Fiber Structure, Shoe, Garment, Bag, and Method for Producing Fiber Structure

The present application claims priority to and incorporates by reference the entire contents of Japanese Patent Application No. 2024-096963 filed in Japan on Jun. 14, 2024.

The present disclosure relates to a fiber structure and a method for producing a fiber structure.

In products such as shoes, garments, and bags, various functions are required for each part depending on the intended use and the like. An upper of a shoe may be required to have different stretchability depending on, for example, a part.

In the shoe disclosed in WO 2022/157894 A, the first member extending in one direction is disposed on the upper. The first member has stretchability only in the one direction and is arranged in a non-bonded state. This configuration partially changes the stretchability of the upper.

In order to change the stretchability depending on the part of the product, as the number of parts increases, materials such as an adhesive and a sewing thread for combining the parts increase. An increase in the number of parts leads to an increase in environmental load.

An object of the present disclosure is to obtain a fiber structure used for a product (for example, an upper of a shoe) having different stretchability for each part of the product while suppressing an increase in the number of parts.

A fiber structure comprising a knitted structure and a woven structure adjacent to each other, wherein the knitted structure is formed by a plurality of first linear bodies, and the woven structure is formed continuously with the knitted structure by the plurality of first linear bodies and a plurality of second linear bodies that intersect with the plurality of first linear bodies and are different from the plurality of first linear bodies.

Hereinafter, embodiments of a fiber structure and a method for producing a fiber structure according to the present disclosure will be described in detail with reference to the drawings. Note that the present disclosure is not limited by these embodiments. In the following description, the same portions are denoted by the same reference numerals, and redundant description will be omitted.

is a perspective view of an appearance of a shoe according to a first embodiment of the present disclosure. In each drawing including, only a shoefor a left foot is illustrated. In the present embodiment, only the shoefor a left foot will be described, and the description of a shoe for a right foot will be omitted.

In addition, in the anatomical position of the foot, a median side is referred to as a medial foot side, and a side opposite to the median side is referred to as a lateral foot side. That is, the side closer to the median line in the anatomical position is referred to as the medial foot side, and the side farther from the median line in the anatomical position is referred to as the lateral foot side. In addition, a vertical direction means a direction orthogonal to both a foot length direction and a foot width direction unless otherwise specified.

The shoeincludes an upperand a sole. The upperincludes an upper bodythat covers an upper surface of the soleby disposing an internal space in which a foot of a wearer enters between the upper bodyand the sole. The upper bodyis fixed to the soleby methods such as stitching, welding, and bonding. A foot insertion openingis disposed in the upper body. The foot insertion openingis an opening for inserting a foot of a wearer into the internal space of the upper body.

is an enlarged view of a part of the upper body in the first embodiment. The upper bodyis a cloth formed using a linear body. The linear bodyis formed of, for example, polyester. The linear bodymay be formed of a single polyester. The linear bodymay be formed of polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), or polybutylene terephthalate (PBT). The linear bodymay be a polyurethane-based thermoplastic elastomer, polyurethane, nylon, spandex, Kevlar (registered trademark), ultra-high-molecular-weight polyethylene, a single covered yarn (SCY) or double covered yarn (DCY) obtained by covering polyurethane, or the like. In addition, the linear bodymay be a yarn obtained by bundling a plurality of fibers, a yarn obtained by making a resin linear, a twisted yarn, or the like.

The upper bodyhas a first regionand a second regionadjacent to each other.

The first regionis a knitted structure formed by knitting the linear bodies. In the knitted structure, a plurality of loops are formed by a plurality of first linear bodies, and adjacent loops are disposed so as to hook each other.

The second regionis a woven structure formed by weaving the linear bodies. In the woven structure, the linear bodiesintersect with each other. The second regionis formed by the plurality of first linear bodiesforming the knitted structure in the first regionextending along a knitting direction of the knitted structure and intersection of the first linear bodieswith second linear bodiesdifferent from the first linear bodies. The knitted structure in the first regionand the woven structure in the second regionare continuously disposed. The knitted structure in the first regionand the woven structure in the second regionare continuously disposed by the same device. The knitted structure has higher stretchability than the woven structure. Therefore, the stretchability of the upper bodycan be partially changed by arranging the first region at a part where the stretchability of the upper bodyis desired to be increased and arranging the second regionat a part where the stretchability of the upper bodyis desired to be lower than that of the first region. In addition, since a weight of the woven structure is more easily reduced than the knitted structure, the second regionmay be arranged at a part to be reduced in weight.

The types of knitted structure constituting the first regioninclude warp knitting knitted by a warp knitting machine and weft knitting knitted by a flat knitting machine.illustrates an example in which the first regionis warp knitting knitted by a warp knitting machine. Note that a knitting direction of the knitted structure is indicated by an arrow X. In addition, a direction intersecting with the knitting direction is indicated by an arrow Y. In addition, in the warp knitting, the knitting direction is also referred to as a vertical direction, and the direction intersecting with the knitting direction is also referred to as a horizontal direction. In the weft knitting, the knitting direction is also referred to as a horizontal direction, and the direction intersecting with the knitting direction is also referred to as a vertical direction.

