Layered fiber structure, and thermal conditioning products and filtration members using the same.

Abstract

This invention provides a layered fiber structure that achieves a balance of shape retention, compression recovery, lightweight heat retention, breathability, moisture wicking, and fine fiber retention, making it applicable to thermal conditioning products and filtration components. [Solution] The layered fiber structure 1 comprises a skeletal fiber section 10 including a first skeletal fiber 11, a second support fiber 12 and a third auxiliary fiber 13 as needed, and a fine fiber section 20 including nanofibers 21. The second support fiber 12 or the third auxiliary fiber 13 forms an elastic support section 14, and the nanofibers 21 form bridging sections 22 and fine voids 23 within the thickness, while leaving large voids 24 or intermediate voids 27. This ensures void recovery after compression, heat retention, ventilation, moisture removal, and suppression of consolidation during filtration.

Description

TECHNICAL FIELD

[0001] (Technical Field) The present invention relates to a hierarchical fiber structure combining skeleton fibers with fine fibers or nanofibers, as well as a thermal conditioning article and a filtration member using the same.

BACKGROUND ART

[0002] (Conventional heat insulating materials) Down, cotton, polyester batting, foams, nonwoven fabrics, three-dimensional knitted fabrics and other heat insulating materials are used in clothing, bedding, sleeping bags, mattresses, seat articles, heat insulating articles and the like. These materials retain air inside them and suppress heat conduction and convection, thereby exhibiting heat retaining properties.

[0003] (Weight reduction and heat retaining properties) Increasing the weight or thickness of a heat insulating material may improve the heat retaining properties in some cases, but the weight, storability, flexibility and use feel will be impaired. For this reason, it is required to enhance the heat retaining performance per unit weight and per unit thickness.

[0004] (Ultrafine fibers and nanofibers) Ultrafine fibers or nanofibers have a larger specific surface area than fibers of normal diameter and tend to form fine voids, so their application to heat insulating materials, heat insulation materials and filter materials is under investigation.

[0005] (Limitations of two-layer structure) A structure formed by simply laminating a batting layer composed of normal-diameter fibers and a fine fiber layer may cause interlayer displacement, consolidation of the fine fiber layer, reduction in air permeability, or peeling during washing. In addition, fibers having an intermediate diameter or an intermediate supporting function between normal-diameter fibers and nanofibers may not be sufficiently utilized in some cases.

[0006] (Compression recovery property) Laying bedding, mattresses, clothing, sleeping bags and filters are repeatedly compressed or deformed during use, storage, transportation, fluid passage or washing. For this reason, performance that allows the thickness and void structure to recover is required.

[0007] (Fiber shedding) In a structure where nanofibers are simply laminated on the surface of a substrate, the nanofibers may detach from the substrate due to friction, bending, washing, drying, fluid pressure, or long-term use.

[0008] (Performance degradation in wet conditions) When liquid water or sweat is retained in the insulating material, the air between the fibers is replaced by water, making it easier for heat to transfer. As a result, the insulating performance may decrease when the material is wet.

[0009] (Balancing breathability and performance) While increased breathability facilitates moisture release, the ease with which air passes through also increases convective heat loss. Therefore, achieving both heat retention and breathability is difficult in a uniform structure.

[0010] (Challenges in applying this to mattresses) Mattresses experience prolonged compression due to body pressure, repetitive loading due to turning over in bed, and the accumulation of sweat and moisture. Therefore, it is desirable to achieve body pressure support, thickness recovery, breathability, moisture removal, and heat insulation all within the same core material.

[0011] (The issue of using both sides) While reversible products with different textures on each side are well-known, simply changing the outer fabric may not adequately switch the internal ventilation, moisture pathways, contact area, and insulation properties.

[0012] (Changes in filter shape) In filters, if the fine fiber layer is compacted or deformed due to fluid pressure, dust load, washing, or drying, pressure loss increases, which can lead to unstable collection or fluid permeability. Furthermore, structures are known in which nanofibers are incorporated within the thickness of a filter medium primarily composed of coarse fibers, bridging or subdividing the pores between the coarse fibers with nanofibers. However, there is still room for improvement in ensuring that such internal fine fiber structures maintain elastic recovery after repeated compression, provide heat retention, ventilation, and moisture removal in thermal applications, and restore thickness and voids after washing.

[0013] (Washable and reusable filter) In washable and reusable filters, even if collected material is removed during washing, the fine fiber layer may peel off, the voids may collapse, or the thickness may not recover after washing.

[0014] (Relationship between multiple issues) The above challenges can potentially be solved integrally through a multi-stage division of roles: support by large-diameter fibers, intermediate elastic retention by thinner supporting fibers, and void control or collection by fine fibers. [Prior art documents] [Patent Documents]

[0015] [Patent Document 1] Patent No. 7515165 [Patent Document 2] Patent No. 4922654 [Patent Document 3] Patent No. 7105508 [Patent Document 4] Patent No. 6463733 [Patent Document 5] U.S. Patent No. 7754123 [Overview of the project] [Problems that the invention aims to solve]

[0016] (Main issues) The present invention aims to provide a hierarchical fiber structure that achieves both lightness, shape retention, compression recovery, void control, and fine fiber retention by assigning different roles to a main skeleton made of relatively thick fibers, intermediate diameter or intermediate support fibers as needed, and fine fibers or nanofibers.

[0017] (Challenges of hierarchical structure) Another object of the present invention is to provide a flexible hierarchical structure that may be constituted solely by skeleton fibers of a single diameter, or may have fibers of a plurality of diameters or supporting functions arranged stepwise so as to correspond to trunks, branches and twigs.

[0018] (Problem of elastic support) Still another object of the present invention is to enhance shape recoverability after repeated loads by forming the intermediate support portion into a coil shape, spiral shape, loop shape, wave shape, or a cooperative structure of a tension member and a compression support member.

[0019] (Problem of thermal conditioning) Still another object of the present invention is to enable heat retention performance per unit weight, heat retention maintenance when wet, air permeability, moisture dissipation, and thermal conditioning for front and back sides or different parts.

[0020] (Problem of mattress) Still another object of the present invention is to realize body pressure support, rolling-over followability, air ventilation, moisture dissipation and heat insulation in a mattress or a mattress inner material by the same or a plurality of hierarchical fiber regions.

[0021] (Problem for filtration applications) Still another object of the present invention is to provide a reusable hierarchical fiber structure for filtration that suppresses shape change and increase in pressure loss when a fluid passes therethrough, and recovers its thickness or void structure after washing. [Means for Solving the Problems]

[0022] (Basic configuration) The hierarchical fiber structure of the present invention includes a skeleton fiber portion containing a plurality of skeleton fibers, and a fine fiber portion containing fine fibers or nanofibers having a smaller diameter than the skeleton fibers.

[0023] (Types of skeleton fibers) The skeleton fiber portion may be formed of skeleton fibers of a single type of thickness, or may be formed of a plurality of types of skeleton fibers differing in thickness, bending rigidity, elastic modulus, cross-sectional shape, material or function.

[0024] (First skeletal fiber) The skeletal fiber portion may include relatively thick first skeletal fibers that primarily maintain the overall shape and large voids.

[0025] (Second support fiber) The skeletal fiber portion may include second support fibers that are thinner than the first skeletal fibers but thicker than the microfiber portion. The second support fibers connect the first skeletal fibers and assist in elastic support during deformation and in holding the microfibers.

[0026] (Third auxiliary fiber) A third auxiliary fiber or even more layers of fiber groups may be provided between the second support fiber and the fine fiber section. The diameter of each fiber group may be distributed in stages or continuously.

[0027] (Same diameter configuration) The names "first skeletal fiber," "second support fiber," and "third auxiliary fiber" are primarily used to distinguish the support function performed by each fiber group. Therefore, when forming a hierarchy based on diameter differences, the first skeletal fiber can be made relatively thicker, while the second support fiber and third auxiliary fiber can be made progressively thinner. On the other hand, when forming a hierarchy based on functional differences, these fibers can be made to have the same or similar diameter, and different support functions can be assigned depending on their shape, material, orientation, tension state, three-dimensional arrangement, or bonding state.

[0028] (dendritic hierarchy) The first skeletal fiber, second support fiber, third auxiliary fiber, and microfiber section may be connected in a stepwise or branching manner from a relatively large support structure to a fine void control structure, corresponding to the trunk, branches, twigs, and leaf veins of a tree.

