multi-corrugated sheet according to the present invention is characterized in that three or more layers of sheet-like prepreg are laminated, and the sheet-like prepreg on the top surface and the bottom surface is a woven fabric formed by weaving warp and weft yarns made of carbon fiber bundles.

[0011] The carbon fiber multi-corrugated board according to the present invention is a carbon fiber multi-corrugated board, wherein the fiber direction of the carbon fibers constituting each of the one or more sheet-like prepregs sandwiched between the sheet-like prepregs of the woven fabric on the outermost surface and the outermost surface is oriented in one direction, The fiber direction of the one or more sheet-like prepregs is oriented in the same direction as the warp or weft direction of the woven fabric on the outermost surface and the innermost surface, respectively.

[0012] The carbon fiber multi-corrugated board according to the present invention is a carbon fiber multi-corrugated board in which a plurality of sheet-like prepregs are sandwiched between the sheet-like prepregs of the woven fabric on the outermost surface and the outermost surface, and all of the fiber directions of the plurality of sheet-like prepregs are oriented in one direction, The fiber direction of the plurality of sheet-like prepregs is oriented in the same direction as the direction of the warp or weft of the woven fabric on the top surface and the bottom surface.

[0013] In the carbon fiber multi-corrugated sheet according to the present invention, the fabric may be plain weave, twill weave, or satin weave.

[0014] The carbon fiber sofa of the present invention comprises a base consisting of a front base and a rear base, each having a flat front surface, a flat rear surface, left and right side surfaces, and a bottom surface, a back panel, a seat panel, and left and right side panels, and is placed by abutting the bottom surfaces of the front base and the rear base on a placement surface, The direction from the rear to the front of the sofa in a side view is taken as the reference direction of the placement surface, and clockwise from the reference direction, the front surface of the front base has an inclination of 90 degrees or more and 120 degrees or less from the reference direction, and a front panel is formed on the front surface along the inclination, the rear surface of the rear base has an inclination of 60 degrees or more and 90 degrees or less from the reference direction, and a rear panel is formed on the rear surface along the inclination, the left and right side panels are fixed to the side surfaces of both the front base and the rear base, and the seat panel is located above the front base with a small gap between it and the front panel. the back panel, the seat panel, the left and right side panels, the front panel are fixed to the left and right side panels and / or the front base with a small gap between them or in contact with them to obtain a tilt at a positive angle of less than 30 degrees clockwise from a reference direction, and the back panel is fixed to the left and right side panels and / or the rear base with a small gap between them or in contact with the rear end of the seat panel and the rear panel to cover the front and upper parts of the rear base to obtain a tilt at an angle of 90 degrees or more and 120 degrees or less clockwise from the reference direction; and A carbon fiber sofa in which all panels of the rear panel are made of carbon fiber composite laminates, At least one of the panels is made of the carbon fiber multi-corrugated sheet.

[0015] In the carbon fiber sofa according to the present invention, the front base and the rear base may be made of a carbon fiber composite material.

[0016] The carbon fiber sofa of the present invention is characterized in that the seat panel is fixed to the left and right side panels and / or the front base above the front base with a small gap between it and the front panel or in contact with it, and its front end protrudes forward from the front panel.

[0017] The carbon fiber sofa of the present invention is characterized in that the back panel, which is fixed to the left and right side panels and / or the rear base, has its upper end protruding above the rear panel so as to cover the front and upper part of the rear base with a small gap between it and the rear end of the seat panel and the rear panel or in contact with it.

[0018] The carbon fiber sofa according to the present invention is a sofa assembled from a front base having front insertion portions on the left and right sides, a rear base having rear insertion portions on the left and right sides, a back panel, a seat panel, and left and right side panels, The left and right side panels have front insertion pieces and rear insertion pieces that can be fitted into the front insertion portion and the rear insertion portion, respectively, and also have seat guide pieces that allow the seat panel to slide in an approximately horizontal direction, rear guide pieces that allow the back panel to slide in an approximately vertical direction, and a rear insertion portion below that supports the lower end of the back panel, and the front insertion pieces and rear insertion pieces of the left and right side panels are fitted into the left and right front insertion portions of the front base and the left and right rear insertion portions of the rear base, respectively, the back panel is guided by the rear guide pieces of the left and right side panels and fixed to the rear insertion portions, and the seat panel is guided by the seat guide pieces of the left and right side panels and fixed to

[0019] The carbon fiber sofa according to the present invention is the carbon fiber sofa, The seat guide piece, which allows the seat panel to slide in a substantially horizontal direction, is a hollow body that is open at the front and closed at the rear by a stopper St, and has a gap Sp inside, with a groove cut in the upward direction, and is attached to the seat panel side of the left and right side panels by mounting pieces, and a seat slide piece from which a slider Sl that fits into the gap Sp of the seat guide piece protrudes is attached to the underside of the seat panel by the mounting piece so that the slider Sl protrudes downward, and the slider Sl that protrudes downward of the seat panel is inserted into the gap Sp of the hollow body up to the stopper St through the grooves of the seat guide pieces attached to the left and right side panels and fits into it, and the seat panel is fixed to the left and right side panels.

[0020] The carbon fiber sofa according to the present invention is the carbon fiber sofa, The rear guide piece, which allows the rear panel to slide in an approximately vertical direction, is a hollow body that is open at the top and closed at the bottom by a stopper St, and has a gap Sp inside, with a groove cut in the front, and is attached to the seat panel side of the left and right side panels by mounting pieces, and a rear slide piece from which a slider Sl that fits into the gap Sp of the rear guide piece protrudes is attached to the back surface of the rear panel by the mounting piece so that the slider Sl protrudes rearward, and the slider Sl protruding rearward of the rear panel is inserted into the gap Sp of the hollow body up to the stopper St through the grooves of the rear guide pieces attached to the left and right side panels and fits into them, and the lower end of the rear panel is guided into the rear insertion portion of the left and right side panels and fixed to the rear insertion portion.

[0021] The carbon fiber sofa according to the present invention comprises a front base, which is a quadrangular prism with square sides, having a front surface, a rear surface, a top surface, and a bottom surface, with the front panel formed on the front surface, and a rear base, which is a triangular prism with triangular sides, having a front surface, a rear surface, and a bottom surface, with the rear panel formed on the rear surface, and the bases are integrally molded at their joints; the back panel has a fitting portion near its lower end; the seat panel; and the left and right side panels. The upper surface of the front base is inclined clockwise from the reference direction at a positive angle of less than 30 degrees, and the front surface of the rear base is inclined clockwise from the reference direction at an angle of 90 degrees or more and 120 degrees or less. At the joint where these two bases are joined, a rear insertion portion is formed along the slope of the front surface of the rear base, into which the mating portion of the rear panel can be inserted. The left and right side panels are adhered to the sides of the base, and the seat panel is adhered to the upper surface of the base. The rear panel is inserted into the rear insertion portion along the front slope of the rear base, and the mating portion of the rear panel is removably fitted into the rear insertion portion.

[0022] In the carbon fiber sofa of the present invention, the front panel and / or the rear panel may be integrally molded with the front surface of the front base and / or the rear surface of the rear base.

[0023] In the carbon fiber sofa of the present invention, the left and right width of the fitting portion of the back panel is approximately the same as the left and right width of the back insertion portion, and the left and right width above the fitting portion can be formed narrower than the left and right width of the fitting portion.

[0024] The carbon fiber sofa of the present invention is a carbon fiber sofa in which the left and right side panels are formed from carbon fiber multi-corrugated sheets, and at least a portion of the adhesive portion of the side of the base to which the left and right side panels are adhered may be molded into a wave shape with the same pitch as the wave pitch of the carbon fiber multi-corrugated sheets that form the left and right side panels.

