Baby shoes

Abstract

Using Nishijin-ori fabric, and in order to utilize the beautiful patterns and enjoy the auspicious value that conventional baby shoes do not have, the challenge was the fraying that occurred during the fabric cutting process. [Solution] By laminating nonwoven fabric on the back of Nishijin-ori fabric and adopting a method using an ultrasonic cutter instead of the conventional shearing method (die cutting), fraying of the cut surface is completely prevented, and baby shoes that make the most of the beautiful patterns of Nishijin-ori fabric are provided.

Description

Technical Field

[0001] The present invention provides baby shoes suitable as a lucky charm for gifts, using Nishijin-ori (a registered trademark of the Nishijin-ori Industrial Cooperative. Hereinafter referred to as "Nishijin-ori"), a traditional handicraft, for the surface of baby shoes.

Background Art

[0002] Nishijin-ori is a pre-dyed fabric that weaves patterns by first dyeing the yarns and then crossing the warp and weft yarns. While it can express complex patterns and delicate lines through the combination and layering of colored yarns, it has a structural characteristic that the fabric tends to be thick.

[0003] Baby shoes are composed of a collection of small parts. When shearing (die-cutting) is performed on a thick fabric, fraying occurs from the cut surface, making sewing difficult. In order to establish a suitable material for baby shoes while making use of the beautiful patterns of Nishijin-ori, it is an essential issue to overcome the problem of fraying.

[0004] The invention of Patent Document 1 is baby shoes that are easy for infants to insert their feet and easy to wear. The upper part of the baby shoes has an operation part operated by infants or guardians. When the operation part is lifted upward, an opening for foot insertion is formed that is connected to the shoe opening of the baby shoes. However, there is a problem that the material used for the baby shoes of Patent Document 1 does not have functions such as hygroscopicity, moisture permeability, antibacterial effect, deodorant effect, moisture retention, and texture.

[0005] The invention of Patent Document 2 discloses that by cutting a cloth material in which a pile layer using natural fibers, synthetic fibers, etc. and a base cloth using natural fibers, synthetic fibers, etc. are laminated by melting a hot melt adhesive with an ultrasonic cutter, cutting can be performed without generating fiber dust, etc. However, in the cutting method described in Patent Document 2, a hot-melt adhesive is used to laminate the two types of fabric. This hot-melt adhesive softens when heated to bond the fabrics and hardens at room temperature, causing the fabrics themselves to harden as well. Applying this bonding method to the present invention presents the problem that the suppleness and flexibility characteristic of Nishijin-ori fabrics will be compromised. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2013-154081 [Patent Document 2] Japanese Patent Publication No. 2005-161503 [Overview of the project] [Problems that the invention aims to solve]

[0007] Traditional baby shoes were mass-produced, and die-cutting was done by shearing. However, when using thicker fabrics like Nishijin-ori, and when complex patterns and intricate lines are expressed through the combination and layering of colored threads, the fabric tends to become thicker, and die-cutting by shearing results in a lot of fraying, making subsequent sewing difficult.

[0008] When die-cutting is done by shearing, the force is applied from above while shifting, causing the object to deform in accordance with the direction of the force. As a result, the patterns of Nishijin-ori textiles are distorted, and their beauty is diminished. The aim of this invention is to provide high-value-added baby shoes by utilizing the beautiful patterns of Nishijin weaving while establishing a material suitable for baby shoes. [Means for solving the problem]

[0009] In a baby shoe comprising an opening, sole, toe, and ankle support, the upper of the baby shoe is made of a fabric laminated with Nishijin-ori and non-woven fabric, and the Nishijin-ori is a thick fabric. To create a pattern from the aforementioned layered fabric, an ultrasonic cutter is used to cut it, This Nishijin-ori textile is characterized by its use of the Shippo pattern in its colors and designs.

[0010] Furthermore, the baby shoes are characterized in that the ultrasonic cutter used to create the pattern of the laminated Nishijin-ori fabric and non-woven fabric is used in the frequency range of 20kHz to 40kHz, preferably in the range of 25kHz to 35kHz.

[0011] Furthermore, the baby shoe body and the laminated fabric of Nishijin-ori and nonwoven fabric use an adhesive with a free formaldehyde content of 0.01 ppm or less, and the entire baby shoe is characterized by having a free formaldehyde content of 0.05 ppm or less (tested according to Ministry of Health Ordinance No. 34 / JIS L 1041 Method A). [Effects of the Invention]

[0012] The baby shoes according to the present invention are made by laminating a nonwoven fabric onto the back of Nishijin-ori fabric and cutting the fabric using an ultrasonic cutter. This completely eliminates the problem of fraying of parts that has existed in the past, and makes subsequent processes such as piping and sewing the baby shoes together in a three-dimensional shape easier, resulting in a reduction in labor and material costs for the entire process.

