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. 2024-096964 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 depending on the intended use and the like. In the shoe, for example, an upper may be required to have rigidity and flexibility at a specific 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 impart rigidity and flexibility to a specific part of a product, as the number of parts increases, materials such as an adhesive and a sewing thread for combining the parts increase. Since an increase in the number of parts leads to an increase in the number of processes and an increase in environmental load, it is desirable that a product is formed with a small number of parts.

An object of the present disclosure is to obtain a fiber structure used for a product (for example, an upper of a shoe) having rigidity and flexibility at a specific part of the product while suppressing an increase in the number of parts.

A fiber structure formed of linear bodies and having a first region and a second region adjacent to each other, wherein a density of the linear bodies included in the second region is smaller than a density of the linear bodies included in the first region, the first region are arranged in a lattice pattern, the second region is arranged between the first regions arranged in the lattice pattern, and the linear bodies included in the second region connect the adjacent first regions.

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 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 the shoefor 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 regionsare arranged in a lattice pattern. Two or more first regionsmay be disposed. The first regionis a knitted structure formed by knitting the linear bodies. In the knitted structure, a plurality of loops are formed by the linear bodies, and adjacent loops are disposed so as to hook each other. A density of the linear bodiesdiffers between the first regionand the second region. Specifically, the density of the linear bodiesincluded in the second regionis smaller than the density of the linear bodiesincluded in the first region. The difference between the density of the linear bodiesin the first regionand the density of the linear bodiesin the second regionis caused by a difference in the configuration of each region described below.

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 the second region, the linear bodiesare disposed to extend linearly. Note that the linear bodiesextending linearly include not only a case where the linear bodiesare completely linear but also a state where the linear bodiesare bent. The linear bodiesdisposed in the second regionconnect the adjacent first regions.

The second regionarranged between the first regionsadjacent in a knitting direction includes a plurality of first linear bodiesextending along the knitting direction from the knitted structure of the first region.

The second regionarranged between the first regionsadjacent in a direction intersecting with the knitting direction includes a plurality of second linear bodiesdifferent from the plurality of first linear bodies. The plurality of second linear bodiesextend from a front surface or a rear surface of the knitted structure in the first region, or between the front surface and the rear surface. When the plurality of second linear bodiesare arranged on the surface of the knitted structure in the first region, the plurality of second linear bodiesmay protect the knitted structure in the first region. When the plurality of second linear bodiesare arranged on the rear surface of the knitted structure of the first region, the knitted structure of the first regioncan protect the plurality of second linear bodies. The plurality of second linear bodiesmay connect the plurality of first regions, and a length is not limited. Note that the second linear bodyis indicated by a thick line inand subsequent drawings.

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 first modification, the knitted structure of the first regionis formed by weft knitting.

The second regionarranged between the first regionsadjacent in a direction intersecting with the knitting direction includes a plurality of first linear bodiesextending in the direction intersecting with the knitting direction from the knitted structure of the first region.

The second regionarranged between the first regionsadjacent in the knitting direction includes a plurality of second linear bodiesdifferent from the plurality of first linear bodies. The plurality of second linear bodiesin the second regionarranged between the first regionsadjacent in the knitting direction extend from the front surface or the rear surface of the knitted structure in the first region, or between the front surface and the rear surface.

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, the knitted structure of the first regionis formed by warp knitting.

The first regionincludes a warp knitted structure formed by the plurality of first linear bodies. The second regionarranged between the first regionsadjacent in a knitting direction includes a plurality of first linear bodiesextending along the knitting direction from the knitted structure of the first region.

The second regionarranged between the first regionsadjacent in a direction intersecting with the knitting direction includes a plurality of second linear bodiesdifferent from the plurality of first linear bodies. The plurality of second linear bodiesin the second regionarranged between the first regionsadjacent in the direction intersecting with the knitting direction extend from the front surface or the rear surface of the knitted structure in the first region, or between the front surface and the rear surface.

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. In the third modification, the knitted structure of the first regionis formed by warp knitting.

The second regionarranged between the first regionsadjacent in a direction intersecting with the knitting direction includes a plurality of first linear bodiesextending along the direction intersecting with the knitting direction from the knitted structure of the first region.

The second regionarranged between the first regionsadjacent in the knitting direction includes a plurality of second linear bodiesdifferent from the plurality of first linear bodies. The plurality of second linear bodiesin the second regionarranged between the first regionsadjacent in the knitting direction extend from the front surface or the rear surface of the knitted structure in the first region, or between the front surface and the rear surface.

According to the upper bodyillustrated in, the density of the linear bodiesincreases in the first regionin which the linear bodiesare woven, and the density of the linear bodiesdecreases in the second regionin which the linear bodiesare linearly disposed. The first regionhas higher rigidity than the second region, and the second regionhas higher flexibility than the first region.

Therefore, the upper bodyhaving rigidity and flexibility can be formed at a specific part of the upper body. In addition, when the linear bodyused for forming the upper bodyis formed of a single material, recyclability is improved.

Note that, in the first regionformed of the knitted structure, the density of the linear bodies may vary depending on a part. In addition, as the linear bodieshaving different colors are used, the upper bodymay have regions having different colors. For example, the colors of the linear bodiesand the linear bodiesmay be different from each other. The upper bodymay include a plurality of layers.

The first regionmay be a woven fabric in which the linear bodiesare woven. In addition, in the first region, the linear bodiesmay be formed by embroidering.

Note that the upper bodyillustrated incan be produced by the following processes. The linear bodiesare woven to form a plurality of first regionsincluding a knitted structure. The first regionsformed in this case are aligned in a lattice pattern. The second regionis formed by connecting the plurality of aligned first regionsto the linear bodiesextending linearly.

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 arranged in the first linear bodiesdisposed in the first regionformed by weft knitting and extending along the direction Y intersecting with the knitting direction X.is a view illustrating another arrangement example of carbon fibers in a 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 a 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. That is, the first regionof the garmenthas higher rigidity than the second region, and the second regionhas higher flexibility than the first region. Therefore, the garment having rigidity and flexibility can be formed at a specific part of the garment.

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 rigidity and flexibility at a specific 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.