[0025] The method for assembling a carbon fiber sofa according to the present invention comprises the steps of: (1) preparing a front base having front insertion portions on left and right side surfaces and a rear base having rear insertion portions on left and right side surfaces; (2) preparing a back panel and a seat panel, both of which are made of carbon fiber multi-corrugated panels; (3) preparing left and right side panels made of carbon fiber multi-corrugated sheets, each having a front insertion piece and a rear insertion piece that can be fitted into the front insertion part and the rear insertion part, respectively, and each having a seat guide piece that allows the seat panel to slide in a substantially horizontal direction, a back guide piece that allows the back panel to slide in a substantially vertical direction, and a back insertion part below the seat guide piece that supports the lower end of the back panel; (4) fitting the front insertion pieces and rear insertion pieces of the left and right side panels into the left and right front insertion portions of the front base and the left and right rear insertion portions of the rear base, respectively; (5) The rear panel is guided by the rear guide pieces of the left and right side panels and fixed to the rear insertion portion, a step of guiding and fixing the seat panel along the seat guide pieces of the left and right side panels; Includes. [Effects of the Invention]

[0026] The carbon fiber multi-corrugated panel of the present invention is made by laminating multiple sheets of prepreg and forming them into a corrugated shape with a pitch of 10 mm to 15 mm. Therefore, while maintaining the flexibility of a carbon fiber composite laminate, the rigidity in the direction perpendicular to the wave direction is higher than that of conventional flat carbon fiber composite laminates, making it possible to provide a carbon fiber panel with higher breaking strength for the same thickness. Note that "rigidity" is roughly synonymous with elasticity and refers to hardness or softness (flexibility). Also, "breaking strength" is hereinafter referred to as "breaking strength" or simply "strength" or "toughness," and refers to the strength with which a carbon fiber composite laminate or the like can withstand an external force such as a tensile force or bending stress without breaking when the external force is applied to the carbon fiber composite laminate or the like.

[0027] The carbon fiber sofa of the present invention is composed of a base, a back panel, a seat panel, and left and right side panels, and by forming all of the panels, including the front and rear panels formed on the entire front and rear of the base, from carbon fiber composite laminates, a lightweight and high-strength sofa can be realized.In other words, because lightweight and high-strength carbon fiber composite material is used throughout, the sofa can be made about 1 / 10 to 1 / 15 the weight of a conventional sofa while maintaining its weight-bearing properties.

[0028] Furthermore, by forming at least one of the panels from a carbon fiber multi-corrugated sheet, it is possible to provide a carbon fiber sofa with higher rigidity and breaking strength. That is, if the carbon fiber multi-corrugated sheet of the present invention is used for the back panel and seat panel and fixed to a base made of a carbon fiber composite laminate, it is possible to provide a sofa with a backrest and seat panel that are strong and have an appropriate curvature or deflection.

[0029] Furthermore, the carbon fiber sofa of the present invention is configured so that, with the direction from the rear to the front of the sofa in a side view as the reference direction for the placement surface, the front surface of the front base is inclined at an angle of 90 degrees to 120 degrees, the rear surface of the rear base is inclined at an angle of 60 degrees to 90 degrees, the seat panel is inclined at a positive angle of less than 30 degrees, and the back panel is inclined at an angle of 90 degrees to 120 degrees, all in a clockwise direction from the reference direction, and coupled with the fact that the entire exterior is made of carbon fiber composite laminates, it is possible to provide a sofa that exudes elegance and luxury, is comfortable to sit on, and does not cause fatigue.

[0030] In this carbon fiber sofa according to the present invention, the seat panel located above the front base is fixed to the front panel with a small gap between them, thereby preventing the generation of friction noises caused by rubbing between the panels. Furthermore, by making the front end of the seat panel protrude forward from the front panel, the soft, elastic front end comes into contact with the backs of the knees of the sitter, generating a moderate amount of curvature and flexure. This allows the sitter to secure a comfortable seating position and posture without having to shift their seating position excessively or losing their posture according to their physique, resulting in a comfortable sitting experience that reduces fatigue.

[0031] Similarly, by fixing the back panel, which is arranged to cover the front and upper parts of the rear base, with a small gap between the rear end of the seat panel and the rear panel, it is possible to prevent the generation of fretting noises caused by rubbing between the panels. Furthermore, by making the upper end of the back panel protrude above the rear panel, the upper end of the soft, elastic back panel can bend and flex appropriately, providing a comfortable seating experience that reduces fatigue.

[0032] This carbon fiber sofa, which is an example of the carbon fiber sofa according to the present invention, can be disassembled and carried around because all of the components, including the front base, rear base, back panel, seat panel, and left and right side panels, can be assembled and disassembled freely using a knock-down method. The total weight after disassembly is very light, at 5 to 6 kg, which significantly reduces the cost of transportation by air, etc.

[0033] Furthermore, in another example of a fixed carbon fiber sofa, the front and rear bases are integrally molded at their joints to form a single base, and a back insert part is formed at this joint into which the fitting part of the back panel can be inserted, so that only the back panel is detachably fitted into the back insert part, thereby increasing the stability and strength of the entire sofa. In other words, the left and right side panels are glued to the sides of the base, and the seat panel is fixed to the top surface of the base, resulting in high stability and strength.

[0034] In addition, in the fixed carbon fiber sofa, the left and right width of the fitting portion on the back panel is made to approximately match the left and right width of the back insertion portion, and the left and right width above the fitting portion is made narrower than the left and right width of the fitting portion, thereby avoiding contact between the back panel and the left and right side panels and preventing the generation of scraping noise due to rubbing between the panels.

[0035] Furthermore, in a carbon fiber sofa in which the left and right side panels are formed from carbon fiber multi-corrugated sheets, at least a portion of the adhesive area on the side of the base to which the left and right side panels are adhered can be molded into a wave shape with the same pitch as the wave pitch of the carbon fiber multi-corrugated sheets that form the left and right side panels, thereby increasing the adhesive area between the left and right side panels and the base and firmly adhering them to each other.

[0036] A durability test was conducted on a prototype of this fixed carbon fiber sofa according to the present invention at the Gifu Prefectural Institute of Living Technology, and the results showed that the seat and backrest were sufficiently durable. Furthermore, a rigidity test and simulation was conducted on a prototype of this fixed carbon fiber sofa according to the present invention at the Fukui Prefectural Industrial Technology Center, and it was found that the sofa was strong enough to withstand a person weighing just under 100 kg (approximately 97 kg), with the front of the seat panel displacing about 6 to 10 cm and the upper part of the back panel displacing about 10 cm, confirming that sufficient warping or bending occurred while ensuring the safety of both panels. [Brief explanation of the drawings]