[0029] (Elastic support section) The second support fiber or third auxiliary fiber can form an elastic support portion consisting of a crimped, wave-shaped, loop-shaped, coil-shaped, helical, torsionally deformable shape, or a combination thereof. These shapes are not limited to simple planar shapes that bend or meander along the plane, but may also be three-dimensional shapes that bulge, curve, wind, or rise in the thickness direction. For example, they may be configured as an upright coil-shaped portion, a helical portion extending in an oblique direction, a wave-shaped portion with amplitude in the vertical direction, a three-dimensionally bulging loop-shaped portion, or a combination of these oriented in multiple directions. The elastic support portion can be used to support the microfiber portion or bridging portion from the thickness direction, surface direction, or oblique direction, thereby suppressing excessive consolidation of microvoids and breathable continuous voids during compression. In particular, when multiple elastic support portions are arranged facing different directions from each other, they exert restoring forces in the thickness direction, surface direction, and oblique direction, forming a three-dimensional elastic support structure or three-dimensional reaction force structure as a whole.

[0030] (3D tension structure) As shown in Figures 3(F) and (G), the tension member 17 and the compression support portion 18 may be connected at a distance from each other, and the structure may be maintained by the balance between tension and compression. The tension member 17 can be formed from fibers, threads, strips, membranes, or bundles of fine fibers, and the compression support portion 18 can be formed from rod-shaped, columnar, coil-shaped, loop-shaped, bundle-shaped, or spiral-shaped fibers. When the compression support portions 18 are not directly fixed to each other, and their posture or spacing is maintained by the tension member 17, a tensegrity-like structure can be obtained, which is lightweight while providing three-dimensional stability, elastic support, and void retention.

[0031] (Stereoelasticity due to multi-directional orientation) Even if coiled, helical, wave-shaped, or loop-shaped sections are individually prone to elastic deformation in a specific direction, when multiple members are arranged in different directions, angles, or height positions, the structure as a whole can exhibit three-dimensional elastic support. For example, when multiple coiled sections are arranged facing different axial directions, a three-dimensional support network can be formed that exhibits restorative force against external forces in the thickness, surface, and oblique directions. Furthermore, by placing the elastic support section or three-dimensional tension structure near the micro-voids formed by the micro-fiber section, the complete collapse of the micro-fiber section when a load is applied can be suppressed, and the thickness, porosity, or ventilation path of the structure can be easily restored after the load is removed.

[0032] (Method for forming a three-dimensional elastic support) The elastic support portion may be formed using a second support fiber or a third auxiliary fiber that has been pre-shaped into a three-dimensional form. For example, thermoplastic fibers, monofilaments, composite fibers, core-sheath composite fibers, or elastic resin fibers can be shaped into a corrugated, loop, coil, spiral, three-dimensional curved, or torsionally deformable shape, and the shape can be maintained by heating, cooling, thermal fixing, or mechanical fixing. Furthermore, the second support fiber or third auxiliary fiber may be placed on a three-dimensional uneven mold, a pin-shaped jig, a cylindrical jig, a spiral jig, a corrugated roll, a three-dimensional mold, or a porous suction mold, and an elastic support portion that is raised in the thickness direction or rises diagonally may be formed by heating, pressurizing, suction, hot air treatment, ultrasonic treatment, or high-frequency heating treatment.

[0033] (Method for forming multi-directional oriented structures) Multiple elastic support parts may be aligned in the same direction, but it is preferable to arrange them so that they have different directions, angles, height positions, or curvatures from one another. For example, by arranging multiple coil-shaped or helical parts so that they face different axial directions, or by mixing wave-shaped parts, loop-shaped parts, and coil-shaped parts, a multi-directional oriented structure can be formed that exhibits restoring force against external forces in the thickness direction, surface direction, and oblique direction. Such multi-directional oriented structures may be formed by airflow dispersion, suction molding, vibration application, deposition on a rotating drum, lamination onto a three-dimensional mold, needle punching, entanglement, knitting, weaving, three-dimensional knitting, or a combination thereof. If necessary, low-melting-point fibers, heat-fusible fibers, adhesive fibers, or adhesive resins can be used in combination to locally fix only selected intersections or contact points, thereby achieving both three-dimensional shape and elastic deformability.

[0034] (Method for forming a three-dimensional tension structure or a tensegrity-like structure) A three-dimensional tension structure or tensegrity-like structure can be formed by combining coil-shaped, loop-shaped, columnar, helical, or three-dimensionally curved sections that receive compressive loads with tension members stretched between them. For example, by arranging multiple compression support sections at predetermined intervals and stretching fibers, thread-like members, strip-like members, fine fiber bundles, or elastic threads that receive tension between them in an oblique, planar, or thickness direction, and locally fixing the ends or intersections, a support structure with three-dimensional stability can be formed. The tension members are positioned to maintain the spacing, inclination, or orientation of the compression support sections, and the compression support sections elastically deform when subjected to a load, while suppressing excessive compaction of the microfiber sections or bridging sections. As a result, after the load is removed, the tension of the tension members and the elastic restoration of the compression support sections facilitate the reformation of micro voids, breathable continuous voids, or voids in the thickness direction.

[0035] (Integration process with microfiber section) After forming a three-dimensional elastic support portion, a microfiber portion may be formed by depositing, spraying, spinning, scattering, entangling, or attaching nanofibers or microfibers to the skeletal fiber portion including the elastic support portion. The microfiber portion may be arranged to bridge the elastic support portion or the first skeletal fibers, or it may be held on the surface, inside, at intersections, or in the vicinity of the elastic support portion. After the formation of the fine fiber portion, the fine fiber portion and the elastic support portion may be partially fixed as needed by hot air treatment, local heating, ultrasonic treatment, softening of adhesive fibers, fusion of low-melting-point components, or mechanical entanglement. In this case, rather than firmly fixing the entire surface, discrete fixing at selected locations can be performed, thereby suppressing the shedding of fine fibers due to washing, compression, or fluid pressure while leaving fine voids and breathable continuous voids.

[0036] (Retention of microfibers) At least a portion of the fine fibers or nanofibers are arranged within the thickness of the skeletal fiber portion, bridged between spaced-apart skeletal fibers, or between skeletal fibers and supporting fibers or elastic supports, entangled with the skeletal fibers, partially embedded in the surface of the skeletal fibers, or locally fused to them.

[0037] (hierarchical void) Large voids formed by the first skeletal fibers, intermediate voids formed by the second support fibers or third auxiliary fibers, and fine voids formed by fine fibers or nanofibers can coexist, and at least a portion of the large voids or intermediate voids can be left as breathable continuous voids communicating in the thickness direction or planar direction. After compression, at least a portion of the fine voids and the breathable continuous voids can be reformed by restoring the skeletal fiber portion, the second support fiber, or the elastic support portion.

[0038] (partial joint) Skeletal fibers do not need to be completely fixed to each other, nor to skeletal fibers and supporting fibers, but can be partially joined by point-like, linear, grid-like, or discrete joints.

[0039] (Preventing falling off) The fine fibers can be held in place by entanglement, embedding, local fusion with low-melting-point components, bonding points, mechanical engagement, or end fixation.

[0040] (Moisture transfer) For thermal conditioning applications, a moisture transfer unit can be provided that prioritizes transferring or diffusing liquid water supplied from the user side in the planar direction rather than directly permeating it in the thickness direction of the insulating area.

[0041] (Liquid water intrusion control) A boundary can be formed between the moisture transfer section and the heat insulating region to suppress the intrusion of liquid water through hydrophobicity, surface energy difference, pore size difference, density difference, or fiber orientation difference.

[0042] (Ventilation and moisture removal) The ventilation areas, grooves, or main ventilation passages can be interconnected and connected to a peripheral discharge path or peripheral moisture removal section.

[0043] (Front and back reversed) The hierarchical fiber structure can be configured to allow selection between a first usage state in which the first surface faces the user and a second usage state in which the second surface faces the user.

[0044] (Structure by part) By varying the fiber diameter distribution, arrangement density, basis weight, porosity, bonding ratio, elastic modulus, hydrophilicity / hydrophobicity, or thickness in a stepwise or continuous manner in the planar or thickness direction, multiple functional regions corresponding to body parts or fluid-loaded areas can be formed.

[0045] (Thermal heating products) The layered fiber structure can be used in mattress pads, mattress toppers, mattresses, mattress fillings, bed pads, bedding, blankets, sleeping bags, sleeping bag liners, clothing, clothing liners, seat pads, thermal covers, or insulating products.