[0013] Furthermore, since each part can be neatly cut out using an ultrasonic cutter, the design quality and auspicious value of Nishijin-ori are maintained, enhancing the overall design and decorative appeal, making it possible to offer high-value baby shoes for purchase as gifts or presents. [Brief explanation of the drawing]

[0014] [Figure 1] This is a perspective view of baby shoes according to the present invention. [Figure 2] (a) Cross-sectional view of Nishijin-ori fabric according to the present invention after shearing. (b) Cross-sectional view of Nishijin-ori fabric according to the present invention after cutting with an ultrasonic cutter. [Figure 3] This is a perspective view showing another embodiment of the present invention. [Figure 4] View of the cross-section along line AB in Figure 1. [Figure 5] Test Results for Confirming the Content of Free Formaldehyde Related to the Present Invention

Explanation of Signs

[0015] 1 Baby shoes 2 Opening 3 Shoe bottom 4 Toe part 5 Ankle fixing part 6 Nishijin textile 7 Non-woven fabric 8 Fabric containing urethane sponge

Modes for Carrying Out the Invention

[0016] For the entire interior of the baby shoes 1 body and the part that touches the baby's skin at the opening 2, a fabric 8 containing a urethane sponge with flexibility, excellent cushioning and impact absorbency is used. To make it easy for the mother to put on and take off, and to make it difficult for the feet to move inside the shoes and firmly fix the heels, it is made in a form of a surface fastener. The shoe bottom 3 uses a material made of soft and flexible synthetic rubber, natural rubber or synthetic resin, etc., which is not slippery. Since the baby's feet are soft, it is more preferable to use a vinyl chloride material that is softer and less slippery than a firm rubber sole, and it can be used not only indoors but also for outdoor wear. The toe part 4 is the part where the baby first walks. So, to prevent compressing the toes and causing deformation, and to allow the toes to kick the ground well, the width of the toe is wide and has a slightly loose structure. Also, to make it easy to start kicking and prevent stubbing the toes, the toe part is structured to be slightly warped upward.

Examples

[0017] Based on the drawings, the baby shoes of the present invention and the method for manufacturing them will be explained. Figure 1 is a perspective view of the baby shoes 1 of the present invention, in which Nishijin-ori woven fabric 6 is used for the entire outer material of the baby shoes 1 body, and nonwoven fabric 7 is laminated to the back of the Nishijin-ori 6 with adhesive. The adhesive used should preferably be one that does not generate free formaldehyde, such as a vinyl acetate resin system, acrylic resin system, vinyl copolymer resin system, rubber latex type, epoxy resin system, modified silicone resin system, or silylated urethane resin system, and more preferably one that has high flexibility and bendability when cured, such as a rubber latex type, modified silicone resin system, or silylated urethane resin system. The above adhesive is also used when manufacturing the baby shoes 1. The Nishijin-ori fabric used in Baby Shoes 1 in Figure 1 features a Shippo (seven treasures) pattern. However, since there are countless Nishijin-ori fabrics available, it is of course possible to select and use the appropriate fabric according to the intended use and function. Baby Shoes 1 are made by sewing together small parts.

[0018] The entire interior of the baby shoe 1 is made of fabric 8 containing urethane sponge, and the two fabrics are sewn together with bias tape or the like to create the parts of the main body. Finally, the parts are sewn together to form the baby shoe 1. This embodiment is just one example, and the present invention is not limited to this; it can also be applied to baby shoes with other designs and functionalities. Furthermore, by using different threads and various weaving techniques unique to Nishijin weaving (plain weave, twill weave, satin weave, tapestry weave, gold brocade, etc.), the fabric stiffness can be adjusted to be optimal for baby shoes.