[0037] [Figure 1] 1 is a cross-sectional view of a carbon fiber multi-corrugated plate according to the present invention. [Figure 2] Schematic plan and cross-sectional views of a woven sheet-like prepreg. [Figure 3] 1 is a side perspective view of a carbon fiber sofa according to the present invention. [Figure 4] 1 is a perspective view of a carbon fiber sofa according to the present invention; [Figure 5] 1 is a perspective photograph of a carbon fiber sofa according to the present invention. [Figure 6] FIG. 2 is a side view of a side panel of the prefabricated carbon fiber sofa according to the embodiment. [Figure 7] FIG. 2 is a front view of the right side panel of the prefabricated carbon fiber sofa according to the embodiment. [Figure 8] In the assembled carbon fiber sofa according to the embodiment, (a) is a front view of the seat panel, and (b) is a side view of the seat slide piece attached to the underside of the seat panel from the side pipe of the seat panel. [Figure 9] (a) Plan view, (b) AA cross-sectional view, and (c) BB cross-sectional view of a seat guide piece or a back guide piece attached to a seat panel or a side panel that constitutes an assembled carbon fiber sofa according to an embodiment. [Figure 10] (a) Front view, (b) side view, and (c) AA plan view of the back insert part that supports the lower end of the back panel that constitutes the knockdown carbon fiber sofa according to the embodiment. [Figure 11] (a) rear view, (b) side view, and (c) plan view of the rear sliding piece of the rear panel that constitutes the assembled carbon fiber sofa of the embodiment. [Figure 12] 10 is a cross-sectional view of a slide piece and a guide piece attached to a seat panel, a back panel, or a side panel in an assembled carbon fiber sofa according to an embodiment. FIG. [Figure 13] FIG. 1 is a side perspective view of a knockdown carbon fiber sofa according to an embodiment. [Figure 14(a)] FIG. 10 is a side perspective view of a fixed carbon fiber sofa according to another embodiment. [Figure 14(b)]A side view of a base that constitutes a fixed carbon fiber sofa according to another embodiment. [Figure 15] (a) A front view of the back panel of the carbon fiber sofa according to the present invention, and (b) an enlarged front view of the fitting portion of the back panel. [Figure 16(a)] Schematic side view of a side panel made of a carbon fiber multi-corrugated sheet of a fixed carbon fiber sofa according to an embodiment. [Figure 16(b)] Schematic side view of a base with a corrugated side surface for a fixed carbon fiber sofa according to an embodiment. [Figure 16(c)] FIG. 10 is a side view of a base of a fixed carbon fiber sofa according to an embodiment, the side of which is partially corrugated. [Figure 17] FIG. 1 is a perspective view of a mold for making a base having a wavy side for a fixed carbon fiber sofa according to an embodiment of the present invention. [Figure 18] (a) A perspective photograph of the bottom of a fixed carbon fiber sofa according to an embodiment, (b) A perspective photograph of the bottom of a fixed carbon fiber sofa according to another embodiment. [Figure 19] (a) A schematic front view of the back panel of a carbon fiber sofa according to the present invention, showing the specific position where a load of 330 N (33.7 kg) is uniformly applied to the back panel, and (b) a perspective view of the carbon fiber sofa created by 3D CAD. [Figure 20] (a) Schematic front view of the seat panel showing the specific position where a load of 950N (96.9Kg) is applied uniformly to the seat panel of the carbon fiber sofa of the present invention, (b) a perspective view of the carbon fiber sofa created by 3D CAD (when the load is applied to the entire surface), and (c) a perspective view of the carbon fiber sofa created by 3D CAD (when the load is applied only to the front). [Figure 21] These are 3D CAD oblique views of a carbon fiber sofa showing the simulation results of applying uniform loads of 330N (33.7Kg) and 950N (96.9Kg) to specific positions on the back panel and seat panel of a carbon fiber sofa according to the present invention, where (a) is a perspective view showing the displacement of the back panel, (b) is a perspective view showing the displacement of the seat panel (when the load is applied to the entire surface), and (c) is a perspective view showing the displacement of the seat panel (when the load is applied only to the front). [Figure 22](a) A perspective view showing the static strength test of the seat, (b) a perspective view showing the static strength test of the backrest, and (c) a perspective view showing the durability test of the seat and backrest of the carbon fiber sofa of this embodiment. [Figure 23] 1 is a flow diagram showing a manufacturing process of a carbon fiber multi-corrugated plate according to the present invention. [Figure 24] FIG. 1 is a perspective schematic diagram of a prepreg. [Figure 25] FIG. 1 is a graph of test force (N) versus bending deflection (mm) according to an example. BEST MODE FOR CARRYING OUT THE INVENTION

[0038] Hereinafter, with reference to the drawings, (1) a carbon fiber multi-corrugated sheet, (2) a manufacturing method of a carbon fiber multi-corrugated sheet, (3) a carbon fiber sofa using a carbon fiber multi-corrugated sheet, and (4) a method of assembling a carbon fiber sofa according to the present invention will be described using embodiments and examples. Note that the same reference numerals will be used for the same components throughout the drawings. (1) Carbon fiber multi-corrugated sheet

[0039] (carbon fiber multi-corrugated sheet) The carbon fiber multi-corrugated board 1 according to the present invention is a carbon fiber composite laminate having a front surface and a back surface, formed by laminating a plurality of flexible sheet-like prepregs 2 (see FIG. 24) containing a plurality of flexible and resin-permeable carbon fibers 4 and a matrix resin 6 that impregnates the same, as shown in FIG. 1. The carbon fiber multi-corrugated board 1 according to the present invention is characterized in that the carbon fiber composite laminate is formed into a wave shape with a pitch of 10 mm to 15 mm.

[0040] For example, commercially available polycarbonate corrugated sheets are classified into small corrugated steel sheet type (32 corrugated sheet), small corrugated slate type (63 corrugated sheet), large corrugated steel sheet type (76 corrugated sheet), and large corrugated slate type (130 corrugated sheet), and their pitches are 32 mm, 63 mm, 76 mm, and 130 mm, respectively.Compared to these polycarbonate corrugated sheets, the pitch of the carbon fiber multi-corrugated sheet 1 of the present invention is very small, making it difficult to mold.

[0041] As shown in Fig. 24, for example, a unidirectional sheet-like prepreg 2 is made by impregnating a plurality of carbon fibers 4 having flexibility and resin permeability with a matrix resin 6. The thickness of the sheet-like prepreg 2 is, for example, 0.1 mm, and the weight per unit area is 40 g / m. 2 However, the thickness and basis weight are not limited to these and can be set as appropriate.

[0042] The carbon fiber multi-corrugated board 1 of the present invention is characterized in that three or more layers of sheet-like prepreg 2 are laminated, and the sheet-like prepreg 2 on the top surface and the bottom surface is a woven sheet-like prepreg 3 (hereinafter also referred to as "woven fabric 3") constructed by weaving warp and weft yarns made of carbon fiber bundles 5 each formed by binding carbon fibers 4. The weave of this woven fabric 3 may be a plain weave, twill weave, satin weave, or the like, as shown in Figures 2(a) to (c), but is not particularly limited as long as it is a woven fabric formed by weaving warp and weft yarns, and may also be a figured weave, for example. By using woven sheet-like prepreg 3 for the top surface and the bottom surface of the sheet-like prepreg 2, the design of the carbon fiber multi-corrugated board 1 of the present invention can be improved and it can have a beautiful appearance.

[0043] The one or more sheet-like prepregs 2 sandwiched between the sheet-like prepregs 3 of the outermost and innermost woven fabrics are preferably oriented such that the fiber direction of the carbon fibers 4 constituting each sheet-like prepreg 2 is unidirectional. Furthermore, it is desirable that the fiber direction of the one or more sheet-like prepregs 2 is oriented in the same direction as the warp or weft direction of the outermost and innermost woven fabrics 3, respectively.

[0044] Furthermore, in the carbon fiber multi-corrugated board 1 of the present invention, a plurality of sheet-like prepregs 2 are sandwiched between the sheet-like prepregs 3 of woven fabric on the top surface and the bottom surface, and it is preferable that all of the fibers of the plurality of sheet-like prepregs 2 are oriented in one direction. It is also preferable that the fiber direction of the plurality of sheet-like prepregs 2 is oriented in the same direction as the warp or weft direction of the woven fabric 3 on the top surface and the bottom surface. (2) Manufacturing method of carbon fiber multi-corrugated sheet

[0045] A method for manufacturing a carbon fiber multi-corrugated board 1 according to the present invention will be described below with reference to Fig. 23. Note that this method for manufacturing a carbon fiber multi-corrugated board 1 is one example, and the method for manufacturing a carbon fiber multi-corrugated board 1 according to the present invention is not intended to be limited to this.

[0046] (1) First, the sheet-like prepregs 2 to be laminated are selected and cut to a predetermined size. (2) A plurality of cut sheets of prepreg 2 are laminated to form a preform from the laminate. (3) A preform made of a laminate of sheet-like prepregs 2 is sandwiched between concave-convex forming jigs from above and below to form concave-convex shapes. (4) The preform is covered with a bag film together with the concave-convex molding jig that holds it, the periphery is sealed with a sealing material, and the inside of the bag film is vacuumed to reduce the pressure. (5) The preform, together with the uneven molding jig covered with the bag film, is placed in an autoclave and heated and pressurized.

