JP7048706B1 - Three-dimensional knitting, air conditioning filters and air conditioning equipment - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-dimensional knitted fabric capable of achieving both ease of air passage and high air conditioning function (for example, humidification function). SOLUTION: In a three-dimensional knitted fabric 1 in which a first knitted fabric 10 and a second knitted fabric 20 are connected by a connecting thread 30, each of the first knitted fabric 10 and the second knitted fabric 20 is formed by a dense knitting structure. The dense portions 10a and 20a are made to have a structure in which the dense portions 10a and 20a and the sparse portions 10b and 20b formed by the sparse knitting structure are repeatedly arranged. It was arranged so as to overlap the sparse portion 10b. As a result, the air introduced into the inside of the three-dimensional knitted fabric 1 from the sparse portion 10b of the first knitted fabric 10 is derived from the sparse portion 20b of the second knitted fabric 20 by bypassing the dense portion 20a of the second knitted fabric 20. Become so. Therefore, it is possible to lengthen the path length through which the air passes through the three-dimensional knitted fabric 1 while suppressing the pressure loss of the air to a small value, and the air is brought into contact with the moisture held in the three-dimensional knitted fabric 1 for a long time to firmly hold the air. Can be humidified. [Selection diagram] Fig. 1

Description

The present invention relates to a three-dimensional knit, and an air-conditioning filter and an air-conditioning device using the three-dimensional knit.

In recent years, there has been increasing interest in improving the indoor air environment from the viewpoint of virus infection prevention and beauty. Among them, the humidifier is a remarkable product for which many new technologies have been developed in recent years. Humidifiers are roughly classified into vaporization type, steam type, ultrasonic type, and hybrid type according to the humidification method.

Of these, the vaporization type humidifier humidifies the air by passing the air through a humidifying filter soaked with water. Unlike other types of humidifiers, the vaporization type humidifier does not require a heat source, so it has the advantages of high safety and reduction of electricity costs. The humidifying filter used in the vaporization type humidifier is required to have both a function of retaining a large amount of water and a function of allowing air to pass through well.

Examples of the humidifying filter include the humidifying filters 10 described in paragraphs 0017 to 0018 of Patent Document 1 and FIGS. 2 and 3. The humidifying filter 10 is obtained by folding a fiber sheet made of paper or the like into a pleated shape (corrugated shape). As shown by the arrow 8a in FIG. 2, the dry air can be humidified by passing the dry air through the humidifying filter 10 in a state of being impregnated with water.

Japanese Unexamined Patent Publication No. 2015-140950

However, the humidifying filters 10 described in paragraphs 0017 to 0018 of Patent Document 1 and FIGS. 2 and 3 are difficult to pass air (the pressure loss of the passing air is large) and have a high blowing ability as a fan or the like for sending air. I had the problem of having to adopt something. This is because the fiber sheet forming the humidifying filter 10 is formed by entwining fibers in a fine mesh pattern, and the capillary phenomenon due to this mesh structure enhances the holding power of water. This is because the fiber sheet having the above has a large air flow resistance.

In this regard, paragraph 0026 of Patent Document 1 and FIG. 4 describe another form of the humidifying filter 10. As shown in FIG. 4 of the same document, the humidifying filter 10 comprises two knitted fabrics arranged on the upstream side and the downstream side, and a plurality of connecting fibers connecting the two knitted fabrics at intervals. It is a three-dimensional knitted fabric. Both the knitted fabric 15 on the upstream side and the knitted fabric 16 on the downstream side have a structure in which a hexagonal structure is spread, and the inside of the hexagon is a ventilation hole that penetrates the humidifying filter 10 on the front and back. ing. Humidifying water is retained between the knitted fabric and the connecting fibers. Since the humidifying filter 10 has the above-mentioned ventilation holes, unlike the humidifying filters 10 described in FIGS. 2 and 3 of the same document, it is easy for air to pass therethrough.

However, this humidifying filter 10 has a problem that it is difficult to increase the humidifying capacity. This is because the humidifying filter 10 allows air to pass through the ventilation holes in a short time, so that it is difficult to bring the air into contact with the moisture held in the humidifying filter 10 for a long time.

The present invention has been made to solve the above problems, and provides a three-dimensional knitted fabric capable of achieving both ease of air passage and high air conditioning function. It is also an object of the present invention to provide an air conditioning filter using this three-dimensional knitted fabric. Further, it is also an object of the present invention to provide an air conditioner using this air conditioner filter.

The above issues are
It is a three-dimensional knit that connects the first knitted fabric and the second knitted fabric with a connecting thread.
Each of the first knitted fabric and the second knitted fabric has a structure in which dense parts formed by a dense knitted structure and sparse parts formed by a sparse knitted structure are repeatedly arranged.
It is solved by providing a three-dimensional knit characterized in that the dense part of the second knitted fabric is arranged so as to overlap the sparse part of the first knitted fabric.