The plurality of first linear bodiesforming a loop in the first regionextend along the knitting direction X without forming a loop in the second region. In the second region, a plurality of second linear bodiesextending in a direction intersecting with the knitting direction are arranged and intersect with the plurality of first linear bodiesto form a woven structure.

is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a first modification of the first region and the second region. In the example illustrated in, the knitted structure in the first regionis formed by weft knitting.

The plurality of first linear bodiesforming a loop in the first regionextend along the knitting direction X without forming a loop in the second region. In addition, in the second region, a plurality of second linear bodiesdifferent from the first linear bodiesare disposed, and the first linear bodiesand the second linear bodiesintersect with each other to form a woven structure.

is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a second modification of the first region and the second region. In the second modification, similarly to the first modification illustrated in, the knitted structure in the first regionis formed by weft knitting. In addition, in the second modification, unlike the first modification, third linear bodiesare not disposed in the first region.

Some of the first linear bodiesforming a loop in the first regionextend along the knitting direction X without forming a loop in the second region.

The plurality of second linear bodiesextend along the direction intersecting with the knitting direction X in the second region, and are folded back along the direction intersecting with the knitting direction X at an endand the like of the second region. In addition, the plurality of folded second linear bodiesare disposed side by side along the knitting direction X. Thus, although the second linear bodiesare locally bent, the second linear bodiescan be regarded as extending in the direction intersecting with the knitting direction X, and the plurality of first linear bodiesextending along the knitting direction X and the second linear bodiesextending in the direction intersecting with the knitting direction can form a woven structure.

is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a third modification of the first region and the second region. As illustrated in, the first regionmay include a plurality of third linear bodiesextending along the second linear bodies. Since the plurality of first linear bodiesform a loop in the first region, a woven structure is not disposed between the plurality of first linear bodiesand the plurality of third linear bodies

Note that the upper bodyillustrated incan be produced by the following processes. That is, a knitted structure is formed by the plurality of first linear bodies, the plurality of first linear bodiesextend in the knitting direction from the knitted structure, the plurality of second linear bodiesintersect with the plurality of first linear bodies, and a woven structure is formed continuously with the knitted structure.

is a developed view of the upper body according to the first embodiment. The upper bodyincludes an upper fore foot position Rcovering a fore foot position of a foot of a wearer, an upper middle foot position Rcovering a middle foot position of the foot of the wearer, and an upper rear foot position Rcovering a rear foot position of the foot of the wearer. The upper fore foot position R, the upper middle foot position R, and the upper rear foot position Rare arranged in this order from the fore to the rear of the upper. In addition, a direction in which a shoe center axis C, which is a straight line passing through the center of the shoein a plan view of the shoe, extends is referred to as a foot length direction, and a direction orthogonal to the center axis in the plan view of the shoeis referred to as a foot width direction.

The upper bodyhas a plurality of first regionsand a plurality of second regions. As illustrated in, the second regionmay be disposed in the upper fore foot position R, the upper middle foot position R, and the upper rear foot position R. Since the second regionformed of the woven structure has lower stretchability than the first region, the second regionmay be arranged in a region of the upper bodythat is not desired to be stretched. The first regionand the second regionmay be arranged in one or more regions of the upper fore foot position R, the upper middle foot position R, or the upper rear foot position R. Note that the first regionand the second regioncan be arranged in all or a part of at least one region of the upper fore foot position R, the upper middle foot position R, or the upper rear foot position R.

As such, the stretchability can be changed for each part of the upper bodyby arranging the plurality of first regionsand the plurality of second regionsin the upper body. In addition, since a weight of the woven structure is more easily reduced than the knitted structure, the second regionmay be arranged at a part to be reduced in weight.

In addition, since the linear bodiesused for forming the upper bodycan be formed of a single material, recyclability is improved. In addition, since the linear bodiesused for the knitted structure are also used for the woven structure, it is not required to use an adhesive for joining the ends of the linear bodies, and the recyclability is further improved.

In the first regionformed of the knitted structure, a density of the linear bodies may be changed according to the part of the upper. In the second regionformed of the woven structure, the density of the linear bodies may be changed according to the part of the upper. The stretchability of the upper bodycan be more flexibly changed by changing the density of the linear bodies for each part of the upper body.

A throat portionmay be disposed in the upper body. The throat portionis an opening extending forward from a foot insertion openinginto which a foot is inserted when the shoeis worn. In addition, the edges of the throat portionand the foot insertion openingmay be formed by cutting. The edges of the throat portionand the foot insertion openingmay be formed without cutting.