[0047] [Irregularity forming process] In step (3), the upper and lower dies that make up the uneven molding jig have inner surfaces that come into contact with the preform and are wavy with a pitch of 10 mm to 15 mm. By pressing the preform with the upper and lower dies, the preform can be molded into a wave shape with a desired pitch within 10 mm to 15 mm.

[0048] In step (4), when forming recesses on the outer surface of the preform, it is preferable to heat the preform in advance to facilitate deformation. This heating is sufficient as long as the preform is softened, and can be suitably carried out at, for example, 50°C to 120°C. If the preform (laminate of sheet-like prepregs 2) is heated to 50°C or higher, the resin can be sufficiently softened, and if it is heated to 120°C or lower, the resin will not harden before molding.

[0049] [Compression process] In step (5), heat and pressure are applied using an autoclave to form the molded body. The preform (laminate of sheet-like prepregs 2) sandwiched between the concave-convex molding jigs is vacuumed together with the concave-convex molding jigs in a bag film, and then pressurized in the autoclave. The molding pressure is preferably 1 MPa or higher. If the molding pressure is 1 MPa or higher, a molded body with high density can be obtained. There is no upper limit to the molding pressure, but since the first binder is softened by applying heat, a pressure of 10 MPa can be applied to obtain a molded body with sufficient density.

[0050] In the pressure molding process, after the pressure has been sufficiently increased, it is preferable to heat the molded product to melt and harden the matrix resin 6, which is a thermosetting resin contained in the sheet-like prepreg 2. This allows the molded product to be fixed in shape so that it does not deform. The curing temperature of the matrix resin 6 can generally be set at 150°C or higher. The higher the temperature, the more rapidly the thermosetting resin hardens. If the molding process is performed in an autoclave, for example, and sufficient heating is possible during the molding process, the curing process can also be performed simultaneously with the molding process. There is no particular upper limit to the curing temperature, but the thermosetting resin can be sufficiently hardened by applying a temperature of 200°C.

[0051] Through the above steps (1) to (5), a multi-corrugated carbon fiber sheet 1 according to the present invention can be obtained, which is formed into a wave shape at a desired pitch within a range of 10 mm to 15 mm. Example 1

[0052] The stiffness of carbon fiber multi-corrugated sheet 1 and carbon fiber multi-corrugated sheet was compared through bending experiments. The four-point bending test according to JIS K7074 was used as the experimental method. Three carbon fiber multi-corrugated sheets 1 and three carbon fiber multi-corrugated sheets, each approximately 15 mm x 100 mm in size, were prepared as specimens for the bending tests. The average size of the measured carbon fiber multi-corrugated sheets was 1.161 mm thick and 14.965 mm wide. The average size of the measured carbon fiber multi-corrugated sheet 1 was 1.135 mm thick and 14.979 mm wide. The carbon fiber multi-corrugated sheet 1 had twill weave 3 on the top and bottom surfaces of the prepreg sheets. Three unidirectional prepreg sheets 2 were sandwiched between the twill weave 3 so that the fiber direction of all three sheets was the same as the warp or weft direction of the twill weave 3. The carbon fiber multi-corrugated sheet was a carbon fiber composite laminate with the fiber direction of all five sheets aligned.

[0053] [Table 1]

[0054] [Table 2]

[0055] The graph in Figure 25 was obtained as a result of the experiment. The left graph shows the measurement results of the test force (N) versus deflection (mm) for five-fold corrugated sheet specimens 1 to 3, and the right graph shows the measurement results for the five-fold flat sheet specimen. The average slope of the left line was 844 (N / mm), and the average slope of the right line was 102 (N / mm). This shows that carbon fiber multi-corrugated sheet 1 is 8.27 times less likely to bend than the carbon fiber multi-fold flat sheet.

[0056] Furthermore, from the table above, the maximum point test force for corrugated sheets is 861.913 (N) to 88 (kgf), while the maximum point test force for flat sheets is 630.53 (N) to 64 (kgf). Therefore, it can be seen that a force 1.37 times that of a flat sheet is required to bend and destroy a corrugated sheet.

[0057] Furthermore, regarding the maximum point stress, from the table above, the maximum point stress of the corrugated sheet is 2144.09 (MPa) ~ 219 × 10 6 (kg weight / mm 2 ), the maximum point stress of the plate is 1499.42 (MPa) ~ 153 × 10 6 (kg weight / mm 2 ), it can be seen that, to break a corrugated sheet in bending, a bending stress 1.37 times that of a flat sheet is required, similar to the maximum point test force. In this example, a four-point bending test was performed, so the bending breaking strength σ and bending modulus E were calculated using the following formulas.

number

number

[0058] As described above, the carbon fiber multi-corrugated sheet 1 is highly durable, strong, and lightweight, and is therefore expected to be widely used as a component of furniture and other structures. As an example, an embodiment and several examples of a carbon fiber sofa using the carbon fiber multi-corrugated sheet 1 will be described below. In the drawings relating to the carbon fiber sofa, the up, down, front, back, left, and right directions when sitting on the sofa will be referred to as the up, down, front, back, left, and right directions of the sofa.

[0059] (Carbon fiber sofa 50) The carbon fiber sofa 50 according to the present invention, the photograph of which is shown in FIG. 5, comprises a base 52, a back panel 56, a seat panel 58, and left and right side panels 54 (54L, 54R) as its constituent elements. The base 52 is comprised of a front base 52F and a rear base 52B, each of which has a flat front surface (52Ff, 52Bf), a rear surface (52Fb, 52Bb), left and right side surfaces 52s (52Fs, 52Bs), and a bottom surface 52d (52Fd, 52Bd) (see FIG. 3). The shapes of the front base 52F and the rear base 52B are not particularly limited as long as they have the above-mentioned surfaces, and may also have a shape that includes a top surface (52Fu, 52Bu) as shown in FIG. 3.

[0060] 3 is a side perspective view of the carbon fiber sofa 50 according to the present invention, which is placed with the bottom surfaces 52d (52Fd, 52Bd) of the front base 52F and the rear base 52B in contact with a placement surface. In the following description, as shown in FIG. 3, the direction from the rear to the front of the carbon fiber sofa 50 in a side view is set as the reference direction of the placement surface, and angles are measured clockwise from this reference direction. Below, the above-mentioned components of the carbon fiber sofa 50 according to the present invention and their configuration will be described mainly with reference to FIG. 3.

[0061] (Base) In the carbon fiber sofa 50 of the present invention, the front surface 52Ff of the front base 52F is inclined at an angle of 90 to 120 degrees from the reference direction, and the front panel 60F is formed on the front surface 52Ff along this inclination. Also, the rear surface 52Bb of the rear base 52B is inclined at an angle of 60 to 90 degrees from the reference direction, and the rear panel 60B is formed on the rear surface 52Bb along this inclination.

[0062] (Side panel) Next, the left and right side panels 54 (54L, 54R) are fixed to the side surfaces 52s (52Fs, 52Bs) of both the front base 52F and the rear base 52B. For safety and decorative purposes, it is desirable to attach a pipe 20 with a circular cross section and pipe covers 22 (see Figure 8(a)) attached to both ends to the upper ends of the left and right side panels 54 (54L, 54R). The pipe 20 has a linear notch along its length, and the end of a panel such as the side panel 54 can be inserted into this notch and fixed to the end of the panel.

[0063] (Seat panel) The seat panel 58 is fixed to the left and right side panels 54 (54L, 54R) and / or the front base 52F above the front base 52F with a small gap between it and the front panel 60F or in contact with it, so as to be tilted at a positive angle of less than 30 degrees clockwise from the reference direction. If pipes 20 are also attached to the front and rear ends of the seat panel 58, it is possible to avoid the risk of the exposed ends of the seat panel 58 coming into contact with objects or people and causing damage.