Here, the descriptions "dense part formed by dense knitting structure" and "sparse part formed by sparse knitting structure" are intended to indicate the relative degree of sparseness between the dense part and the sparse part. be. That is, in the dense part of the first knitted fabric, the knitting yarns are arranged more densely than the sparse part of the first knitted fabric, and in the dense part of the second knitted fabric, the knitting yarn is arranged more than the sparse part of the second knitted fabric. Are densely arranged. For this reason, the dense part of the first knitted fabric is less likely to allow air to pass through than the sparse part of the first knitted fabric (the sparse part of the first knitted fabric is easier to pass air than the dense part of the first knitted fabric). The dense part of the second knitted fabric is more difficult to pass air than the sparse part of the second knitted fabric (the sparse part of the second knitted fabric is easier to pass air than the dense part of the second knitted fabric). The knitting structure can be made denser, for example, by increasing the knitting density (decreasing the knitting density) or thickening the knitting yarn, and conversely, decreasing the knitting density (increasing the knitting density). It can be made sparse by making things and making the knitting yarn thinner.

In the three-dimensional knitted fabric of the present invention, since sparse portions through which air can easily pass are provided in both the first knitted fabric and the second knitted fabric, air can easily pass through in the thickness direction of the three-dimensional knitted fabric. Therefore, it is possible to maintain a high air permeability of the three-dimensional knitted fabric (suppress the pressure loss of the passing air to a small value). In addition, in the three-dimensional knitting of the present invention, since the dense part of the second knitted fabric is arranged so as to overlap the sparse part of the first knitted fabric, the inside of the three-dimensional knitted fabric from the sparse part of the first knitted fabric (first knitted fabric and the first knitted fabric). The air introduced into the gap between the two knitted fabrics) bypasses the dense part of the second knitted fabric and is derived from the sparse part of the second knitted fabric. Therefore, it is possible to secure a long path length of air passing through the inside of the three-dimensional knit (that is, secure a long residence time of air inside the three-dimensional knit). Therefore, it is possible to obtain a better humidifying effect by contacting the air introduced into the inside of the three-dimensional knit with the moisture held in the three-dimensional knit for a long time. In addition, it is possible to more effectively collect dust, pollen, etc. contained in the air introduced into the three-dimensional knitted fabric. As described above, the three-dimensional knitted fabric of the present invention can achieve both ease of air passage and high air-conditioning function.

In the three-dimensional knitting of the present invention, the specific knitting method of the first knitted fabric and the second knitted fabric is not particularly limited. In the three-dimensional knitting of the present invention, for example, the dense part of the first knitted fabric and the dense part of the second knitted fabric are formed by a knitted structure in which warp and weft are knitted in a mesh pattern, and the sparse portion of the first knitted fabric is formed. And the sparse part of the second knitted fabric can be formed by the knitting structure in which the warp and weft are chain-knitted. This makes it possible to knit dense parts and sparse parts with a simple structure.

In the three-dimensional knitting of the present invention, it is preferable to use a covering yarn in which a sheath yarn is wound around a core yarn in any of the knitting yarn of the first knitted fabric, the knitting yarn of the second knitted fabric, and the connecting yarn. The covering yarn has a large specific surface area and is strong. Therefore, when the covering yarn is used, the water retention capacity and the dust collecting capacity of the three-dimensional knit can be enhanced, and at the same time, the morphological stability of the three-dimensional knit can be enhanced (the three-dimensional structure can be easily maintained).

Further, in the three-dimensional knitting of the present invention, it is also preferable to use microfiber as any of the knitting yarn of the first knitted fabric, the knitting yarn of the second knitted fabric, and the connecting yarn. Microfiber usually refers to a multifilament in which a plurality of ultrafine fibers having a fineness of 1 dtex or less are bundled. Since this microfiber has a very large specific surface area, it has excellent water retention and dust catching power. Therefore, if microfibers are used for any of the knitting yarns of the first knitting fabric, the knitting yarns of the second knitting fabric, and the connecting yarns, the water retention capacity and the dust collecting capacity of the three-dimensional knitted fabric can be further enhanced.

Further, in the three-dimensional knitted fabric of the present invention, it is also preferable to use heat-sealed fibers for any of the knitted yarn of the first knitted fabric, the knitted yarn of the second knitted fabric, and the connecting yarn. Here, the heat-sealed fiber means a fiber whose surface or the whole is formed of a thermoplastic polymer. When heat is applied to the heat-fused fibers, the thermoplastic polymer melts, so that the heat-fused fibers can be fused with each other or the heat-fused fibers can be fused with other fibers. Therefore, if heat-fused fibers are used for either the knitting yarn of the first knitting fabric, the knitting yarn of the second knitting fabric, or the connecting yarn, the shape of the three-dimensional knitted fabric is stabilized by applying heat to the knitted three-dimensional knitted fabric. It is possible to make the three-dimensional knit into a desired shape, and to prevent the three-dimensional knit from fraying.