[0046] (Mattress structure) In mattresses, a layered fiber structure can be arranged as a surface layer, intermediate layer, support layer, peripheral layer, or replaceable cassette, allowing for variations in support, heat insulation, and breathability depending on the area or thickness.

[0047] (Filtering component) The layered fiber structure can be used as a filter that allows air, gas, water, oil, or other liquids to pass through and capture particles, droplets, oil, or foreign matter.

[0048] (Division of labor during filtration) In filtration applications, the first skeletal fibers maintain the overall shape and main flow path, the second support fibers or elastic support parts suppress deformation due to fluid pressure, and the fine fibers or nanofibers form the collection area.

[0049] (Washing and backwashing) The filtration member has a washing channel or backwashing direction for removing collected material, and after washing, the thickness, porosity, or channel can be restored by the restoring force of the elastic support.

[0050] (Method for regenerating filtration components) A method for regenerating a filter member may include a filtration step of passing a fluid through a layered fiber structure to collect collected material, a washing step of passing a washing liquid or gas in the normal fluid direction or backwashing direction to remove the collected material, a recovery step of restoring at least a portion of the thickness, porosity, or flow path by the restoring force of the elastic support, and a reuse step of reusing the recovered filter member. [Effects of the Invention]

[0051] (hierarchical support) According to the present invention, by assigning roles to fibers that form the main skeleton, fibers that provide intermediate support, and fine fibers, shape retention and void control can be improved compared to a homogeneous fiber aggregate without such division of roles. Each role may be assigned by differences in fiber diameter, or by differences in shape, material, orientation, tension state, three-dimensional arrangement, or bonding state.

[0052] (Lightweight, highly insulating) By incorporating large voids, intermediate voids, and fine voids, it is possible to maintain ventilation paths while suppressing air movement without excessively increasing the material weight.

[0053] (Compression recovery) Elastic support parts, including coil-shaped, spiral-shaped, loop-shaped, wave-shaped, multi-directionally oriented elastic support parts, or three-dimensional tension structures formed by the cooperation of tension members and compression support parts, can improve the recovery of thickness and void structure after repeated compression. In particular, by having the elastic support parts support the bridging part from the thickness direction, surface direction, or oblique direction, and by reforming fine voids and breathable continuous voids after load removal, it becomes easier to maintain heat retention, breathability, and moisture exhaust.

[0054] (Mattress effect) When applied to a mattress, it allows for easy adjustment of body pressure support, movement during sleep, heat retention, ventilation, and moisture wicking, either by area or in the thickness direction.

[0055] (Preventing falling off) By entangling, embedding, or locally fixing microfibers within the framework, detachment due to washing, fluid pressure, or long-term use can be suppressed.

[0056] (Insulates when wet) By transporting liquid water in a planar direction and discharging it to the periphery while suppressing its intrusion into the insulating area, the decrease in heat retention performance when wet can be suppressed.

[0057] (Filter shape retention) In filtration applications, the skeletal fiber section and elastic support section bear the fluid pressure, which helps suppress consolidation of the collection area and blockage of the flow path, thus preventing a sharp increase in pressure loss.

[0058] (Wash and reuse) Because the layered voids and thickness are easily restored after washing or backwashing, the likelihood of maintaining filtration performance or air permeability and allowing for repeated use increases.

[0059] (Application development) The common hierarchical fiber structure can be applied to thermal conditioning, mattresses, insulation, sound absorption, filtration, oil-water separation, and other uses.

[0060] (Manufacturability) Since the three-dimensional elastic support can be formed by the processes of shaping with a jig, heat fixing, multi-directional orientation, deposition of microfibers, and partial joining, the three-dimensional elastic support, bridging section, and hierarchical void can be easily reproduced in the manufacturing process. Furthermore, since it is possible to select a process to form the microfiber section after shaping, or to partially join the microfiber section after its formation, a manufacturing method can be adopted according to the application, material, and mass production equipment. [Brief explanation of the drawing]

[0061] [Figure 1] This is a schematic cross-sectional view showing the basic structure of the hierarchical fiber structure of the present invention, with the first skeletal fiber 11, second support fiber 12, third auxiliary fiber 13, and fine fiber portion 20 indicated by leader lines.

[0062] [Figure 2] This is a magnified section showing a tree-like hierarchical structure consisting of first skeletal fibers, second supporting fibers, third auxiliary fibers, and microfibers.

[0063] [Figure 3] Figure 3 is an explanatory diagram showing various examples of the elastic support portion 14. Figure 3(A) shows a wave-shaped portion, Figure 3(B) shows a loop-shaped portion, Figure 3(C) shows a coil-shaped portion, Figure 3(D) shows a helical portion, Figure 3(E) shows a multi-directionally oriented elastic support portion, Figure 3(F) shows an example of a three-dimensional tension structure, and Figure 3(G) shows an example of a tensegrity-like structure.

[0064] [Figure 4] This is a magnified view showing a state in which microfibers are arranged in a bridging manner between skeletal fibers, forming large voids, intermediate voids, and fine voids.

[0065] [Figure 5]Figure 5 is an explanatory diagram showing the joint, local fusion, and end fixing parts. Figure 5(A) is an overall schematic diagram showing the joint and fixing state including the first skeletal fiber 11, the second support fiber 12, the third auxiliary fiber 13, and the nanofiber 21. Black circles indicate examples of the location of the joint 25, line circles or ellipses indicate examples of the location of the local fusion 26, and dashed lines and fixing pieces indicate examples of the location of the end fixing part 60. Figure 5(B) is a partially enlarged view showing a comparison between the joint 25, which is formed as a point or in a small area at the intersection or contact of the fibers, and the local fusion part 26, where the fibers are locally fused and integrated. Figure 5(C) is a partially enlarged view showing the end fixing part 60, which holds the end of the nanofiber 21 with a fixing piece, fixing band, frame-shaped holding part, or resin fixing part.

[0066] [Figure 6] Figure 6 is a schematic cross-sectional view comparing (A) a heat retention usage state with the first surface 30 facing the user, and (B) a ventilation and moisture removal usage state with the second surface 40 facing the user, using rectangular cross-sections.

[0067] [Figure 7] Figure 7 is a plan view (A) showing a mattress 101 having multiple functional areas corresponding to body parts, and a cross-sectional view (B) showing the thickness-direction structure of the mattress 101 including the layered fiber structure 1, moisture transfer section 50, ventilation area 71, heat insulating area 70, elastic support section 14 and replaceable cassette 91, and also shows the manner in which the cassette 91 is attached, detached, reversed, or stacked.

[0068] [Figure 8] Figure 8 is a schematic cross-sectional view showing (A) surface-direction moisture transfer along the moisture transfer section 50, suppression of downward intrusion by the liquid water intrusion suppression boundary section 52, discharge of water vapor by the water vapor discharge passage 58, and discharge to the discharge end 73 and peripheral moisture removal section 74 via the peripheral discharge path 56, and (B) a schematic plan view showing the ventilation area 71 and main ventilation passage 72 formed between the multiple heat insulating areas 70 communicating with the peripheral discharge path 56, the discharge end 73 and the peripheral moisture removal section 74.

[0069] [Figure 9]Figure 9 is a schematic diagram showing an overall cross-section of the filter member 110, which includes a hierarchical fiber structure 1 held by a support frame 116, and a partially enlarged view of the internal structure of the hierarchical fiber structure 1, including the collection region 111.

[0070] [Figure 10] Figure 10 is an enlarged schematic diagram of the interior showing a state in which large voids 24 formed by the first skeletal fibers 11, intermediate voids 27 formed by the second support fibers 12, and fine voids 23 formed by nanofibers 21 coexist, and the fine voids 23 function as fine collection voids for filtration purposes.

[0071] [Figure 11] Figure 11 is a schematic diagram illustrating a comparison between (A) the state before fluid pressure is applied and (B) the state in which the first skeletal fiber 11 and the elastic support portion 14 support the collection region 111 and hold at least a portion of the main flow path when the thickness is compressed by a compressive load or fluid pressure.

[0072] [Figure 12] Figure 12 is a schematic diagram of the process, showing in order (A) the state in which collected material 115 is collected during normal filtration, (B) the state in which the washing flow in the backwashing direction 117 is passed through the washing channel 114 to discharge the collected material 115 to the outside, and (C) the state in which the thickness and voids have been restored after washing, along with arrows indicating the flow direction.