[0064] (rear panel) Furthermore, the back panel 56 is fixed to the left and right side panels 54 (54L, 54R) and / or the rear base 52B so as to cover the front and upper parts of the rear base 52B, with a small gap between or in contact with the rear end of the seat panel 58 and the rear panel 60B, and to be tilted at an angle of 90 degrees to 120 degrees clockwise from the reference direction. As shown in FIG. 15(a), the back panel 56 preferably has a backrest portion 56Q and a fitting portion 56R, and the pillow portion 56P is connected to the upper end of the backrest portion 56Q. Pipes 20 may be attached to the upper and lower ends of the pillow portion 56P, and the pillow portion 56P may be connected to the pipe 20 attached to the lower end.

[0065] (material) In the carbon fiber sofa 50 according to the present invention having such a configuration, it is desirable that all of the panels, including the back panel 56, seat panel 58, left and right side panels 54 (54L, 54R), front panel 60F, and rear panel 60B, are formed from carbon fiber composite laminates. The carbon fiber sofa 50 according to the present invention is characterized in that at least one of these panels is made of a carbon fiber multi-corrugated panel 1.

[0066] In the carbon fiber sofa 50 of the present invention, the front base 52F and the rear base 52B may be made of a carbon fiber composite material, but they may also be made of other materials such as low-cost glass fiber, as this does not affect the appearance.

[0067] (Features) Furthermore, in the carbon fiber sofa 50 according to the present invention, as described above, the seat panel 58 is fixed to the left and right side panels 54 (54L, 54R) and / or the front base 52F above the front base 52F with a small gap between it and the front panel 60F or in contact with it, but its front end protrudes forward of the front panel 60F. This protruding front end of the seat panel 58 is the portion against which the backs of the knees of a person sitting on the carbon fiber sofa 50 come into contact, and this front end has elasticity not found in conventional chairs or sofas. This elasticity allows the front end of the seat panel 58 to flex in accordance with the physique and posture of the person sitting on the carbon fiber sofa 50. Therefore, the carbon fiber sofa 50 according to the present invention can solve the problem of conventional sofas where the front end of the seat is fixed with almost no flex, forcing small people to sit shallowly, which in turn leads to poor posture and makes it difficult to relax. The elasticity of the seat panel 58 is related to the hardness or softness of the seating surface felt by the person sitting on it, and the carbon fiber composite laminate can be pre-selected according to the user's preference by selecting a soft carbon fiber multi-layer flat panel or a harder carbon fiber multi-corrugated panel 1.

[0068] As described above, the back panel 56 is fixed to the left and right side panels 54 (54L, 54R) and / or rear base 52B with a small gap between it and the rear end of the seat panel 58 and the rear panel 60B, or in contact with it, so as to cover the front and upper parts of the rear base 52B, but the carbon fiber sofa 50 according to the present invention is characterized in that its upper end protrudes above the rear panel 60B. For this rear panel 60B as well, a soft carbon fiber multilayer flat panel or the harder carbon fiber multilayer corrugated panel 1 of the present invention can be selected in advance according to the user's preference. (3-1) Assembled carbon fiber sofa (knock-down carbon fiber sofa) Example 2

[0069] In this second embodiment, an assembly-type carbon fiber sofa 50A (knock-down type carbon fiber sofa) in which all components can be freely assembled and disassembled will be described.

[0070] As shown in Fig. 13 (side perspective view), Fig. 4 (perspective view), and Fig. 5 (perspective photograph), the carbon fiber sofa 50A according to this embodiment is a sofa assembled from a front base 52F having front insertion portions 523F on the left and right side surfaces 52Fs, a rear base 52B having rear insertion portions 523B on the left and right side surfaces 52Bs, a back panel 56, a seat panel 58, and left and right side panels 54 (54L, 54R), all of which are made of carbon fiber multi-corrugated sheets 1. It is preferable that the carbon fiber sofa 50A of this embodiment use carbon fiber multi-corrugated sheets 1 and / or carbon fiber multi-flat sheets for the front base 52F and the rear base 52B.

[0071] In the carbon fiber sofa 50A according to this embodiment, the left and right side panels 54 (54L, 54R) have front insertion pieces 541F and rear insertion pieces 541B that can be fitted into the front insertion parts 523F and rear insertion parts 523B (see FIG. 13) attached to the front base 52F and rear base 52B, respectively, as shown in FIG. 6. The left and right side panels 54 (54L, 54R) also have seat guide pieces 543 (543F, 543B) that allow the seat panel 58 to slide in a substantially horizontal direction, a back guide piece 545 that allows the back panel 56 to slide in a substantially vertical direction, and a back insertion part 547 below that supports the lower end (fitting part 56R) of the back panel 56.

[0072] The front insertion pieces 541F and rear insertion pieces 541B of the left and right side panels 54 (54L, 54R) are fitted into the left and right front insertion portions 523F of the front base 52F and the left and right rear insertion portions 523B of the rear base 52B, respectively, and the left and right side panels 54 (54L, 54R) are fixed to the front base 52F and the rear base 52B (see FIG. 13). In this manner, it is preferable to attach the back panel 56 and the seat panel 58 with the left and right side panels 54 (54L, 54R) fixed to the base 52 (front base 52F and rear base 52B).

[0073] That is, the back panel 56 is guided by the back guide pieces 545 of the left and right side panels 54 (54L, 54R) and fixed to the back insertion parts 547, and the seat panel 58 is guided by the seat guide pieces 543 (543F, 543B) of the left and right side panels 54 (54L, 54R), and the carbon fiber sofa 50A according to this embodiment can be assembled as shown in Figure 13 (and Figure 5). Such an assemblable carbon fiber sofa 50A can be easily disassembled into the front base 52F, the rear base 52B, the back panel 56, the seat panel 58, and the left and right side panels 54 (54L, 54R).

[0074] (Seat panel) In the carbon fiber sofa 1 shown in Figures 6 and 13, the seat surface guide pieces 543 that allow the seat surface panel 58 to slide in a substantially horizontal direction can be attached to the seat surface panel 58 sides of the left and right side panels 54 (54L, 54R) by attachment pieces 542, for example, a front seat surface guide piece 543F and a rear seat surface guide piece 543B, as shown in Figure 7. As shown in Figures 7 and 9(a) to (c), the seat surface guide pieces 543 (543F, 543B) are hollow bodies that are open at the front and closed at the rear by a stopper St, have an internal space Sp, and have a groove cut in the upward direction.

[0075] 8(a) and 8(b), the seat panel 58 has seat slide pieces 581 (front seat slide piece 581F, rear seat slide piece 581B) from which protruding sliders Sl that fit into the gaps Sp of the seat guide pieces 543 (543F, 543B) are attached to its underside by attachment pieces 542 so that the sliders Sl protrude downward. The sliders Sl that protrude downward from the seat panel 58 are inserted into the gaps Sp of the hollow body up to the stoppers St and fitted into them through the grooves of the seat guide pieces 543 attached to the left and right side panels 54 (54L, 54R). That is, the seat slide pieces 581 (front seat slide piece 581F, rear seat slide piece 581B) of the seat panel 58 are fitted into and fixed to the seat guide pieces 543 (543F, 543B) of the left and right side panels 54 (54L, 54R) (see Figure 12).

[0076] (rear panel) In the carbon fiber sofa 1 assembled as shown in Fig. 13 (and Fig. 5), the back panel 56 is slidable in a substantially vertical direction by the back guide pieces 545, which can be attached to the upper rear sides of the left and right side panels 54 (54L, 54R) by the attachment pieces 542, similar to the seat guide pieces 543 (see Fig. 6).Such a back guide piece 545, like the seat guide pieces 543 (543F, 543B), may be configured as a hollow body with an open front and a closed rear by a stopper St, with an internal space Sp, and with a groove cut in the upper part, as shown in Figs. 9(a) to (c).