The use of the three-dimensional knitted fabric of the present invention is not particularly limited, and can be used for various purposes. The three-dimensional knitted fabric of the present invention can be particularly suitably used as an air-conditioning filter for humidity control, dustproofing, temperature control and the like. Here, the "air-conditioning filter" refers to a member through which air is passed for the purpose of air-conditioning. The concept of "air conditioning filter" shall include not only those that remove a specific substance from the air, but also those that add a specific substance to the air. For example, a humidifying member that adds moisture to the air passing through it is also included in the concept of "air conditioning filter".

As described above, the present invention makes it possible to provide a three-dimensional knitted fabric capable of achieving both ease of air passage and high air conditioning function. It is also possible to provide an air conditioning filter using this three-dimensional knitted fabric. Further, it becomes possible to provide an air conditioner using this air conditioner filter.

It is a figure which represented the cross section of the three-dimensional knitting of this invention schematically. It is a photograph which took the three-dimensional knitting of this embodiment from the first knitting ground side. It is an organization chart of the three-dimensional knitting of this embodiment. It is an electron micrograph of the covering yarn used for the connecting yarn in the three-dimensional knitting of this embodiment.

1. 1. Outline of the Invention A preferred embodiment of the present invention will be described more specifically with reference to the drawings. FIG. 1 is a diagram schematically showing a cross section of the three-dimensional knitted fabric 1 of the present invention.

As shown in FIG. 1, the three-dimensional knitted fabric 1 of the present invention includes a first knitted fabric 10, a second knitted fabric 20, and a connecting thread 30 for connecting the first knitted fabric 10 and the second knitted fabric 20. It has become a thing. The first knitted fabric 10 is a substantially flat knitted fabric, and has a structure in which dense portions 10a and sparse portions 10b are repeatedly arranged. The dense portion 10a is formed of a knitted structure that is denser than the sparse portion 10b, and is less likely to allow air to pass through than the sparse portion 10b. Conversely, the sparse portion 10b is formed of a knitted structure that is sparser than the dense portion 10a, and is easier for air to pass through than the dense portion 10a. The second knitted fabric 20 is also a substantially flat knitted fabric like the first knitted fabric 10, and the dense portion 20a formed by the dense knitting structure and the sparse portion 20b formed by the sparse knitting structure are formed. It has a structure that is repeatedly arranged. The sparse portion 10b of the first knitted fabric 10 is overlapped with the dense portion 20a of the second knitted fabric 20, and the sparse portion 20b of the second knitted fabric 20 is arranged in the dense portion 10a of the first knitted fabric 10. Are arranged overlapping. Here, "overlapping and arranging" means that the three-dimensional knitted fabrics 1 appear to overlap when viewed from a direction parallel to the thickness direction.

When an air flow is applied to the three-dimensional knitted fabric 1 of the present invention from the side of the first knitted fabric 10, the air mainly follows the path as shown by the arrow A in FIG. That is, most of the air is introduced into the three-dimensional knitted fabric 1 through the sparse portion 10b of the first knitted fabric 10 through which air can easily pass. Most of the introduced air collides with the dense portion 20a of the second knitted fabric 20 where it is difficult for air to pass through, and changes the traveling direction, so that the inside of the three-dimensional knitted fabric 1 is angled with respect to the thickness direction of the three-dimensional knitted fabric 1. Proceed in the direction (direction non-parallel to the thickness direction of the three-dimensional knitted fabric 1). After that, the air is led out to the outside of the three-dimensional knitted fabric 1 mainly through the sparse portion 20b adjacent to the dense portion 20a. A similar phenomenon occurs when an air flow is applied from the second knitted fabric 20 side.

As described above, in the three-dimensional knitted fabric 1 of the present invention, since the sparse portions 10b and 20b that allow air to easily pass through both the first knitted fabric 10 and the second knitted fabric 20, air is also provided to the three-dimensional knitted fabric 1 as a whole. It is easy to pass through (the pressure loss of the passing air is small). In addition, since the air derived into the three-dimensional knitting 1 travels while meandering inside the three-dimensional knitting 1, the path length of the air passing through the three-dimensional knitting 1 is lengthened (the residence time of the air in the three-dimensional knitting 1 is increased). Can be lengthened). Therefore, when the three-dimensional knitted fabric 1 of the present invention is used as a humidifying filter, air can be brought into contact with the moisture retained in the three-dimensional knitted fabric 1 for a long time, and an excellent humidifying function is exhibited. Further, when the three-dimensional knitting material 1 of the present invention is used as a dust collecting filter, air can be brought into contact with the fibers of the knitting yarn constituting the three-dimensional knitting material 1 for a long time, and an excellent dust collecting function is exhibited. .. In particular, the dense portions 10a and 20a formed of the dense structure have a high dust collecting power, and the air introduced from the sparse portion 10b of the first knitted fabric 10 collides with the dense portion 20a of the second knitted fabric 20. At that time, dust, pollen, etc. contained in the air are firmly collected by the dense portion 20a.