[0073] [Figure 13]Figure 13 is a schematic diagram of a process showing an example of a method for manufacturing a hierarchical fiber structure 1 including a three-dimensional elastic support portion 14. Figure 13(A) shows the state in which the second support fiber 12 or the third auxiliary fiber 13 is arranged along the jig 120, pin-shaped jig 121, or three-dimensional mold 123; Figure 13(B) shows the state in which the shaping support fiber 124 is formed by heating, pressurizing, suction, or heat fixing; Figure 13(C) shows the state in which a multi-directional orientation structure 125 is formed by arranging a plurality of elastic support portions 14 in different directions from each other; Figure 13(D) shows the state in which nanofibers 21 are deposited or bridged from the nanofiber supply portion 126; and Figure 13(E) shows the state in which the selected intersection or contact portion is partially joined by the partial joining processing portion 127, and integrated while leaving fine voids 23 and breathable large voids 24. [Modes for carrying out the invention]

[0074] (Overall structure) The hierarchical fiber structure 1 shown in Figure 1 comprises a skeletal fiber section 10 and a microfiber section 20. The skeletal fiber section 10 includes a first skeletal fiber 11 and, optionally, a second support fiber 12 and a third auxiliary fiber 13. The microfiber section 20 includes microfibers or nanofibers 21, and at least a portion thereof can be arranged within the thickness of the skeletal fiber section 10.

[0075] (Definition of nanofibers) In this specification, nanofiber 21 refers to a fiber with a fiber diameter of 1 μm or less. A group of fibers containing nanofiber 21 may, for example, have a number-average fiber diameter of 1 μm or less, or have 30% or more of the fibers in the group having a diameter of 1 μm or less based on the number of fibers or observed length.

[0076] (Scope of microfibers) The fine fiber portion 20 may consist solely of nanofibers 21, or it may be a mixture of nanofibers 21 and microfibers having a fiber diameter greater than 1 μm and less than or equal to 20 μm.

[0077] (Single-diameter skeleton) The skeletal fiber portion 10 may be formed from skeletal fibers of a single type, having a specific fiber diameter, material, or shape. Even in this case, the functions of the main skeleton and auxiliary support can be divided by varying the orientation, bonding state, tension state, or three-dimensional arrangement.

[0078] (Multiple diameter skeleton) The skeletal fiber portion 10 may include a first skeletal fiber 11, a second support fiber 12, and a third auxiliary fiber 13, each having a different fiber diameter. The first skeletal fiber 11 can perform a support function corresponding to the trunk, the second support fiber 12 to the branches, and the third auxiliary fiber 13 to the twigs.

[0079] (Continuous diameter distribution) Fiber diameter is not limited to three distinct stages, but may be continuously distributed from large to small diameters. Furthermore, even with the same diameter, the bending stiffness or elastic modulus may differ.

[0080] (Candidate fiber diameter) The fiber diameter of the first skeletal fiber 11 can be, for example, 20 μm to 3000 μm, the second supporting fiber 12 can be 5 μm to 500 μm, the third auxiliary fiber 13 can be 1 μm to 100 μm, and the nanofiber 21 can be 10 nm to 1 μm. However, these ranges may overlap.

[0081] (Skeleton material) The first skeletal fiber 11, the second support fiber 12, and the third auxiliary fiber 13 can be polyester, polybutylene terephthalate, polypropylene, polyethylene, polyamide, polyurethane, polylactic acid, acrylic, elastomer, cellulose fibers, natural fibers, metal fibers, composite fibers, or combinations thereof.

[0082] (Microfiber material) Nanofiber 21 can be made from polypropylene, polyethylene, polyester, polylactic acid, polyamide, polyurethane, polyacrylonitrile, polyvinylidene fluoride, cellulose-based materials, inorganic fibers, carbon-based fibers, or composite materials.

[0083] (Skeletal formation method) The skeletal fiber portion 10 can be formed as a card web, airlaid web, three-dimensional knitted fabric, three-dimensional mesh, crimped short fiber aggregate, long fiber nonwoven fabric, laminated web, quilting, woven or knitted fabric, molded mesh, or a combination thereof.

[0084] (Tree-like branching) As shown in Figure 2, a structure may be formed in which a second support fiber 12 branches from the first skeletal fiber 11, and a third auxiliary fiber 13 further branches from the second support fiber 12, thereby holding the fine fiber portion 20. The branched portion can be formed by fusion, entanglement, bonding, braiding, or integral spinning.

[0085] (Elastic support section) The elastic support portion 14 shown in Figure 3 is formed by creating at least a portion of the second support fiber 12 or the third auxiliary fiber 13 as a wave-shaped portion, loop portion 16, coil portion 15, helical portion, torsion deformation portion, multi-directional orientation structure, three-dimensional tension structure, or tensegrity-like structure. Figures 3(A) to (D) show examples of individual elastic forms, and Figures 3(E) to (G) show examples of three-dimensional support by combining multiple members.

[0086] (Coil structure) The coil section 15 may be a cylindrical coil, a conical coil, a barrel-shaped coil, a leaf spring-shaped coil, or a structure combining multiple coils. The coil section 15 can be arranged axially, obliquely, or planar with respect to the load direction, and by oriented multiple coil sections 15 in different axial directions from each other, a three-dimensional support network can be formed that exhibits restoring force against external forces in the thickness direction, planar direction, and oblique direction.

[0087] (Loops and waveforms) The loop portion 16 or the corrugated portion is not limited to a shape that curves or meanders along the plane, but may also have a shape that rises in the thickness direction, extends diagonally, or bulges three-dimensionally. By changing the curvature, amplitude, or rise angle during compression and returning to the original shape after the load is removed, thickness recovery, reversibility, and gap retention can be provided.

[0088] (3D tension structure) The tension member 17 and the compression support portion 18 may be connected at a distance from each other, and the structure may be configured to maintain its three-dimensional shape through the balance between tension and compression. The tension member 17 can be made of fibers, threads, strips, or membranes, and the compression support portion 18 can be made of rod-shaped, coil-shaped, or bundle-shaped fibers.

[0089] (Flexible three-dimensional deformation structure) The elastic support section 14 may be a flexible three-dimensional deformable structure in which multiple rings, arcs, rods, coils, helices, or threads are interconnected in a deformable manner, a foldable three-dimensional structure, or a squish-like structure. These structures deform not only under compression in the thickness direction but also under oblique shear, tension in the plane direction, or localized indentation, and are easily restored three-dimensionally after the load is removed.

[0090] (Shaping process for the three-dimensional elastic support) As shown in Figures 13(A) and (B), the second support fiber 12 or the third auxiliary fiber 13 can be positioned along a jig 120, a pin-shaped jig 121, a spiral jig, or a three-dimensional mold 123, and formed as a shape-forming support fiber 124 by heating, pressurizing, suction, hot air, ultrasonic waves, high-frequency heating, or cooling and fixing. If the support fiber contains a thermoplastic component, a low-melting-point component, or an elastic resin component, the component can be softened or melted and then cooled to maintain a shape that can be deformed in a corrugated, three-dimensional loop, coil, spiral, three-dimensional curve, or torsion manner.

[0091] (Manufacturing process for multi-directional oriented structures) As shown in Figure 13(C), a multi-directional orientation structure 125 can be formed by arranging multiple elastic support parts 14 in different directions, angles, or height positions. For example, by arranging multiple coil parts 15 in different axial directions, intersecting wave-shaped parts and loop parts 16 in an oblique direction, or arranging helical parts at multiple angles between the thickness direction and the surface direction, a three-dimensional support network that exhibits restoring force against loads in the thickness direction, surface direction, and oblique direction can be formed. The multi-directional orientation structure 125 may also be formed by lamination into a three-dimensional mold, suction molding, rotary drum deposition, airflow spraying, vibration application, needle punching, entanglement, knitting, weaving, or three-dimensional knitting.

[0092] (Manufacturing process for three-dimensional tension structures) When forming a three-dimensional tension structure or a tensegrity-like structure, coil sections 15, loop sections 16, columnar sections, bundle sections, or three-dimensional curved sections that function as compression support sections 18 can be arranged at predetermined intervals, and tension members 17 can be stretched between them. The tension members 17 can be formed from fibers, thread-like members, strip-like members, bundles of fine fibers, or elastic threads, and are stretched in an oblique direction, a plane direction, or a thickness direction. By locally fixing the ends or intersections of the tension members 17, the posture or spacing of the compression support sections 18 can be maintained, and a structure can be obtained in which tension changes and compression deformation cooperate when a load is applied to suppress excessive crushing of the fine fiber sections 20.