[0077] Furthermore, rear insertion portions 547 are provided on the lower rear sides of the left and right side panels 54 (54L, 54R) (see FIG. 6), and these rear insertion portions 547 also have the same configuration as the rear guide pieces 545 and may be attached to the left and right side panels 54 (54L, 54R) by the attachment pieces 542 in the same manner. However, in this embodiment, as shown in FIGS. 10(a) to 10(c), the rear insertion portions 547 are configured so that the lower end of the rear panel 56 (fitting portion 56R) is directly inserted therein, and attachment plate portions are attached directly to the left and right side panels 54 (54L, 54R), and the lower end of the rear panel 56 (fitting portion 56R) is directly guided into the grooves of the rear insertion portions 547, whereby the rear panel 56 (fitting portion 56R) is fitted and fixed.

[0078] 11(a) to 11(c), a rear slide piece 561 from which a slider Sl protrudes, which fits into a gap Sp of the rear guide piece 545 or the like, is attached to the rear surface of the rear panel 56 by an attachment piece 542 so that the slider Sl protrudes rearward. The slider Sl protruding rearward from the rear panel 56 is inserted into the gap Sp of the hollow body up to the stopper St and fitted into the groove of the rear guide piece 545 attached to the left and right side panels 54 (54L, 54R). At the same time, as described above, the lower end of the rear panel 56 (fitting portion 56R) is directly guided into the groove of the rear insertion portion 547, and fitted and fixed.

[0079] The carbon fiber sofa 50A of Example 2 has been described above, but the carbon fiber sofa 50 according to the present invention is not limited to Example 50A. The carbon fiber sofa 50A according to Example 2 is a knock-down sofa in which the front base 52F, the rear base 52B, the back panel 56, the seat panel 58, and the left and right side panels 54 (54L, 54R) can be freely assembled and disassembled, but to increase stability, as in Example 3 described below, the front base 52F, the rear base 52B, the seat panel 58, and the left and right side panels 54 (54L, 54R) may all be fixed together with an adhesive or the like to form a single unit, with only the back panel 56 being insertable and removable. (3-2) Fixed carbon fiber sofa 50B Example 3

[0080] In the third embodiment, a carbon fiber sofa 50B in which components other than the back panel 56 are fixed will be described.

[0081] Similar to the carbon fiber sofas 50 and 50A described above, the carbon fiber sofa 50B according to this embodiment includes a base 52, a back panel 56, a seat panel 58, and left and right side panels 54 (54L, 54R) as components, as shown in FIG. 14(a). The back panel 56 has a fitting portion 56R near its lower end. In addition, in the carbon fiber sofa 50B according to this embodiment, the left and right side panels 54 (54L, 54R) are formed from a carbon fiber multi-corrugated sheet 1, as shown in FIG. 16(a). Note that in FIG. 16(a), the vertical lines on the side panels 54 represent the convex or concave portions of the waves of the carbon fiber multi-corrugated sheet 1.

[0082] In the carbon fiber sofa 50B of this embodiment, the base 52 is formed by integrally molding a front base 52F and a rear base 52B at their joints, as shown in FIG. 14(b). The front base 52F is a quadrangular prism with square side surfaces 52Fs, a front surface 52Ff, a rear surface 52Fb, a top surface 52Fu, and a bottom surface 52Fd, and a front panel 60F is formed on the front surface 52Ff. The rear base 52B is a triangular prism with triangular side surfaces 52Bs, a front surface 52Bf, a rear surface 52Bb, and a bottom surface 52Bd, and a rear panel 60B is formed on the rear surface 52Bb. Such a base 52 can be integrally molded using a mold such as that shown in FIG. 17.

[0083] 18(a) and 18(b), in order to reduce weight, it is preferable to make the inside of the base 52 hollow. If the bottom surface 52d (52Fd, 52Bd) is simply a frame connecting both side surfaces 52s, the front surface 52Ff, and the rear surface 52Bb of the base 52 as shown in Fig. 18(a), it is possible to make it lighter, but as shown in Fig. 18(b), an auxiliary frame may be provided at the joint between the front base 52F and the rear base 52B to reinforce the bottom surface 52d (52Fd, 52Bd).

[0084] In the base 52, the front panel 60F and / or the rear panel 60B may be attached to the front surface 52Ff of the front base 52F and / or the rear surface 52Bb of the rear base 52B with an adhesive or the like, but are preferably integrally molded.

[0085] The upper surface 52Fu of the front base 52F that constitutes this base 52 is inclined at a positive angle of less than 30 degrees clockwise from the reference direction, and the front surface 52Bf of the rear base 52B is inclined at an angle of 90 degrees or more and 120 degrees or less clockwise from the reference direction (see Figure 14(b)).

[0086] In the carbon fiber sofa 50B of this embodiment, a rear insertion portion 53 into which the fitting portion 56R of the rear panel 56 can be inserted is formed along the slope of the front surface 52Bf of the rear base 52B at the joint where these two bases are joined (see FIGS. 14(a) and 14(b)). The rear panel 56 is inserted into the rear insertion portion 53 along the front slope (front surface 52Bf) of the rear base 52B, and the fitting portion 56R of the rear panel 56 is detachably fitted into the rear insertion portion 53.

[0087] In the carbon fiber sofa 50B of this embodiment, the left and right side panels 54 (54L, 54R) are adhered to the side surfaces 52s (52Fs, 52Bs) of the base 52, and the seat panel 58 is adhered to the upper surface 52Fu of the base 52. The side panels 54 and / or the seat panel 58 can be fixed to the base 52 by bolts or the like in addition to adhesive, but in order to maintain a beautiful appearance, the carbon fiber sofa 50B of this embodiment uses adhesive for fixation.

[0088] In the carbon fiber sofa 50B of this embodiment, the left and right width of the fitting portion 56R of the back panel 56 is preferably formed so that it approximately matches the left and right width of the back insertion portion 53, and the left and right width of the backrest portion 56Q above this is narrower than the left and right width of the fitting portion 56R (see Figures 15(a) and (b)). When the left and right edges of the backrest portion 56Q of the back panel 56 come into contact with the left and right side panels 54 (54L, 54R), a rubbing noise is generated, so by shaping the back panel 56 in this way, it is possible to prevent this rubbing noise from being generated.

[0089] Furthermore, it is desirable that at least a portion of the adhesive portions of the side surfaces 52s (52Fs, 52Bs) of the base 52 to which the left and right side panels 54 (54L, 54R) are attached be formed into a corrugated pattern with the same pitch as the wave pitch of the carbon fiber multi-corrugated sheet 1 forming the left and right side panels 54 (54L, 54R) (see Figures 16(a) and 15(a)). Figure 16(b) is a side view of the base 52 in which all of the adhesive portions have been formed into a corrugated pattern with the same pitch as the wave pitch of the carbon fiber multi-corrugated sheet 1, and Figure 16(c) is a side view of the base 52 in which a portion of the adhesive portions have been formed into a corrugated pattern with the same pitch as the wave pitch of the carbon fiber multi-corrugated sheet 1. In this way, the adhesive portions of the side surfaces 52s (52Fs, 52Bs) of the base 52 are formed into a corrugated pattern with the same pitch as the wave pitch of the carbon fiber multi-corrugated sheet 1. By aligning the convex portions and concave portions, and the concave portions and convex portions, of the side panels 54 and the side surfaces 52s of the base 52, the adhesive area between the left and right side panels 54 (54L, 54R) and the base 52 can be increased, and the two can be firmly bonded together. Note that such a base 52 in which at least a portion of the adhesive portion of the side surfaces 52s (52Fs, 52Bs) is corrugated can be molded as a single unit by producing a mold with corrugated sides as shown in Figure 17 (see the left side surface inside the mold)) and using this mold in the manufacturing method described above. (3-3) Test and Simulation of Fixed Carbon Fiber Sofa 50B

[0090] In the following Examples 4 and 5, strength tests, durability tests, and simulations conducted using the fixed carbon fiber sofa 50B described above will be described. Example 4

[0091] [Strength and durability tests for carbon fiber sofas] The carbon fiber sofa 50B of this example was subjected to strength and durability tests at the Gifu Prefectural Institute of Living Technology. In the following explanations of the strength tests (1) and (2) and the durability test (3), the "seat" refers to the seat panel 58, and the "backrest" refers to the back panel 56.

