Method for manufacturing resin-coated wire, resin-coated wire, fiber product, method for manufacturing fiber product, double-layer coated wire, and method for manufacturing double-layer coated wire

Abstract

The resin-coated wire (41) includes a core wire portion (42) formed of fibers and a resin coating (43) covering the core wire portion (2), wherein the resin coating (43) includes a thermoplastic resin and an adhesion enhancer that enhances the adhesion of the thermoplastic resin to prevent slippage between the surface of the thermoplastic resin and a contact object.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a resin-coated wire having a core formed of synthetic fibers and a resin layer (sheath) configured to coat the core, by partially braiding a composite wire and heat-setting and cooling the braided portion to form a resin region; a resin-coated wire; a fiber product; a method for manufacturing a fiber product; a double-layer coated wire; and a method for manufacturing a double-layer coated wire. Background Art

[0002] In fiber products (knitwear) such as socks, there are technologies that increase the friction between the fiber product and the part of the body it contacts, thereby imparting an anti-slip effect or improving grip. Examples of such technologies include printing and coating vinyl chloride resin, silicone resin, or the like onto fiber products, and using silicone thread in the manufacture of fiber products.

[0003] Patent document 1 discloses a technique in which anti-slip parts such as natural rubber and silicone rubber are provided at corresponding positions on the inside and outside of the contact area between the toes and the phalanges located at the foot circumference (toe pad) in the sock body.

[0004] Patent Document 2 below discloses socks that use a high-friction thread on the inner side of the heel and toes to provide an anti-slip function between the sole and the outer surface of the sock and between the sole and the inner surface of the sock.

[0005] Furthermore, a decorative thread having a hot-melt synthetic adhesive attached to its entire length is known (Patent Document 3). This decorative thread is arranged to draw a predetermined decorative pattern on a decorative material, and then heated by appropriate heating means to melt the hot-melt synthetic adhesive, which then adheres to the decorative material to form the predetermined decorative pattern.

[0006] Furthermore, a fused yarn with a hot-melt adhesive applied to the outer surface of a core yarn is known (Patent Document 4). During the weaving process of a carpet in which the fused yarn is used as the warp and the raised yarns are used as the weft, the hot-melt adhesive is melted by, for example, irradiation with far infrared rays, thereby bonding the hot-melt adhesive to the weft, thereby obtaining a carpet in which the warp and weft are firmly bonded.

[0007] A sheath-core thermally adhesive composite fiber is known, in which the sheath component is formed of a thermally adhesive component and the core component is formed of a fiber-forming component (Patent Document 5). This thermally adhesive composite fiber is used to bond dissimilar materials such as diapers and sanitary napkin components, filters, wipers, agricultural materials, food packaging materials, garbage bags, interior materials, and industrial materials to metals, inorganic materials, resin materials (plastics, foams, etc.), and cellulose materials (wood, etc.).

[0008] Prior art literature

[0009] Patent Literature

[0010] Patent Document 1: Japanese Patent Publication No. 2017-20149 (published on January 26, 2017)

[0011] Patent Document 2: Japanese Patent Publication No. 2017-162149 (published on September 14, 2017)

[0012] Patent Document 3: Japanese Utility Model Publication No. 168568 (published on November 28, 1989)

[0013] Patent Document 4: Japanese Patent Publication No. 7-292536 (published on November 7, 1995)

[0014] Patent Document 5: Japanese Patent No. 4438998 (published on January 15, 2010) Summary of the Invention

[0015] Problems to be solved by the invention

[0016] However, the technology described in Patent Document 1 suffers from a problem in which the anti-slip component falls off, thereby reducing the anti-slip effect. Furthermore, the technology described in Patent Document 2 suffers from a problem in which the anti-slip effect is reduced due to surface wear. In other words, conventional technologies suffer from an inability to fully maintain the anti-slip effect.

[0017] The techniques described in Patent Documents 3 to 5 are techniques related to firm adhesive fixation of fiber products, and do not suggest a structure for imparting an anti-slip effect to fiber products.

[0018] One solution of the present invention is completed in view of the above-mentioned problems, and its purpose is to realize a manufacturing method of a resin-coated wire, a resin-coated wire, a fiber product, a manufacturing method of a fiber product, a double-layer coated wire, and a manufacturing method of a double-layer coated wire that can fully maintain an anti-slip effect.

[0019] Methods used to solve problems

[0020] In order to solve the above-mentioned problems, a method for manufacturing a resin-coated wire according to one embodiment of the present invention is characterized in that it includes the following steps: a liquefaction step, in which a resin coating material containing a thermoplastic resin and an adhesion enhancer that enhances the adhesion of the thermoplastic resin is heated to liquefy it; a supply step, in which the resin coating material liquefied by the liquefaction step is pressed by a gear pump and supplied to a nozzle; and a coating step, in which the resin coating material pressed by the gear pump and supplied to the nozzle is coated around a core wire portion formed by fibers to form a resin coating covering the core wire portion.

[0021] In order to solve the above-mentioned problems, a resin-coated wire according to one embodiment of the present invention is characterized in that it includes a core wire portion formed of fibers and a resin coating covering the core wire portion, wherein the resin coating contains a thermoplastic resin and an adhesion enhancer that enhances the adhesion of the thermoplastic resin to prevent slippage between the surface of the thermoplastic resin and a contact object.

[0022] In order to solve the above-mentioned problems, a fiber product according to one embodiment of the present invention is characterized in that it is braided using the resin-coated yarn according to one embodiment of the present invention.