[0093] (Integration process with microfiber section) As shown in Figure 13(D), a fine fiber portion 20 can be formed by spraying, spinning, scattering, suction depositing, or entangling nanofibers 21 from a nanofiber supply unit 126 onto a skeletal fiber portion 10 including a shaping support fiber 124, a multi-directional orientation structure 125, or a stereotactic structure. Preferably, the nanofibers 21 are arranged to form a bridging portion 22 between the first skeletal fiber 11 and the elastic support portion 14, or between a plurality of elastic support portions 14. As shown in Figure 13(E), the partial joining section 127 can then form a joint 25 or a local fused section 26 at the selected intersection or contact point. The partial joining section 127 may be a hot air nozzle, a heating roll, an ultrasonic horn, a high-frequency heating section, adhesive fibers, low-melting-point fibers, a needle, or a local pressurizing section. By performing discrete partial joining rather than full joining, it is possible to suppress the shedding of the fine fiber section 20 while leaving fine voids 23, large voids 24, and intermediate voids 27.

[0094] (Preferred dimensions and manufacturing conditions) The height of the three-dimensional elastic support portion 14, i.e., the amount of undulation in the thickness direction, can be, for example, 0.3 mm to 30 mm, preferably 1 mm to 20 mm. The outer diameter of the coil portion 15 or the maximum width of the loop portion 16 can be, for example, 0.5 mm to 30 mm, and the pitch or adjacent spacing can be 0.2 mm to 30 mm. The area ratio or bonding ratio of the joint portion 25 can be, for example, 1% to 70%, preferably 3% to 50%, from the viewpoint of avoiding complete fixation. These numerical ranges can be changed according to the application, and can be selected considering flexibility and breathability for heating products, and pressure loss, collection efficiency and recovery after washing for filtration members.

[0095] (Bridging structure) As shown in Figure 4, at least a portion of the nanofibers 21 form bridging portions 22 within the thickness of the skeletal fiber portion 10 between a plurality of spaced-apart fibers or support portions from among the first skeletal fibers 11, second support fibers 12, third auxiliary fibers 13, or elastic support portions 14. Preferably, the bridging portions 22 are supported by the second support fibers 12 or elastic support portions 14 from the thickness direction or the surface direction.

[0096] (Definition of a bridging section) The bridging portion 22 refers to a portion of the nanofiber 21 where both ends or multiple portions are held by different skeletal fibers or support fibers, and at least a part of the intermediate portion crosses the void without making full contact with the skeletal fiber surface. This allows for subdivision of the inside of the void, unlike structures that simply cover the skeletal fiber surface.

[0097] (hierarchical void) Large voids 24 can be formed by the first skeletal fibers 11, intermediate voids 27 can be formed by the second support fibers 12 or third auxiliary fibers 13, and fine voids 23 can be formed by the nanofibers 21.

[0098] (Void remaining) It is preferable that the nanofibers 21 do not completely block the large voids 24 and the intermediate voids 27, but leave continuous voids that are larger than the fine voids 23 and through which air, gas, or liquid can pass in the thickness direction or planar direction.

[0099] (Recovery of gaps) By compressing and then restoring the skeletal fiber portion 10, the second support fiber 12, or the elastic support portion 14, at least a portion of the fine voids 23 partitioned by the bridging portion 22 and the large voids 24 or intermediate voids 27 that allow air to pass through can be reformed. At this time, the second support fiber 12 or the elastic support portion 14 supports the bridging portion 22, which helps to suppress excessive aggregation of the nanofibers 21, blockage of the fine voids 23, or disappearance of continuous voids.

[0100] (Local fixation) As shown in Figures 5(A) and (B), the nanofibers 21 can be entangled with the skeletal fibers, partially embedded in the surface of the skeletal fibers, or fixed by localized fusion portions 26 formed by locally heating and softening the low-melting-point components contained in the skeletal fibers or nanofibers 21. The localized fusion portion 26 may be an embodiment of the joint portion 25, where a part of the fiber material, low-melting-point components, adhesive components, or nanofibers 21 is locally softened or melted at the intersection or contact portion of the fibers, and integrated in an elliptical, island-like, short-line, or point-like shape. In Figure 5(B), the joint portion 25 is exemplified as a black circular or small-knot-like joint, and the localized fusion portion 26 is exemplified as an elliptical or island-like fusion region formed at the intersection or contact portion. The localized fusion portion 26 does not fuse the entire contact portion between the fibers, but can be formed to leave fine voids 23 or breathable continuous voids.

[0101] (partial joint) A joint 25 can be formed at a selected location among the intersections or contacts of the first skeletal fiber 11, the second support fiber 12, and the third auxiliary fiber 13. The joint 25 can be formed, for example, by heat fusion, thermocompression, ultrasonic welding, high-frequency heating, local heating, bonding with hot melt adhesive or reactive adhesive, sewn, braided, entangled, needle punched, wound, tied, crimped, integrally spun, or a combination thereof. Alternatively, the sheath component of the core-sheath composite fiber, low-melting-point fibers, adhesive fibers, or adhesive resin may be melted or softened at a selected location. The joint 25 is a broader concept that includes areas where fibers are held together so as not to separate, and the local fusion portion 26 may be a specific embodiment of the joint 25 formed by local fusion of fibrous material or low-melting-point components. As shown in Figure 5(B), the joint 25 is shown as a point-like or small-area joint at the intersection, and the local fusion portion 26 is shown as a region around the intersection or contact area that is locally fused or integrated. By arranging the joints 25 discretely in a point-like, short-line, or island-like manner, and leaving unjointed areas between the joints 25, relative displacement between fibers can be permitted, maintaining flexibility against bending, shearing, and compression, as well as resilience after load removal. The joints 25 can be formed before or after the introduction of the nanofibers 21. If formed after introduction, it is preferable to select a temperature, pressure, and processing time that suppresses excessive melting, aggregation, or blockage of the fine voids 23 of the nanofibers 21.

[0102] (fixed end) As shown in Figures 5(A) and (C), end fixing portions 60 can be provided on the periphery of the hierarchical fiber structure 1. The end fixing portion 60 is a fixing portion for holding the ends of the nanofibers 21 or fine fiber portions 20 without letting them escape, and can be formed as, for example, a skeletal fiber portion 10, an outer frame, a fixing piece, a fixing band, a surrounding tape, a cover material, a resin fixing portion, a heat sealing portion, a clamp portion, a sewing portion, or a frame-shaped holding portion. Figure 5(C) schematically shows the state in which the ends of the nanofibers 21 are guided toward the end fixing portion 60 and held by pressing, clamping, fusing, bonding, suturing, or embedding. The arrangement area of ​​the fine fibers may be terminated inward from the cut edge and fixed by heat compression, ultrasonic welding, suturing, tape wrapping, or cover sealing.

[0103] (Method for forming microfibers) Nanofibers 21 can be formed by melting or solution blowing with high-speed airflow, melt blowing, electrospinning, centrifugal spinning, splitting after composite spinning, mechanical fibrillation, or a combination thereof.

[0104] (Internal implementation) Nanofibers 21 can be introduced into the skeletal fiber section 10 by utilizing suction, air pressure difference, vibration, double-sided spraying, fiber opening of the skeleton, or deformation during transport.

[0105] (Placement control) The arrangement density of nanofibers 21 can be controlled by the nozzle movement speed, resin discharge rate, airflow rate, collection distance, spraying time, suction volume, mask shape, or transport speed.

[0106] (partial placement) The insulating regions 70 shown in Figure 8(B) can be formed as islands, stripes, grids, meshes, dots, waves, layers, or combinations thereof. Between adjacent insulating regions 70, interconnected ventilation regions 71 or main ventilation channels 72 can be formed. Similarly, the collection regions 111 for filtration applications can also be formed as islands, stripes, grids, meshes, dots, waves, layers, or combinations thereof.

[0107] (Moisture transfer section) The moisture transfer unit 50 shown in Figure 8(A) includes hydrophilic fibers, irregularly shaped cross-section fibers, grooved fibers, hygroscopic fibers, or hydrophilic treated fibers, and can transfer liquid water received from the user side by spreading it to the left or right or in the peripheral direction along the surface direction moisture transfer arrows shown in the figure.

[0108] (Intrusion control boundary) A liquid water intrusion suppression boundary 52 can be provided between the moisture transfer section 50 and the heat insulating region 70. The liquid water intrusion suppression boundary 52 can be formed by hydrophobic material, a difference in pore size, a difference in density, or a difference in fiber orientation, and can be configured to allow the movement of water vapor or air while suppressing the rapid intrusion of liquid water in the thickness direction.