The first knitted fabric 10 is usually formed with a plurality of dense portions 10a. Each dense portion 10a is usually formed in a band shape. In this case, the sparse portion 10b is also formed in a band shape. Therefore, in the first knitted fabric 10, a striped pattern in which the dense portions 10a and the sparse portions 10b are alternately arranged in one direction is formed.

However, the shapes of the dense portion 10a and each sparse portion 10b are not limited to the strip shape. Each dense portion 10a (or each sparse portion 10b) may be formed in a substantially polygonal shape (rectangular shape or the like), a substantially circular shape, or a substantially elliptical shape, for example. In this case, how to arrange each dense portion 10a (or each sparse portion 10b) is not particularly limited. For example, the dense portions 10a and the sparse portions 10b may be arranged alternately in two or more directions. More specifically, for example, the dense portions 10a and the sparse portions 10b, both of which are substantially rectangular, can be arranged alternately in two directions substantially orthogonal to each other. In this case, a checkered pattern (checkerboard pattern) is formed on the first knitted fabric 10.

When both the dense portion 10a and the sparse portion 10b are formed in a band shape, even if the width of each dense portion 10a (the width in the left-right direction on the paper surface of FIG. 1; the same applies hereinafter) is constant, each dense portion 10a It may be different depending on. Further, the width of each sparse portion 10b may be constant or different depending on each sparse portion 10b. The same applies to the dense portion 20a and the sparse portion 20b of the second knitted fabric 20.

The ratio (area ratio) occupied by the dense portion 10a in the first knitted fabric 10 is not particularly limited. However, if the ratio of the dense portion 10a is too high, the air permeability of the first knitted fabric 10 may decrease, and it may be difficult to maintain the air permeability of the entire three-dimensional knitted fabric 1 as high. Therefore, the ratio of the dense portion 10a in the first knitted fabric 10 is preferably 90% or less, more preferably 80% or less, and further preferably 75% or less. On the other hand, if the ratio of the dense portion 10a is too low, it may be difficult to enhance the air conditioning function of the three-dimensional knitted fabric 1. Therefore, the ratio of the dense portion 10a in the first knitted fabric 10 is preferably 10% or more, more preferably 20% or more, and further preferably 25% or more. The same applies to the ratio occupied by the dense portion 20a in the second knitted fabric 20.

As already described, the dense portion 20a of the second knitted fabric 20 is arranged so as to overlap the sparse portion 10b of the first knitted fabric 10, and how much of the dense portion 20a of the second knitted fabric 20 is arranged. It is not particularly limited whether the portion overlaps with the sparse portion 10b of the first knitted fabric 10. However, if the portion of the dense portion 20a of the second knitted fabric 20 that overlaps with the sparse portion 10b of the first knitted fabric 10 is too small (of the dense portion 20a of the second knitted fabric 20, the dense portion of the first knitted fabric 10 is dense). (If there are too many parts that overlap with the part 10a), the part of the dense part 20a of the second knitted fabric 20 that hits the air introduced from the sparse part 10b of the first knitted fabric 10 is reduced, and the air path length is sufficient. It may be difficult to secure it for a long time. In addition, it may be difficult to enhance the dust collecting function of the three-dimensional knitted fabric 1. Therefore, it is preferable that 50% or more of the dense portion 20a of the second knitted fabric 20 overlaps with the sparse portion 10b of the first knitted fabric 10. It is more preferable that 70% or more of the dense portion 20a of the second knitted fabric 20 overlaps with the sparse portion 10b of the first knitted fabric 10, and 80% or more thereof overlaps with the sparse portion 10b of the first knitted fabric 10. Is more preferable. The dense portion 20a of the second knitted fabric 20 may be entirely (100%) overlapped with the sparse portion 10b of the first knitted fabric 10. The same applies to how much of the dense portion 10a of the first knitted fabric 10 overlaps with the sparse portion 20b of the second knitted fabric 20.