By using the linear bodieshaving different colors, the upper bodymay have regions having different colors. For example, the colors of the linear bodiesand the linear bodiesmay be different from each other. In addition, the upper bodymay include a plurality of layers.

is a developed view illustrating a first modification of the upper body according to the first embodiment. In the example illustrated in, a region corresponding to the throat portionillustrated inis not an opening but a first region.

In at least one of the first regionand the second region, carbon fibers may be arranged along the linear bodies. The carbon fibers may be disposed linearly. The carbon fibers may be formed of a carbon fiber alone, or may be a covered yarn in which the carbon fiber is used as a core yarn and the core yarn is covered with a material that enhances the strength of the carbon fiber. Since carbon fibers have lower extensibility and higher strength than fibers such as polyester fibers, the upper bodyis less likely to extend in a direction in which the carbon fibers are arranged in a region in which the carbon fibers are arranged, and the strength is increased.is a view illustrating an arrangement example of carbon fibers in a knitted structure.illustrates an example in which carbon fibersare disposed in the first regionformed by weft knitting and arranged along the direction Y intersecting with the knitting direction X.is a view illustrating another arrangement example of the carbon fibers in the knitted structure.illustrates an example in which the carbon fibersare disposed in the first regionformed by weft knitting and arranged along the knitting direction X.

are developed views of the upper body illustrating an arrangement example of a disposition region. Note that, in the following description, a region where the first regionand the second regionare disposed is referred to as a disposition region.

The disposition regionis disposed in at least a part of the upper body. The disposition regionmay extend in the foot width direction, or may be inclined with respect to the shoe center axis C. An angle α of inclination in a direction in which the disposition regionextends with respect to the shoe center axis C is preferably in a range of 45° or more and less than 90°. By arranging the direction in which the disposition regionextends to be inclined with respect to the shoe center axis C, the disposition regioncan be flexibly arranged corresponding to the movement of the wearer. As illustrated in, the disposition regionmay be disposed in the upper middle foot position R. As illustrated in, the disposition regionmay be disposed in the fore of the upper middle foot position R. As illustrated in, the disposition regionmay be disposed to be inclined with respect to the shoe center axis C so that the medial foot side is located further forward than the lateral foot side.

In the disposition region, the carbon fibers may be arranged along the foot width direction, or may be disposed to be inclined with respect to the shoe center axis C. An angle α of inclination in a direction in which the carbon fibers extend with respect to the shoe center axis C is preferably in a range of 45° or more and less than 90°. By arranging the direction in which the carbon fibers extend to be inclined with respect to the shoe center axis C, the carbon fibers can be flexibly arranged corresponding to the movement of the wearer. Note that the carbon fibers may be arranged in a region other than the disposition region.

As illustrated in, a plurality of disposition regionsmay be disposed side by side in the foot length direction in the upper middle foot position R. As illustrated in, the plurality of disposition regionsmay be disposed to be inclined with respect to the shoe center axis C so that the medial foot side is located further forward than the lateral foot side.

As illustrated in, as for the plurality of disposition regions, the plurality of disposition regionsmay be disposed to be inclined with respect to the shoe center axis C so that the medial foot side is located further forward than the lateral foot side, and may be arranged at positions shifted from each other in the foot length direction.

As illustrated in, the disposition regionmay be disposed in the upper middle foot position Rand the upper rear foot position R.

By disposing the disposition regionas illustrated in, it is possible to exhibit different functions for each part of the upper body. In addition, when the carbon fibers are disposed in the upper body, the upper bodyis hardly stretched in a direction in which the carbon fibers extend, and thus, the upper bodyhaving high strength can be obtained.

Note that the disposition region illustrated inmay be arranged in one or more regions of the upper fore foot position R, the upper middle foot position R, or the upper rear foot position R. The disposition regioncan be arranged in all or a part of at least one region of the upper fore foot position R, the upper middle foot position R, or the upper rear foot position R.

Note that the present disclosure can be applied not only to shoes but also to garments, bags, and the like.is a front view illustrating an arrangement example in a case where a disposition region of a first region and a second region is used for a garment.is a rear view illustrating an arrangement example in a case where a disposition region of a first region and a second region is used for a garment. As illustrated in, when a disposition regionincluding a first regionand a second regionis arranged in a specific region of a garment, the same effect as when the disposition regionis arranged in the upper of the shoe can be obtained. Therefore, the stretchability of the garmentcan be partially changed by arranging the first region at a part where the stretchability of the garmentis desired to be increased and arranging the second regionat a part where the stretchability of the garmentis desired to be lower than that of the first region. In addition, since a weight of the woven structure is more easily reduced than the knitted structure, the second regionmay be arranged at a part to be reduced in weight.

Hereinafter, various aspects of the present disclosure will be described.

According to the present disclosure, it is possible to provide a fiber structure used for a product (for example, an upper of a shoe) having different stretchability for each part of the product while suppressing an increase in the number of parts.

Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.