[0109] (Peripheral discharge) As shown in Figures 8(A) and (B), moisture or water vapor moves to the peripheral discharge path 56 via the surface moisture transfer, water vapor discharge path 58, ventilation area 71, groove 42, or main ventilation path 72, and is guided from the discharge end 73 of the peripheral discharge path 56 to the peripheral moisture removal section 74, where it can be discharged to the outside. The peripheral moisture removal section 74 can be configured as an opening, a breathable end member, a moisture-absorbing and releasing end member, or a space that communicates with the outside air.

[0110] (Inverted front and back structure) The first surface 30 shown in Figure 6 can be configured as a warm surface having a low-permeability region 31 or a radiant heat-reflecting region 32. The low-permeability region 31 can be formed by a region with increased fiber density or bonding rate, a calendered region, a thin film, a coating layer, or a combination thereof. The radiant heat-reflecting region 32 can be formed by a metal foil, a metal vapor-deposited film, a layer containing metal fibers or metal threads, a coating layer containing infrared reflective particles, or a combination thereof. The second surface 40 can be configured as a ventilated / dehumidifying surface having protrusions 41, grooves 42, a moisture diffusion region 43, or a ventilation passage 44. The moisture diffusion region 43 may be formed integrally as the user-side surface portion of the moisture transfer section 50, or it may be formed as a separate surface layer communicating with the moisture transfer section 50. The ventilation passage 44 can communicate with a ventilation region 71 or a main ventilation passage 72. The first surface 30 and the second surface 40 may be opposite surfaces of the same hierarchical fiber structure 1, or they may be surfaces laminated with different surface materials or functional layers.

[0111] (Use on both sides) As shown in Figure 6(A), when the first surface 30 is facing the user, the low-ventilation area 31 suppresses air exchange, and the radiant heat reflection area 32 returns at least a portion of the radiant heat from the user side to the user side or suppresses downward heat transfer, thereby creating a usage state that prioritizes heat retention. As shown in Figure 6(B), when the second surface 40 is facing the user, the protrusion 41 leaves a groove 42 between it and the user, moisture is transferred from the moisture diffusion area 43 to the moisture transfer section 50 shown in Figure 8 and spread in the surface direction, and air and water vapor are moved from the ventilation passage 44 to the ventilation area 71 or main ventilation passage 72 shown in Figure 8, thereby creating a usage state that prioritizes ventilation and dehumidification. The user can reverse the layered fiber structure 1 or cassette 91 depending on the temperature, humidity, sweating state, or preference.

[0112] (Basic mattress components) The mattress 101 shown in Figures 7(A) and (B) includes a layered fiber structure 1 in at least part of the surface layer, intermediate layer, support layer, or replaceable cassette 91. In Figure 7(B), the direction from the user side to the lower support side of the mattress 101 is the thickness direction, and each layer and cassette 91 are arranged to overlap in this thickness direction. The layered fiber structure 1 may be arranged throughout the entire mattress 101, or it may be arranged in a part of the area corresponding to the body part shown in Figure 7(A).

[0113] (Structure of mattress by area) In the shoulder area 81, the chest and abdomen area 82, the back and waist area 83, and the foot area 84, the fiber diameter, skeletal density, number of coil sections 15, nanofiber arrangement density, thickness, or amount of ventilation can be varied.

[0114] (Mattress thickness direction structure) As shown in Figure 7(B), in the thickness direction of the mattress 101, a surface layer including a moisture transfer section 50 and a ventilation area 71 can be provided on the user side, an insulating area 70 or a cassette 91 can be provided in the middle section, and a support layer of first skeletal fibers 11 or an elastic support section 14 can be provided at the bottom. The cassette 91 can be arranged as one layer or an optional area that is stacked in the thickness direction of the mattress 101, and the thermal properties, moisture drainage, or support capacity can be changed by reversing, replacing, or stacking multiple layers. The order, thickness, and arrangement range of each layer can be changed according to the required thermal properties, moisture drainage, and support capacity.

[0115] (Mattress Cassette) The layered fiber structure 1 can be configured as a sheet-like, plate-like, bag-like, or frame-like replaceable mattress cassette 91. As shown in Figure 7(B), the cassette 91 is housed as one layer or a portion of the thickness of the mattress 101 and can be replaced, reversed, or stacked according to the season, user, weight, sweating state, or desired firmness.

[0116] (Cassette attachment / detachment mechanism) As shown in Figure 7(B), the cassette 91 can be detachably held in the mattress 101 or mattress topper by a housing, pocket, slit, openable outer cover, hook-and-loop fastener, wire fastener, snap, string, frame, or a combination thereof. By reversing the front and back of the cassette 91, replacing it with a cassette 91 of a different configuration, or stacking multiple cassettes 91, the thermal properties, moisture dissipation, or support capacity can be changed.

[0117] (Other heat-retaining products) The layered fiber structure 1 can be applied to mattress pads, mattress toppers, bed pads, bedding, blankets, sleeping bags, clothing, liners, seat pads, vehicle interior materials, or building insulation materials.

[0118] (Basic configuration of filtration components) The filtration member 110 shown in Figure 9 comprises a layered fiber structure 1 and, if necessary, a support frame 116 that holds the periphery of the layered fiber structure 1. A collection region 111 can be provided inside the layered fiber structure 1, and as shown in the enlarged portion of Figure 9, it can be formed as a layered structure including a first skeletal fiber 11, a second support fiber 12, and nanofibers 21. The filtration member 110 can be configured as a plate, box, bag, cylinder, or cartridge. Fluid flowing in from the fluid inlet 112 passes through the thickness of the layered fiber structure 1 and is guided to the fluid outlet 113.

[0119] (Collection area) The fine fiber portion 20 can form collection regions 111 that collect particles, droplets, oils, microorganisms, fiber debris, or other foreign matter. The collection regions 111 may be concentrated on the surface side or dispersed within the thickness.

[0120] (Hierarchical void for filtration) As shown in Figure 10, a main channel consisting of large voids 24 through which fluid can pass relatively easily is left between the first skeletal fibers 11, an intermediate channel consisting of intermediate voids 27 is formed around the second support fibers 12, and fine voids 23 can be formed around the nanofibers 21. In filtration applications, at least a portion of the fine voids 23 functions as fine collection voids that collect particles, droplets, or other foreign matter. This allows the fluid passage path and the fine collection region to coexist within the same thickness.

[0121] (Fluid pressure support) As shown in Figures 11(A) and (B), when fluid passes through, the first skeletal fibers 11 and the elastic support portion 14 support the collection region 111. Even if the thickness of the layered fiber structure 1 is partially reduced due to compressive load or fluid pressure, the elastic support portion 14 generates a reaction force while compressively deforming, and works in cooperation with the first skeletal fibers 11 to suppress excessive compaction of the fine fiber portion 20, thereby maintaining at least a portion of the main flow path.

[0122] (Spring-type filter support) The coil section 15, loop section 16, or three-dimensional tension structure can be arranged in a direction oblique to or intersecting with respect to the fluid direction, thereby elastically absorbing fluctuations in fluid pressure.

[0123] (Pressure loss suppression) By retaining the main and intermediate flow paths, it is easier to suppress the initial pressure loss and the increase in pressure loss after dust loading while improving collection efficiency.

[0124] (Washing channel) If collected material 115 accumulates in the collection area 111 by the normal filtration shown in Figure 12(A), a washing liquid or air can be flowed in the backwashing direction 117, as indicated by the arrow in Figure 12(B), and passed through the washing channel 114 which communicates with the inside and outside of the layered fiber structure 1. This allows the collected material 115 to be separated from the collection area 111 and discharged to the outside via the washing channel 114. The washing flow may flow in the same direction as the normal fluid direction, or it may be alternately switched between the backwashing direction 117 and the normal fluid direction.

[0125] (Recovery after cleaning) As shown in Figure 12(C), after washing or backwashing, the elastic support portion 14 can be restored, allowing at least a portion of the thickness, main channel, intermediate channel, and fine voids 23 of the filter member 110 to be recovered. For filtration applications, the recovered fine voids 23 can be used again as fine collection voids, allowing the fluid to pass through the filter member 110 for reuse.

[0126] (Prevents shedding during washing) By entangling or locally fixing the nanofibers 21 within the framework and providing end fixing portions 60, the shedding of fine fibers during washing can be suppressed.