[0019] Figure 2(a) shows the result of cutting Nishijin-ori 6 fabric using a shearing machine. Nishijin-ori 6 is a woven fabric in which patterns are expressed using warp and weft threads. When pressure is applied from above to cut the fabric using a die-cutting (shearing process), the threads fray from the cut surface, resulting in an uneven cut and a lot of fraying. The specifications of the shearing machine used are as follows: Manufacturer: Toko Iron Works Co., Ltd. • Model: High-speed cutting machine SL Shear pressure: 15 tons • Maximum shearable thickness: 5.5 mm Figure 2(b) shows the result of cutting Nishijin-ori fabric using an ultrasonic cutter. When only Nishijin-ori 6 fabric was cut with an ultrasonic cutter, some fraying was observed on the cut surface. Next, a fabric consisting of Nishijin-ori fabric 6 with non-woven fabric 7 laminated to the back by adhesive was cut with an ultrasonic cutter. The cut surface was very clean, and no fraying occurred at all. The specifications of the ultrasonic cutter used are as follows: Manufacturer: Ultrasonic Industries Co., Ltd. • Model: Stand-type ultrasonic cutter (Model: UE-200Z28S-20A) Power supply: Single-phase 100V Output: 200W • Frequency: 28kHz In this embodiment, the fabric was manually cut using a stand-type ultrasonic cutter, but it is of course possible to create parts of the same shape using an automatic ultrasonic cutter and three-dimensional data.

[0020] Figure 3 shows another example of baby shoes made with other Nishijin-ori fabrics according to the present invention. (a) This is a high-top shoe with laces, using a fine-weave Nishijin-ori fabric for the upper and a hook-and-loop fastener for the ankle support. The ankle-covering structure provides high safety and excellent fall prevention. The sole is made of rubber. (b) This is another example of a baby shoe, in which the outer fabric is made of thick, luxurious patterned Nishijin-ori fabric, hook-and-loop fasteners are used for the ankle fastening, and the sole is made of durable synthetic resin material. (c) The outer fabric uses a soft-textured material with gold threads woven in in some areas. The ankle fastening area has hook-and-loop fasteners placed over a slightly larger area to prioritize a snug fit around the ankle. This is another example of a baby shoe using polyvinyl chloride for the sole. (d) This is another embodiment of a baby shoe, in which a thin fabric is used for the outer material, making it lightweight, and hook-and-loop fasteners are used for the ankle fastening, making it easy to put on and take off. The sole is made of polyvinyl chloride.

[0021] Figure 4 is a cross-sectional view taken along line A and B in Figure 1. Reference numeral 6 denotes Nishijin-ori fabric and reference numeral 7 denotes nonwoven fabric, with the Nishijin-ori fabric 6 and the nonwoven fabric 7 being laminated using an adhesive. The adhesive used does not emit free formaldehyde and meets JAS and JIS standards. Reference numeral 8 denotes fabric with urethane sponge embedded throughout the entire interior, which is delicate and soft and serves to protect the feet of babies whose skeletal foundations have not yet been formed. Reference numeral 3 denotes the sole of the baby shoe, which is made of a soft, flexible, and non-slip material such as synthetic rubber, natural rubber, or synthetic resin. An insole is attached to the upper surface of the sole, and is made of a soft material to protect the baby's feet.

[0022] Figure 5 shows the results of a test conducted to confirm the free formaldehyde content in the baby shoes 1 of the present invention. The confirmation test was conducted as follows. • Test administered by: Kaken Test Center, a general incorporated foundation. • Exam date: May 17, 2016 • Test method: Ministry of Health and Welfare Ordinance No. 34 (for infants and young children) JIS L1041 Method A • Test sample: Baby shoes of the present invention made with Nishijin-ori fabric (※Tested on all parts) • Test results: Free formaldehyde content is 0.05 or less (measured value 0.01) *The free formaldehyde content is calculated as the difference in free formaldehyde absorbance by subtracting A0. A: Absorbance measurement values ​​of the test solution + acetylacetone reagent compared to water + acetylacetone reagent as a control. A0: Absorbance measured using water + ammonium acetate buffer as a control. As shown in the test results above, the free formaldehyde content meets the standard values, proving that there is no risk of causing mucosal irritation or skin allergies in babies.

Claims

1. A baby shoe (1) comprising an opening (2), a sole (3), a toe (4), and an ankle fixing part (5), characterized in that the upper fabric of the baby shoe (1) is made of a laminated fabric of Nishijin-ori (6) and non-woven fabric (7), and an ultrasonic cutter (9) is used to cut the laminated fabric to form a pattern.

2. The baby shoes according to claim 1, characterized in that the ultrasonic cutter (9) is used in the frequency range of 20 kHz to 40 kHz.

3. The baby shoe according to claim 1, characterized in that the entire interior of the baby shoe (1) is made of a fabric (8) containing urethane sponge.

4. The baby shoe according to claim 1, characterized in that the main body of the baby shoe (1) and the fabric formed by laminating Nishijin-ori (6) and nonwoven fabric (7) use an adhesive with a free formaldehyde content of 0.01 ppm or less, and the free formaldehyde content of the entire baby shoe (1) is 0.05 ppm or less (tested by Ministry of Health Ordinance No. 34 / JIS L 1041 Method A).

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