There is no particular limitation on how much of the sparse portion 10b of the first knitted fabric 10 overlaps with the dense portion 20a of the second knitted fabric 20. However, if the portion of the sparse portion 10b of the first knitted fabric 10 that overlaps with the dense portion 20a of the second knitted fabric 20 is too small (the sparse portion 10b of the first knitted fabric 10 is sparsely populated with the second knitted fabric 20). If there are too many parts that overlap with the portion 20b), it becomes difficult to secure a sufficiently long path length for the air passing through the inside of the three-dimensional knit (the air is parallel to the thickness direction of the three-dimensional knit 1). It becomes easy to pass through), and it may be difficult to enhance the air conditioning function of the three-dimensional knitted fabric 1. Therefore, it is preferable that 30% or more of the sparse portion 10b of the first knitted fabric 10 overlaps with the dense portion 20a of the second knitted fabric 20. It is more preferable that 40% or more of the sparse portion 10b of the first knitted fabric 10 overlaps with the dense portion 20a of the second knitted fabric 20, and 50% or more thereof overlaps with the dense portion 20a of the second knitted fabric 20. Is more preferable. The sparse portion 10b of the first knitted fabric 10 may be entirely (100%) overlapped with the dense portion 20a of the second knitted fabric 20. The same applies to how much of the sparse portion 20b of the second knitted fabric 20 overlaps with the dense portion 10a of the first knitted fabric 10.

The three-dimensional knitting material 1 of the present invention is not limited to a specific knitting structure as long as it forms the above-mentioned structure. Further, the type of knitting yarn is not particularly limited. In this embodiment, the three-dimensional knitted fabric 1 is knitted as follows.

2. 2. Three-dimensional knitting of the present embodiment FIG. 2 is a photograph of the three-dimensional knitting 1 of the present embodiment taken from the side of the first knitted fabric 10. FIG. 3 is an organizational chart of the three-dimensional knitted fabric 1 of the present embodiment. As shown in FIG. 3, the three-dimensional knitted fabric 1 of the present embodiment is composed of a first knitted fabric 10, a second knitted fabric 20, and a connecting yarn 13. Hereinafter, each of these configurations will be described in detail.

2.1 First knitted fabric As shown in FIG. 2, the first knitted fabric 10 in the three-dimensional knitted fabric 1 of the present embodiment has a strip-shaped dense portion 10a formed of a mesh-like knitted structure and a ridge-shaped knitted structure. The band-shaped sparse portion 10b formed by the above has a structure in which the sparse portions 10b are repeatedly arranged in the wales direction D _W (transverse direction). The ratio of the dense portion 10a in the first knitted fabric 10 is about 40%, and the ratio of the sparse portion 10b is about 60%. Further, about 70% of the sparse portion 10b of the first knitted fabric 10 overlaps with the dense portion 20a of the second knitted fabric 20 (see FIG. 1), and the entire dense portion 20a of the second knitted fabric 20 (100). %) Overlaps the sparse portion 10b of the first knitted fabric 10. That is, about 30% of the sparse portion 10b of the first knitted fabric 10 overlaps with the sparse portion 20b of the second knitted fabric 20. By providing the portions where the sparse portions 10b and 20b overlap each other in this way, it is possible to prevent clogging of the three-dimensional knitted fabric 1.

As shown in FIG. 3, the first knitted fabric 10 is knitted by a chain knitting yarn 11 (warp and weft) and an insertion yarn 12 (warp and weft). The chain knitting yarn 11 forms a chain knitting extending in the Wale direction D _W (warp direction), and has the same structure in the dense portion 10a and the sparse portion 10b. On the other hand, the insertion thread 12 has a different structure between the dense portion 10a and the sparse portion 10b.

Specifically, in the sparse portion 10b, the insertion yarn 12 extends in the wale direction _DW and is woven into the stitch of the chain knitting formed by one chain knitting yarn 11. Therefore, in the sparse portion 10b, the insertion thread 12 is integrated with the chain knitting formed by the chain knitting thread 11 (the state in which the chain knitting thread 11 and the insertion thread 12 are integrated to form the chain knitting). It has become. The chain knitting in which the chain knitting yarn 11 and the insertion yarn 12 are integrated forms a ridge-shaped knitting structure. On the other hand, in the dense portion 10a, the insertion yarns 12 are arranged in a zigzag shape while extending in the course direction DC ( _weft direction), and as shown in FIG. 2, the plurality of chain knitting yarns 11 adjacent to each other are arranged in a zigzag manner. It is in a state of penetrating the stitches. Therefore, the dense portion 10a has a knitting structure in which the chain knitting yarn 11 and the insertion yarn 12 are knitted in a mesh pattern.

As described above, in the three-dimensional knitted fabric 1 of the present embodiment, the degree of sparseness between the dense portion 10a and the sparse portion 10b is switched by changing the knitting structure between the dense portion 10a and the sparse portion 10b. However, even when the dense portion 10a and the sparse portion 10b have the same knitting structure, the degree of sparseness between the dense portion 10a and the sparse portion 10b can be switched. For example, the knitting yarn constituting the dense portion 10a may be thicker than the knitting yarn constituting the sparse portion 10b, or the knitting density in the dense portion 10a may be higher than the knitting density in the sparse portion 10b (stitching). The degree of sparseness and tightness between the dense part 10a and the sparse part 10b can be changed by making the parts finer.