[0092] (method) (1) Static strength test of seat [based on JLS S 1203 7.1 test category 4] A vertical load of 1,600N (approximately 163kgf) was applied 10 times (holding time 10 seconds) via a seat support plate to the seat load position determined by the load positioning jig (see Figure 22(a)). After the test, each part was inspected for abnormalities. (2) Static strength test of backrest [JIS S 1203 7.2 Test Category 4] The rear legs of the carbon fiber sofa 50B were placed against stoppers to prevent it from moving backward. A load of 760 N (approximately 78 kgf) was applied vertically to the backrest 10 times (holding time 10 seconds) via a backrest support plate at the backrest load position determined by the load positioning jig (see Figure 22(b)). For balancing purposes, a vertical load of 1,600 N (approximately 163 kgf) was applied to the seat load position determined by the load positioning jig. After the test, each part was inspected for abnormalities. (3) Seat and backrest durability test [JIS S 1203 7.5-6 Test Category 4] The rear legs of the carbon fiber sofa 50B were placed against stoppers to prevent it from moving backward. A vertical load of 950 N (approximately 97 kgf) was applied 100,000 times at a rate of 24 cycles per minute via a seat support plate to the seat load position determined by the load positioning jig. At the same time, a load of 330 N (approximately 34 kgf) was applied 100,000 times at a rate of 24 cycles per minute via a backrest support plate to the backrest load position determined by the load positioning jig (see Figure 22(c)). After the test, each part was inspected for abnormalities.

[0093] (Test results) The static strength test of the seat (1), the static strength test of the backrest (2), and the durability test of the seat and backrest (3) were conducted by the Gifu Prefectural Institute of Living Technology, and the following test results were obtained from the Institute. (1) Static strength test of seat [based on JLS S 1203 7.1 test category 4] No damage, deformation, loosening, or detachment that would interfere with use was observed. (2) Static strength test of backrest [based on JLS S 1203 7.2 test category 4] No damage, deformation, loosening, or detachment that would interfere with use was observed. (3) Seat and backrest durability test [based on JLS S 1203 7.5-6 test section 4] No damage, deformation, loosening, or detachment that would interfere with use was observed. Example 5

[0094] [Strength simulation of a carbon sofa] A simulation was conducted on the strength and displacement of each part of the fixed carbon fiber sofa 50B. In this simulation, a design drawing was created using 3D CAD, and the simulation was conducted at the Fukui Prefectural Industrial Technology Center using values ​​obtained from the results of stiffness tests on the carbon fiber multi-corrugated sheet 1 and the carbon fiber multi-flat sheet described in Example 1.

[0095] (1) Carbon sofa A simulation was carried out on a CF sofa, the thickness of which is shown in Table 1. All components, including the base, are made of carbon fiber composite laminates, and the back panel and side panels are molded using carbon fiber multi-corrugated sheets.

[0096] [Table 3]

[0097] (2) Simulation The loads and positions applied to the back panel and seat panel are shown below. (2-1) Load application position As shown in Figures 19(a) and 19(b), a load of 330N (33.7kg) was applied uniformly to a specific position on the back panel. Also, as shown in Figures 20(a) to 20(c), a load of 950N (96.9kg) was applied uniformly to a specific position on the seat panel. (2-1-1) Load on the rear panel ● Position: A load was applied to the rear panel at a rectangular area 100 mm below the pillow joint (see Figure 19(a) and (b)). ●Load: 330N (33.7Kg) (2-1-2) Load on the seat panel ● Position: Loads were applied to the seat panel across the entire surface (see Figure 20(b)) and in front of it (see Figure 20(c)) (see Figures 20(a) to (c)). Load capacity: 950N (96.9kg)

[0098] The results of the simulation performed using the above method are shown below. (3) Simulation results (3-1) When 330N is applied to the rear panel When 330N (approximately 33.7kg) is applied to the rear panel While the breaking stress is approximately 1,000 MPa, the strain stress generated in the rear panel was found to be approximately 100 MPa, which is safe. The displacement at the top of the pillow was the greatest, approximately 10 cm (see Figure 21(a)). (3-2) When 950N is applied to the seat panel (3-2A) When 950N (approximately 97kg) is applied to the entire seat panel While the breaking stress is approximately 1000 MPa, the strain stress generated in the seat panel was found to be safe at around 200 MPa. The displacement at the center of the front part of the seat panel was the greatest, measuring approximately 6.3 cm (see Figure 21(b)). (3-2B) When 950N (approximately 97kg) is applied to the front of the seat panel While the breaking stress is approximately 1000 MPa, the strain stress generated in the seat panel was found to be safe at around 400 MPa. The displacement at the center of the front part of the seat panel was the greatest, measuring approximately 11 cm (see Figure 21(c)).

[0099] From the above simulation results, it was confirmed that the fixed carbon fiber sofa 50B of the present invention is strong enough to safely support a person weighing just under 100 kg (approximately 97 kg), and that the front of the seat panel will be displaced by about 6 to 10 cm, and the upper part of the seat panel will be displaced by about 10 cm, resulting in sufficient warping or bending. (4) How to assemble a carbon fiber sofa

[0100] The method for assembling the carbon fiber sofa 50A according to the present invention (Example 2) is as follows: (1) preparing a front base 52F having front insertion portions 523F on left and right side surfaces 52Fs and a rear base 52B having rear insertion portions 523B on left and right side surfaces 52Bs; (2) preparing a back panel 56 and a seat panel 58, both of which are made of carbon fiber multi-corrugated panels; (3) preparing left and right side panels 54 (54L, 54R) made of a carbon fiber multi-corrugated plate, each having a front insertion piece 541F and a rear insertion piece 541B that can be fitted into the front insertion part 523F and the rear insertion part 523B, respectively, and each having a seat guide piece 543 that allows the seat panel 58 to slide in a substantially horizontal direction, a back guide piece 545 that allows the back panel 56 to slide in a substantially vertical direction, and a back insertion part 547 below the seat guide piece 543 that supports the lower end of the back panel 56; (4) fitting the front insertion pieces 541F and the rear insertion pieces 541B of the left and right side panels 54 (54L, 54R) into the left and right front insertion portions 523F of the front base 52F and the left and right rear insertion portions 523B of the rear base 52B, respectively; (5) The rear panel 56 is guided by the rear guide pieces 545 of the left and right side panels 54 (54L, 54R) and fixed to the rear insertion portion 547. a step of guiding and fixing the seat panel 58 to the seat guide pieces 543 of the left and right side panels 54 (54L, 54R); Includes.

[0101] The above describes the carbon fiber multi-corrugated sheet, the manufacturing method of the carbon fiber multi-corrugated sheet, the carbon fiber sofa using the carbon fiber multi-corrugated sheet, and the method for assembling the carbon fiber sofa according to the present invention. However, the present invention is not limited to the above embodiments and examples. The type of carbon fiber prepreg constituting the carbon fiber sofa according to the present invention is not particularly limited, and the carbon fiber composite laminate may be either thermosetting or thermoplastic. The dimensions, thickness, and number of layers of the prepreg and carbon fiber composite laminate can also be changed as appropriate. Furthermore, the carbon fiber and matrix materials constituting the carbon fiber multi-corrugated sheet according to the present invention change over time, and can be changed as appropriate over time without any particular limitations.