[0127] (Procedure for regenerating the filter material) When regenerating the filter member 110, it is removed from the support frame 116 or the main body of the device as needed, and the collected material 115 is removed by cleaning solution, compressed air, pulsating flow, vibration, ultrasound, or a combination thereof. After that, the elastic support part 14 and the layered void are restored by natural restoration, blowing air, heat drying, or mechanical expansion, and it can be reused after confirming that the pressure loss, flow rate, or thickness has returned to a predetermined range.

[0128] (Air filter) The filtration member 110 can be used as an air filter in air purifiers, air conditioning equipment, vehicle air conditioning systems, vacuum cleaners, masks, respiratory protective equipment, industrial dust collectors, clean rooms, or ventilation systems.

[0129] (Liquid filter) The filtration member 110 can be used for water treatment, drinking water treatment, cooling water treatment, processing fluid treatment, cleaning fluid treatment, wastewater treatment, or medical or research fluid treatment.

[0130] (oil / water separation) By selecting the lipophilicity, hydrophobicity, hydrophilicity, or surface treatment of the skeletal fibers or nanofibers, they can be used for oil-water separation, grease trapping, or waste oil collection.

[0131] (Multi-stage filter) A first region for collecting coarse particles, a second region for collecting intermediate particles, and a third region for collecting fine particles can be arranged sequentially along the fluid direction.

[0132] (Filter cassette) The filtration member 110 may be provided as a cassette that can be attached to the support frame 116, allowing for cleaning, replacement, or changing to a cassette with different collection characteristics.

[0133] (Common structure between applications) While thermal control applications and filtration applications have different purposes, they can utilize common structures such as a hierarchical framework, elastic support, fine fiber retention, and the formation of fine voids while leaving large voids.

[0134] (Sound absorption, cushioning, and packaging applications) The layered fiber structure 1 can be used as a sound-absorbing material, a cushioning material, or a packaging material. In sound absorption applications, sound waves passing through the large voids 24, intermediate voids 27, and fine voids 23 can be attenuated by friction with the fiber surface, viscous loss within the voids, and minute vibrations of the fiber group. In cushioning or packaging applications, the first skeletal fibers 11 and elastic support parts 14 deform under impact load, and after the load is removed, at least a portion of the thickness and voids recover, thereby suppressing the transmission of impact to the packaged object. The sound-absorbing or cushioning regions can be partially arranged in the planar direction or thickness direction depending on the required frequency characteristics, impact absorption, or resilience.

[0135] (Positioning of the assumed embodiment) The following hypothetical embodiments do not indicate that they have been experimentally tested at the time of filing, but are design examples for those skilled in the art to select materials, dimensions, proportions, and manufacturing conditions.

[0136] (Imaginary Manufacturing Embodiment 1) By using a corrugated roll or a three-dimensional uneven mold to shape the second support fiber 12 into a corrugated or three-dimensional loop shape that undulates in the vertical direction, and then partially joining it with the first skeletal fiber 11 after cooling or heat fixing, an elastic support portion 14 in the thickness direction can be formed.

[0137] (Hypothetical manufacturing embodiment 2) By forming multiple coil sections 15 or helical sections using a spiral or pin-shaped jig 121, arranging them in a three-dimensional mold so that their respective axial directions are different, and then depositing nanofibers 21 by suction, a multi-directionally oriented three-dimensional support network can be formed.

[0138] (Hypothetical manufacturing embodiment 3) A tensegrity-like structure is formed by arranging multiple compression support parts 18 at intervals, bridging tension members 17 diagonally between them, and locally fixing the ends or intersections, and nanofibers 21 can be arranged in a bridging manner inside or on the surface of the structure.

[0139] (Hypothetical Thermal Embodiment 1) In the lightweight, high-insulation type, the structure may include 50% to 90% by mass of hollow or crimped first skeletal fibers 11, 5% to 40% by mass of second support fibers 12 or third auxiliary fibers 13, and 1% to 30% by mass of nanofibers 21.

[0140] (Hypothetical Thermal Embodiment 2) In the highly resilient type, a portion of the second support fiber 12 is made into a coil or loop shape, and only the intersection with the first skeletal fiber 11 is partially joined.

[0141] (Hypothetical Thermal Implementation 3) In the wet-response type, a combination of a heat insulating region 70 made of hydrophobic nanofibers 21, a hydrophilic moisture transport section 50, and a peripheral discharge path 56 is used.

[0142] (Assumed Thermal Embodiment 4) In the mattress type, different support densities are set for the shoulder and lumbar regions, with more ventilation areas 71 in the back region and more heat insulating areas 70 in the foot region.

[0143] (Assumed thermal embodiment 5) In the inverted type, high-density fine fibers and a flexible surface are provided on the first surface 30 side, and protrusions 41 and grooves 42 are provided on the second surface 40 side.

[0144] (Assumed filtration mechanism 1) In the air filter type, the first skeletal fiber 11 maintains a thickness of 5 mm to 50 mm, and the second support fiber 12 and nanofiber 21 are arranged within the thickness.

[0145] (Hypothetical filtration mechanism 2) In the washable and reusable type, the collection area 111 is dispersed inside the frame, an end fixing part 60 is provided, and the elastic support part 14 is restored after washing or backwashing.

[0146] (Hypothetical filtration mechanism 3) In oil-water separation systems, the fluid inlet side can be made lipophilic or hydrophobic, while the fluid outlet side can be hydrophilic or have a different pore size distribution.

[0147] (Combinations of assumed embodiments) The aforementioned heating embodiment and filtration embodiment are not mutually exclusive and can be combined depending on the application.

[0148] (Basic principles of evaluation) The layered fiber structure 1 can be evaluated according to its application based on thermal resistance, basis weight, thickness, air permeability, thickness recovery rate, heat retention rate when wet, fiber shedding rate, collection efficiency, pressure loss, performance retention rate after washing, or fluid permeability.

[0149] (thermal resistance) Thermal resistance can be measured using a protective heat plate, a sweating heat plate, a heat flow meter, or an equivalent device. The heat retention performance per unit weight can be evaluated by dividing the thermal resistance by the weight.

[0150] (Thickness recovery rate) The thickness recovery rate can be calculated as the ratio of the recovered thickness T1 after a predetermined compression to the initial thickness T0, T1 / T0 × 100.

[0151] (Amount of clothes lost during washing) The amount of fiber shedding can be evaluated by filtering the laundry wastewater or rinse water through a filter with a predetermined pore size and measuring the mass, number, or particle size distribution of the recovered material.

[0152] (Moisture retention rate) The wet thermal insulation retention rate can be calculated as the ratio of the wet thermal resistance Rw to the dry thermal resistance Rd, which is Rw / Rd × 100.

[0153] (Collection efficiency) The collection efficiency of the filtration member 110 can be determined from the particle concentration, oil concentration, turbidity, or target substance concentration on the fluid inlet 112 side and the fluid outlet 113 side.

[0154] (Pressure loss) Pressure loss is measured as the pressure difference between the fluid inlet 112 and the fluid outlet 113 at a predetermined face velocity or flow rate. It is preferable to measure it initially, after loading, after cleaning, and after reuse.

[0155] (Collection capacity) Collection capacity can be evaluated as the mass of particles or liquid collected until a predetermined pressure loss or predetermined collection efficiency is reached.

[0156] (Washing and regeneration rate) The cleaning and regeneration rate can be evaluated as the recovery rate of pressure loss, collection efficiency, thickness, porosity, flow rate, or continuous flow path before and after cleaning.

[0157] (Repeated durability) By repeatedly performing compression, fluid passage, washing, backwashing, and drying, the shape retention rate, the amount of fine fiber shedding, and the performance retention rate can be evaluated.

[0158] (In combination with sensors) The thermal conditioning device or filtration member 110 may be equipped with a sensor that detects temperature, humidity, pressure, flow rate, differential pressure, body movement, or number of uses.

[0159] (Far-infrared material) The skeletal fibers, microfibers, or surface material may contain, fix, or support minerals, ceramics, or other functional materials that emit far-infrared rays. This far-infrared radiating material may be provided in a configuration that performs a different function from the radiant heat reflection region 32 in Figure 6, or it may be provided in combination with the radiant heat reflection region 32. When both are combined, the emission of far-infrared rays and the reflection of radiant heat from the user side or the suppression of downward heat transfer can be adjusted according to the application.