In the three-dimensional knitted fabric 1 of the present embodiment, microfibers are used for the chain knitting yarn 11 and the insertion yarn 12 constituting the first knitted fabric 10. Since microfiber has a large specific surface area and is excellent in water retention and dust catching power, when it is used for the chain knitting yarn 11 and the insertion yarn 12 of the first knitted fabric 10, the air conditioning function of the three-dimensional knitted fabric 1 is further enhanced. be able to. The microfiber is a multifilament in which a plurality of ultrafine fibers having a fineness of 1 dtex or less are bundled. As the microfiber used for the chain knitting yarn 11 and the insertion yarn 12, it is preferable to use a multifilament having 50 or more filaments. The material of the microfiber is not particularly limited, and various materials known as the material of the fiber (for example, polyester, nylon, etc.) can be used. In this embodiment, polyester microfiber is adopted. In the three-dimensional knitting yarn 1 of the present embodiment, the same type of yarn is used for the chain knitting yarn 11 and the insertion yarn 12, but different types of yarn can be used for the chain knitting yarn 11 and the insertion yarn 12. ..

2.2 Second knitted fabric In the three-dimensional knitted fabric 1 of the present invention, the knitted structure forming the second knitted fabric 20 may be different from the knitted structure forming the first knitted fabric 10. In the three-dimensional knitted fabric 1 of the present embodiment, the second knitted fabric 20 is formed of the same knitted fabric as the first knitted fabric 10. That is, as shown in FIG. 3, the second knitted fabric 20 is knitted with the chain knitting yarn 21 (warp and weft) and the insertion yarn 22 (weft), and by changing the knitting method of the insertion yarn 22, the dense portion is formed. The 20a and the sparse portion 20b are knitted separately.

The knitting yarn for knitting the second knitted fabric 20 may be different from the knitting yarn for knitting the first knitted fabric 10. In the three-dimensional knitting fabric 1 of the present embodiment, the same microfiber as the knitting yarn for knitting the first knitted fabric 10 is used as the knitting yarn for knitting the second knitted fabric 20. As for other configurations, the same ones as those adopted in the first knitted fabric 10 can be adopted, so detailed description thereof will be omitted.

2.3 Connecting yarn The connecting yarn 13 connects the first knitted fabric 10 and the second knitted fabric 20 at many places. In the three-dimensional knitting 1 of the present embodiment, the connecting yarn 13 is a chain knitting formed by the chain knitting yarn 11 in the first knitted fabric 10 and a chain knitting formed by the chain knitting yarn 21 in the second knitted fabric 20. It is connected. Since the chain knitting yarns 11 and 12 have the same structure in the dense portions 10a and 20b and the sparse portions 10b and 20b, if the chain knitting yarns 11 and 12 are connected to each other, the connecting yarn 13 can be connected. It is not necessary to change the structure between the dense portions 10a and 20b and the sparse portions 10b and 20b, and the structure of the connecting thread 13 can be simplified.

FIG. 4 is an electron micrograph of the covering yarn 40 used for the connecting yarn 30 in the three-dimensional knitting 1 of the present embodiment. The covering yarn 40 is obtained by winding a sheath yarn 42, which is a multifilament, around a core yarn 41, which is a monofilament. The sheath yarn 42 is a crimped yarn in which each filament constituting the multifilament is crimped. By having such a structure, the covering yarn 40 has both a large specific surface area and a firmness. Therefore, by using the covering yarn 40 for the connecting yarn 30, the air conditioning function of the three-dimensional knitted fabric 1 can be enhanced, and at the same time, the morphological stability of the three-dimensional knitted fabric 1 can be enhanced.

Hereinafter, a method for manufacturing the covering yarn 40 used in the present embodiment will be described. The covering thread 40 is manufactured in a core thread manufacturing process for manufacturing the core thread 41, a sheath thread manufacturing process for manufacturing the sheath thread 42, and a sheath thread manufacturing process around the core thread 41 manufactured in the core thread manufacturing process. It is manufactured through a winding step of winding the sheath thread 42. Of these, in the winding process, the core yarn 41 and the sheath yarn 42 are installed in the covering machine, respectively, and one sheath yarn 42 is wound around the core yarn 41 that has passed through the spindle at high speed. The winding density (number of sheaths) of the sheath yarn 42 with respect to the core yarn 41 is 300 times / m. By winding the sheath yarn 42 around the core yarn 41 at a high winding density in this way, as shown in FIG. 4, a covering yarn 40 in which the sheath yarn 42 is uniformly and tightly wound around the core yarn 41 is manufactured. can do.

The covering yarn 40 used in the present invention is a single-covered yarn in which the sheath yarn 42 is wound around the core yarn 41 in only one of the S direction and the Z direction, and the sheath yarn is wound with respect to the core yarn 41. It may be a double covered yarn in which 42 is wound in the S direction (or Z direction) and then wound in the Z direction (or S direction) from above. In this embodiment, as shown in FIG. 4, a single covered yarn covering yarn 40 is used. In the winding step, the sheath thread 42 may be adhered or fused to the core thread 41, but in the present embodiment, the sheath thread 42 is only wound around the core thread 41.