[0102] In addition, the present invention can be implemented in various forms with various improvements, modifications, and changes made based on the knowledge of those skilled in the art without departing from the spirit of the present invention. [Industrial Applicability]

[0103] The carbon fiber multi-corrugated panel according to the present invention can be widely used as a component of furniture and other structures. [Explanation of symbols]

[0104] 1: Carbon fiber multi-corrugated sheet according to the present invention 2: Sheet prepreg 3: Woven fabric (sheet-like prepreg) 4: Carbon fiber 5: Carbon fiber bundle 6: Matrix resin 20: Pipe 22: Pipe cover 50: (Knockdown) carbon fiber sofa 50A, 50B: (Fixed) carbon fiber sofa 52: Foundation 52s:Side 52d: bottom 52F: Front base 52Ff, 52Fb: Front and rear (of front base) 52Fu, 52Fd: (Front base) top and bottom 52Fs: Side of (front base) 523F: Front insertion section 52B: Rear base 52Bf, 52Bb: (rear base) front, rear 52Bu, 52Bd: (rear base) top and bottom 52Bs: (rear base) side 523B: Rear insertion part 53: Rear insertion part 54: Side panel 54L: Left side panel 54R: Right side panel 541: Insert 541F: Front insertion piece 541B: Rear insert 542: Mounting piece 543: Seat guide piece 543F: Front seat guide piece 543B: Rear seat guide piece 545: Rear guide piece 547: Rear insertion part 56: Rear panel 56P: Pillow part 56Q: Backrest part 56R: Fitting part 561: Rear slide piece 58: Seat panel 581: Seat slide piece 581F: Front seat slide piece 581B: Rear seat slide piece 60F: Front panel 60B: Rear panel

Claims

1. A sofa includes a base made up of a front base and a rear base, each having a flat front surface, a flat rear surface, left and right side surfaces, and a bottom surface, a back panel, a seat panel, and left and right side panels, and is placed with the bottom surfaces of the front base and the rear base in contact with a placing surface, The direction from the rear to the front of the sofa in a side view is the reference direction of the placement surface, and the direction is clockwise from the reference direction. a front surface of the front base has an inclination of 90 degrees or more and 120 degrees or less from a reference direction, and a front panel is formed on the front surface along the inclination; a rear surface of the rear base has an inclination of 60 degrees or more and 90 degrees or less from a reference direction, and a rear panel is formed on the rear surface along the inclination; The left and right side panels are fixed to the side surfaces of both the front base and the rear base, The seat panel is fixed to the left and right side panels and / or the front base so as to be above the front base with a slight gap between the seat panel and the front panel or in contact with the front panel, and to be tilted at a positive angle of less than 30 degrees clockwise from a reference direction, The back panel is fixed to the left and right side panels and / or the rear base so as to cover the upper part of the rear base from the front thereof, with a small gap between the back panel and the rear end of the seat panel and the rear panel or in contact with the rear panel, and to have an inclination of 90 degrees or more and 120 degrees or less clockwise from a reference direction, All of the panels, including the back panel, the seat panel, the left and right side panels, the front panel, and the rear panel, A carbon fiber sofa characterized by comprising a carbon fiber composite laminate having a front surface and a back surface, formed by laminating multiple flexible sheet-like prepregs containing multiple carbon fibers that are flexible and resin-permeable and a matrix resin that impregnates the fibers.

2. At least one of all the panels has:

2. The carbon fiber sofa according to claim 1, wherein the carbon fiber composite laminate is made of a carbon fiber multi-corrugated plate formed into a wave shape with a pitch of 10 mm to 15 mm.

3. 3. The carbon fiber sofa according to claim 1, wherein the front and rear bases are made of a carbon fiber composite material.

4. 3. The carbon fiber sofa according to claim 1, wherein the seat panel is fixed to the left and right side panels and / or the front base above the front base with a small gap between them or in contact with them, and the front end of the seat panel protrudes forward from the front panel.

5. 3. The carbon fiber sofa according to claim 1, wherein the back panel is fixed to the left and right side panels and / or the rear base so as to cover the front and upper part of the rear base with a small gap between or in contact with the rear end of the seat panel and the rear panel, and the upper end of the back panel protrudes above the rear panel.

6. A sofa assembled from a front base having front insertion portions on the left and right sides, a rear base having rear insertion portions on the left and right sides, a back panel, a seat panel, and left and right side panels, The left and right side panels are a front insertion piece and a rear insertion piece that can be fitted into the front insertion portion and the rear insertion portion, respectively; The seat panel has a seat guide piece that allows it to slide in a substantially horizontal direction, a back panel has a back guide piece that allows it to slide in a substantially vertical direction, and a back insertion part below the back guide piece that supports the lower end of the back panel, the front insertion pieces and the rear insertion pieces of the left and right side panels are fitted into the left and right front insertion portions of the front base and the left and right rear insertion portions of the rear base, respectively; The rear panel is guided by the rear guide pieces of the left and right side panels and fixed to the rear insertion portion, 3. The carbon fiber sofa according to claim 1, wherein the seat panel is guided and fixed to the seat guide pieces of the left and right side panels.

7. The carbon fiber sofa according to claim 6, The seat surface guide pieces, which allow the seat surface panel to slide in a substantially horizontal direction, are hollow bodies that are open at the front and closed at the rear by stoppers St, have a space Sp therein, have grooves cut upward, and are attached to the seat surface panel sides of the left and right side panels by attachment pieces. A seat slide piece having a protruding slider S1 that fits into the gap Sp of the seat guide piece is attached to the underside of the seat panel by an attachment piece so that the slider S1 protrudes downward. The slider Sl protruding downward from the seat panel is inserted into the gap Sp of the hollow body up to the stopper St through the grooves of the seat guide pieces attached to the left and right side panels, and is fitted thereto. The carbon fiber sofa has the seat panel fixed to the left and right side panels.

8. The carbon fiber sofa according to claim 6, The rear guide pieces, which allow the rear panel to slide in a substantially vertical direction, are hollow bodies that are open at the top and closed at the bottom by stoppers St, have a space Sp inside, have a groove cut in the front, and are attached to the seat panel sides of the left and right side panels by attachment pieces. A rear slide piece having a protruding slider S1 that fits into the gap Sp of the rear guide piece is attached to the rear surface of the rear panel by an attachment piece so that the slider S1 protrudes rearward. The slider Sl protruding rearward from the rear panel is inserted into the gap Sp of the hollow body up to the stopper St through grooves in rear guide pieces attached to the left and right side panels, and is fitted thereto. A carbon fiber sofa in which the lower end of the back panel is guided into and fixed to the back insertion portions of the left and right side panels.

9. the front base being a rectangular prism with a square side surface, having a front surface, a rear surface, a top surface, and a bottom surface, and the front panel being formed on the front surface; a rear base in the form of a triangular prism with triangular sides, having a front surface, a rear surface, and a bottom surface, with the rear panel formed on the rear surface, and the base being integrally molded at the joints thereof; 3. The carbon fiber sofa according to claim 1, further comprising: the back panel having a fitting portion near a lower end thereof; the seat panel; and the left and right side panels. The upper surface of the front base is inclined at a positive angle of less than 30 degrees clockwise from a reference direction, The front surface of the rear base is inclined at an angle of 90 degrees or more and 120 degrees or less clockwise from a reference direction, a rear insertion portion into which the fitting portion of the rear panel can be inserted is formed along a slope of the front surface of the rear base at the joint where the two bases are joined, the left and right side panels are bonded to the side surfaces of the base, The seat panel is bonded to the upper surface of the base, A carbon fiber sofa in which the back panel is inserted into the back insertion portion along the front slope of the rear base, and the fitting portion of the back panel is removably fitted into the back insertion portion.

10. The carbon fiber sofa according to claim 9, wherein the front panel and / or the rear panel are integrally molded with the front surface of the front base and / or the rear surface of the rear base.

11. The rear panel has a left-right width of the fitting portion that is approximately the same as the left-right width of the rear insertion portion, and the left-right width above the fitting portion is narrower than the left-right width of the fitting portion. Carbon fiber sofa according to claim 9.

12. The carbon fiber sofa according to claim 9, wherein the left and right side panels are formed of carbon fiber multi-corrugated sheets, The base is a carbon fiber sofa in which at least a part of the adhesive portion on the side where the left and right side panels are attached is molded into a wave shape with the same pitch as the wave pitch of the carbon fiber multi-corrugated sheets that form the left and right side panels.

Images