[0160] (Captures sweat and dirt) The user-facing surface may be provided with a fine fiber area that captures sweat, sebum, or dirt, which can then be transferred to the moisture transfer section 50 or removed when the outer cover is washed.

[0161] (Example of change) The present invention is not limited to the embodiments described above, and each component can be added, deleted, replaced, combined, or modified depending on the application, operating environment, target fluid, material, production equipment, or required performance. [Industrial applicability]

[0162] (Industrial applicability) The present invention can be used in bedding, mattresses, clothing, sleeping bags, medical and nursing care products, seating accessories, vehicle interior materials, building insulation materials, sound-absorbing materials, packaging materials, air filters, liquid filters, oil-water separators, and washable and reusable filtration components, among other fields. [Explanation of Symbols]

[0163] (sign) 1. Layered fiber structure 10. Skeletal fiber section 11. First skeletal fiber 12 Second support fiber 13 Third auxiliary fiber 14 Elastic support section 15 Coil section 16 Loop section 17 Tension Member 18 Compression support section 20. Microfiber section 21 nanofibers 22 Bridging section 23. Microvoids (including micro-capsulation voids in filtration applications) 24 Large void 25 Joint 26 Local fusion area 27 Intermediate void 30 Page 1 31 Low ventilation area 32 Radiant heat reflection area 40 Side 2 41 Protrusion 42 Groove 43. Moisture diffusion region 44 Ventilation channel 50 Moisture transfer section 52 Liquid water intrusion suppression boundary (liquid water intrusion suppression boundary) 56 Peripheral discharge path 58 Water vapor discharge channel 60 End fixing part 70 Insulation Area 71 Ventilated area 72 Main ventilation channel 73 Discharge end 74 Peripheral moisture drainage section 81 Shoulder area 82. Corresponding area of ​​the thoracic and abdominal regions 83. Corresponding area for the back and lumbar region 84 Foot area 91 Cassettes 101 Mattress 110 Filtration component 111 Collection area 112 Fluid inlet 113 Fluid outlet 114 Washing channel 115 Collected material 116 support frame 117 Backwash direction 120 jigs 121 Pin-shaped jig 123 Three-dimensional mold 124 Shaping support fibers 125 Multidirectional orientation structure 126 Nanofiber Supply Unit 127 Partial Joining Section

Claims

1. A skeletal fiber portion containing multiple skeletal fibers, A fine fiber portion containing multiple nanofibers smaller in diameter than the aforementioned skeletal fibers, Equipped with, The skeletal fiber portion is formed by the three-dimensional entanglement or partial joining of the plurality of skeletal fibers, and includes support fibers or elastic support portions within the skeletal fiber portion that support the fine fiber portion from the thickness direction or the surface direction. At least a portion of the nanofibers forms a bridge between a plurality of spaced-apart skeletal fibers within the thickness of the skeletal fiber portion, or between the skeletal fibers and the support fibers or elastic support portion, thereby partitioning a portion of the voids within the skeletal fiber portion into fine voids, while leaving open, continuous voids larger than the fine voids that allow for airflow. The support fibers or elastic support portion suppress excessive consolidation of the bridging portion and the fine voids during compression, and reform at least a portion of the fine voids and the breathable continuous voids after the load is removed. A layered fiber structure for thermal regulation.

2. The skeletal fiber portion includes relatively thick first skeletal fibers and second supporting fibers that are thinner than the first skeletal fibers. The second support fiber connects the first skeletal fibers and holds the fine fiber portion. The layered fiber structure for thermal regulation according to claim 1.

3. The skeletal fiber portion further includes support fibers that connect the skeletal fibers, At least a portion of the support fibers or the skeletal fibers form an elastic support portion having a crimped, wave-shaped, loop-shaped, coil-shaped, spiral-shaped, or torsion-deformable shape. The layered fiber structure for thermal regulation according to claim 1.

4. The thermal regulating layered fiber structure has a first surface and a second surface opposite to the first surface. The first surface includes a region with lower air permeability or a region that reflects radiant heat, The second surface includes a plurality of protrusions or grooves that form a ventilation passage between it and the user, and a moisture diffusion region that transports or diffuses moisture in the surface direction, or a ventilation region that communicates with the ventilation passage. In the first usage state, with the first surface facing the user, a usage state prioritizing heat retention is created, and in the second usage state, with the second surface facing the user, a usage state prioritizing ventilation or moisture removal is created. The layered fiber structure for thermal regulation according to claim 1.

5. The skeletal fiber portion includes first skeletal fibers and second support fibers connecting the first skeletal fibers. Large voids formed by the first skeletal fibers, intermediate voids formed by the second supporting fibers, and fine voids formed by the nanofibers coexist. At least a portion of the large void or the intermediate void remains in a state that allows for ventilation. The layered fiber structure for thermal regulation according to claim 1.

6. The skeletal fiber portion further includes support fibers that connect the skeletal fibers, The skeletal fibers are partially joined to each other, or to the skeletal fibers and the supporting fibers, at selected intersections or contact points in the form of points, short lines, or islands, and the entire surface is not integrally fixed. The layered fiber structure for thermal regulation according to claim 1.

7. At least a portion of the nanofibers are entangled with the skeletal fibers, partially embedded on the surface of the skeletal fibers, or fixed by local fusion of low-melting-point components contained in the skeletal fibers or the nanofibers. The peripheral portion of the aforementioned heat-regulating layered fiber structure is provided with an end fixing portion to suppress the shedding of the nanofibers to the outside. The layered fiber structure for thermal regulation according to claim 1.

8. The heat insulating region including the aforementioned fine fiber portion is hydrophobic. At least one surface side of the aforementioned thermal regulating layered fiber structure is provided with a moisture transfer section for transferring or diffusing liquid water in the planar direction. A liquid water intrusion suppression boundary is formed between the moisture transfer section and the heat insulating region to suppress the intrusion of liquid water into the heat insulating region. A dehumidification path is formed that connects from the moisture transfer section or its vicinity to a peripheral discharge path via a ventilation area, groove, or main ventilation passage, and from the peripheral discharge path to a peripheral dehumidification section. The layered fiber structure for thermal regulation according to claim 1.

9. The aforementioned fine fiber portion forms a plurality of heat insulating regions consisting of island-like, striated, grid-like, mesh-like, or combinations thereof. Multiple ventilation regions are formed between adjacent thermal insulation regions, and these multiple ventilation regions communicate with each other to form a main ventilation channel, which communicates with a peripheral discharge path or a peripheral moisture removal section. The layered fiber structure for thermal regulation according to claim 1.

10. At least one of the following properties of the nanofibers—arrangement density, fiber diameter distribution, basis weight, porosity, bonding rate between the skeletal fibers, elastic modulus, hydrophilicity, and hydrophobicity—differs stepwise or continuously in the planar or thickness direction. Multiple functional areas with different properties—heat retention, breathability, moisture wicking, support, or thickness recovery—are formed to correspond to the user's body parts. The layered fiber structure for thermal regulation according to claim 1.

11. A thermal conditioning product comprising a layered fiber structure for thermal conditioning as described in claim 1, The aforementioned heat-regulating products include mattress pads, mattress toppers, mattresses, mattress fillings, bed pads, bedding, blankets, sleeping bags, sleeping bag liners, clothing, clothing liners, or insulating products. Heat therapy products.

12. A thermal conditioning device according to claim 11, The aforementioned heat-regulating product is a mattress or mattress topper. The thermal regulating layered fiber structure is provided as a removable cassette that is housed as one layer or a selected region that is stacked in the thickness direction of the mattress or mattress topper. The cassette is reversible, replaceable, or stackable. Heat therapy products.

13. A method for manufacturing a hierarchical fiber structure, A step of forming a skeletal fiber portion containing multiple skeletal fibers, A step of shaping a second support fiber or a third auxiliary fiber into a wave-like, loop-like, coil-like, spiral-like, three-dimensionally curved, or torsionally deformable shape, thereby forming an elastic support portion that exhibits restoring force in the thickness direction, surface direction, or oblique direction, The process involves arranging the elastic support parts in different directions, angles, or height positions to form a multi-directionally oriented three-dimensional support network. A step of depositing, spinning, scattering, entangling, or attaching nanofibers or fine fibers to at least one of the skeletal fiber portion and the elastic support portion to form a fine fiber portion that bridges the gaps between the skeletal fiber portion or the elastic support portion, A step of partially joining the selected intersection or contact area, leaving fine voids and breathable continuous voids, A method for manufacturing a hierarchical fiber structure, including [the specified element].

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