In the three-dimensional knitting 1 of the present embodiment, the winding density of the sheath yarn 42 with respect to the core yarn 41 is set to 300 times / m, but the winding density of the sheath yarn 42 is the thickness of the core yarn 41, the thickness of the sheath yarn 42, and the like. Since the suitable value differs depending on the type, the value is not particularly limited. However, if the winding density of the sheath yarn 42 is too low, it may be difficult to tightly wind the sheath yarn 42 around the core yarn 41. Therefore, the winding density of the sheath yarn 42 is preferably 50 times / m or more, more preferably 100 times / m or more, and further preferably 150 times / m or more. On the other hand, if the winding density of the sheath yarn 42 is made too high, the sheath yarn 42 is wound around the core yarn 41 at a very high speed, which may impose a burden on the covering machine. Therefore, the winding density of the sheath yarn 42 is preferably 1000 times / m or less, and more preferably 700 times / m or less.

The thickness (fineness) of the core thread 41 is not particularly limited. However, if the core yarn 41 is too thin, the stiffness of the covering yarn 40 becomes weak, and it may be difficult to improve the morphological stability of the three-dimensional knitted fabric 1 (the three-dimensional knitted fabric 1 tends to settle). Therefore, the fineness of the core yarn 41 is preferably 100 dtex or more, and more preferably 200 dtex or more. On the other hand, if the core yarn 41 is too thick, the stiffness of the covering yarn 40 becomes too strong, which may make it difficult to handle as a knitting yarn. Therefore, the fineness of the core yarn 41 is preferably 500 dtex or less, and more preferably 400 dtex or less.

The thickness (fineness) of the sheath thread 42 is also not particularly limited. However, if the sheath yarn 42 is too thin, it becomes difficult to wind the sheath yarn 42 uniformly and densely around the core yarn 41, and as a result, it may be difficult to increase the specific surface area of the covering yarn 40. Therefore, the fineness of the sheath yarn 42 is preferably 50 dtex or more. The fineness of the sheath yarn 42 is more preferably 80 dtex or more, and further preferably 120 dtex. On the other hand, if the sheath thread 42 is made too thick, it may be difficult to uniformly wind the sheath thread 42 around the core thread 41. Therefore, the fineness of the sheath yarn 42 is preferably 400 dtex or less, and more preferably 300 dtex or less.

In the present embodiment, the fineness of the core yarn 41 is about 280 dtex, and the fineness of the sheath yarn 42 is about 167 dtex. As a result, the fineness of the entire covering yarn 40 is about 450 dtex.

The specific number of filaments of the sheath yarn 42 (the number of filaments contained in one sheath yarn 42; the same applies hereinafter) is not limited as long as it is two or more. However, if the number of filaments of the sheath yarn 42 is too small, it may be difficult to increase the specific surface area of the covering yarn 40. Therefore, the number of filaments of the sheath yarn 42 is preferably 5 or more, more preferably 10 or more, and further preferably 20 or more. On the other hand, if the number of filaments of the sheath yarn 42 is too large, the sheath yarn 42 becomes too thick, and it may be difficult to uniformly wind the sheath yarn 42 around the core yarn 41. Therefore, the number of filaments of the sheath yarn 42 is preferably 200 or less, and more preferably 100 or less. In the present embodiment, the number of filaments of the sheath yarn 42 is 36.

The material of the core thread 41 and the sheath thread 42 of the covering thread 40 is not particularly limited. Natural fibers may be used as the core yarn 41 and the sheath yarn 42, but it is preferable to use chemical fibers, and it is more preferable to use synthetic fibers. As the material of the core yarn 41 and the sheath yarn 42, for example, polyester, acrylic, nylon, polyethylene, polypropylene, aramid, vinylon, vinylidene, polyvinyl chloride, polyurethane, polyclar, polylactic acid and the like can be adopted. The core thread 41 and the sheath thread 42 may be formed of the same material or may be formed of different materials. Further, the sheath yarn 42, which is a multifilament, may be a blended spinning of a plurality of types of fibers. In the present embodiment, both the core thread 41 and the sheath thread 42 are made of polyester.

2.4 Others As described above, in the three-dimensional knitting 1 of the present embodiment, microfibers are used for the knitting yarn of the first knitted fabric 10 and the knitting yarn of the second knitted fabric 20, and the connecting yarn 30 is used. The covering thread 40 is used. However, the covering yarn 40 may be used for the knitting yarn of the first knitted fabric 10 and the knitting yarn of the second knitted fabric 20, or microfiber may be used for the connecting yarn 30.

Further, heat-fused fibers (fibers whose surface or the whole is formed of a thermoplastic polymer) may be used for the knitting yarn of the first knitted fabric 10, the knitting yarn of the second knitted fabric 20, and the connecting yarn 30. can. As described above, by using the heat-sealed fibers, it is possible to stabilize the shape of the three-dimensional knit, deform the three-dimensional knit into a desired shape, and prevent the three-dimensional knit from fraying. Examples of such heat-adhesive fibers include polyester fibers, polyolefin fibers (including those grafted with unsaturated carboxylic acids), polyvinyl alcohol fibers, and the like. Examples of the polyester fiber include polyethylene terephthalate (PET) fiber and the like. Further, examples of the polyolefin fiber include polyethylene fiber and polypropylene fiber.

As the heat-adhesive fiber, one made entirely of the same type of resin may be used, but it is preferable to use a composite fiber such as a core-sheath type or an eccentric side-by-side type. In this case, it is preferable that the polymer constituting the inner layer portion (core portion) of the fiber has a higher melting point than the polymer constituting the outer peripheral portion (sheath portion) of the fiber. Examples of such a combination include core polyester / sheath polyethylene, core polypropylene / sheath polyethylene, core polyester / sheath polypropylene, and the like.

2.5 Summary As described above, in the three-dimensional knitted fabric 1 of the present embodiment, the first knitted fabric 10 and the second knitted fabric 20 are divided into chain knitting yarns 11 and 21 (warp and weft) and insertion yarns 12, 22 (warp and weft). It is knitted with two types of knitting yarns, of which the dense portion 20a and the sparse portion 20b are knitted separately by changing the knitting method of the insertion yarn 12. As a result, the sparse portions 10b and 20b and the dense portions 10a and 20a can be formed with a simple knitting structure. Microfiber is used for the knitting yarns of the first knitted fabric 10 and the second knitted fabric 20, and the covering yarn 40 is used for the connecting yarn 30. As a result, the three-dimensional knitted fabric 1 of the present embodiment has high morphological stability, and when it is used as an air conditioning filter, it can exhibit a high humidifying function and a dust collecting function.

3. 3. Applications of the present invention As described above, the three-dimensional knitted fabric 1 of the present invention can be suitably used as an air conditioning filter incorporated in an air conditioner. However, the use of the three-dimensional knitted fabric 1 of the present invention is not limited to this. The three-dimensional knitted fabric 1 of the present invention can also be used, for example, for clothing, bedding, cushioning materials used for seating surfaces, footwear, housing materials, and the like.

When the three-dimensional knitted fabric 1 of the present invention is used as an air-conditioning filter, it is preferable to perform various processing on the three-dimensional knitted fabric 1. Examples of such processing include antibacterial processing, antifungal processing, antiviral processing, antiallergen processing, deodorizing processing and the like. The three-dimensional knitted fabric 1 may be subjected to only one type of processing, or may be subjected to two or more types of processing.

1 Three-dimensional knitting 10 First knitting fabric 10a Dense part 10b Sparse part 11 Chain knitting yarn (warp)
12 Insertion thread (warp and weft)
20 Second knitted fabric 20a Dense part 20b Sparse part 21 Chain knitting yarn (warp)
22 Insertion thread (warp and weft)
30 Connecting thread 40 Covering thread 41 Core thread 42 Sheath thread _{D W} Wale direction DC course direction

Claims (7)

It is a three-dimensional knit that connects the first knitted fabric and the second knitted fabric with a connecting thread.
Each of the first knitted fabric and the second knitted fabric has a structure in which dense parts formed by a dense knitted structure and sparse parts formed by a sparse knitted structure are repeatedly arranged.
A three-dimensional knit that features the dense parts of the second knitted fabric overlapping the sparse parts of the first knitted fabric.
The dense part of the first knitted fabric and the dense part of the second knitted fabric are formed by a knitting structure in which warp and weft are knitted in a mesh pattern.
The three-dimensional knitting according to claim 1, wherein the sparse portion of the first knitted fabric and the sparse portion of the second knitted fabric are formed by a knitted structure in which warp yarns are chain-knitted.
The three-dimensional knitting according to claim 1 or 2, wherein a covering yarn in which a sheath yarn is wound around a core yarn is used for any of the knitting yarn of the first knitting fabric, the knitting yarn of the second knitting fabric, and the connecting yarn.
The three-dimensional knitting according to any one of claims 1 to 3, wherein microfiber is used for any of the knitting yarn of the first knitting fabric, the knitting yarn of the second knitting fabric, and the connecting yarn.
The three-dimensional knitting according to any one of claims 1 to 4, wherein a heat-sealed fiber is used for any of the knitting yarn of the first knitting fabric, the knitting yarn of the second knitting fabric, and the connecting yarn.
An air conditioning filter using the three-dimensional knitted fabric according to any one of claims 1 to 5.
An air conditioner using the air conditioner filter according to claim 6.

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