[0023] In order to solve the above-mentioned problems, a method for manufacturing a fiber product according to one embodiment of the present invention is characterized in that it includes the following steps: a weaving step of weaving the resin-coated yarn of the present invention; a melting step of heating the resin coating of the resin-coated yarn woven in the weaving step to melt it; and a forming step of cooling the resin coating melted in the melting step to form a molten solidification area portion that prevents sliding with a contact object.

[0024] In order to solve the above-mentioned problems, a double-layer coated wire according to one embodiment of the present invention is characterized in that it includes a core wire portion formed of fibers, a first resin coating layer covering the core wire portion, and a second resin coating layer covering the first resin coating layer, wherein the first resin coating layer contains a thermoplastic resin and an adhesion enhancer that enhances the adhesion of the thermoplastic resin to prevent slippage between the thermoplastic resin and a contact object.

[0025] In order to solve the above-mentioned problems, a method for manufacturing a double-layer coated wire according to one embodiment of the present invention is characterized in that it includes the following steps: a liquefaction step, heating a first resin coating material including a thermoplastic resin and an adhesion enhancer for enhancing the adhesion of the thermoplastic resin to liquefy it; a first supply step, pressing the first resin coating material liquefied by the liquefaction step by a gear pump and supplying it to a first nozzle; a first coating step, applying the first resin coating material pressed by the gear pump and supplied to the first nozzle around a core wire portion formed by a fiber to form a first resin coating covering the core wire portion; a second supply step, supplying the liquefied second resin to a second nozzle; and a second coating step, applying the second resin supplied to the second nozzle around the first resin coating applied to the core wire portion in the first coating step to form a second resin coating covering the first resin coating.

[0026] In order to solve the above-mentioned problems, a method for manufacturing a fiber product according to one embodiment of the present invention is characterized in that the second resin coating of the present invention contains a soluble resin having solubility, and includes the following steps: a weaving step of weaving the double-layer coated wire of the present invention; a removal step of applying a fluid to the double-layer coated wire woven in the weaving step to remove the soluble resin from the first resin coating; and a cooling step of cooling the woven first resin coating and core wire portion.

[0027] Effects of the Invention

[0028] According to one aspect of the present invention, a method for manufacturing a resin-coated thread capable of sufficiently maintaining an anti-slip effect, a resin-coated thread, a fiber product, a method for manufacturing a fiber product, a double-coated thread, and a method for manufacturing a double-coated thread can be realized. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a diagram showing an example of a fiber product according to one embodiment of the present invention.

[0030] Figure 2 It means in Figure 1 An example of a core-sheath composite yarn used in a fiber product is shown in FIG.

[0031] Figure 3 It means in Figure 2 An example of the manufacturing conditions of the core-sheath composite wire is shown in the figure.

[0032] Figure 4 It means in Figure 1 Flowchart showing an example of a production process of a fiber product.

[0033] Figure 5This is a diagram showing an example of a fiber product according to a modified example of one embodiment of the present invention.

[0034] Figure 6 This is a diagram showing an example of a fiber product according to another modified example of one embodiment of the present invention.

[0035] Figure 7 This is a cross-sectional view showing an example of a resin coating line according to the second embodiment.

[0036] Figure 8 (a) Figure 8 (b) is a cross-sectional view for explaining the embedding effect of the resin coating formed on the resin coating line on the contact object to be bonded, Figure 8 (c) is a graph for explaining the glass transition temperature.

[0037] Figure 9 It is a schematic diagram for explaining the manufacturing method of the said resin coating wire.

[0038] Figure 10 This is a flowchart showing the process of a method for manufacturing socks involving the resin-coated yarn.

[0039] Figure 11 Schematic diagram showing a friction test apparatus for materials constituting the resin coating of the resin-coated wire.

[0040] Figure 12 This is a graph showing the results of friction tests on the materials constituting the resin coating.

[0041] Figure 13 (a) is an enlarged surface view of the surface yarn side of the knitted fabric of the socks using the resin coated yarn before melting and solidification. Figure 13 (b) is an enlarged cross-sectional view. Figure 13 (c) is an enlarged back view of the dorsal side.

[0042] Figure 14 (a) is an enlarged surface view of the surface yarn side of the knitted fabric of the socks using the above-mentioned resin coated yarn after melting and solidification. Figure 14 (b) is an enlarged cross-sectional view. Figure 14 (c) is an enlarged back view of the dorsal side.

[0043] Figure 15 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned resin-coated yarn before melting and solidification. Figure 15 (b) is an enlarged cross-sectional view. Figure 15 (c) is an enlarged back view of the dorsal side.

[0044] Figure 16(a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned resin-coated yarn after melting and solidification. Figure 16 (b) is an enlarged cross-sectional view. Figure 16 (c) is an enlarged back view of the dorsal side.

[0045] Figure 17 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned resin-coated yarn before melting and solidification. Figure 17 (b) is an enlarged cross-sectional view. Figure 17 (c) is an enlarged back view of the dorsal side.

[0046] Figure 18 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned resin-coated yarn after melting and solidification. Figure 18 (b) is an enlarged cross-sectional view. Figure 18 (c) is an enlarged back view of the dorsal side.

[0047] Figure 19 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned resin-coated yarn before melting and solidification. Figure 19 (b) is an enlarged cross-sectional view. Figure 19 (c) is an enlarged back view of the dorsal side.

[0048] Figure 20 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned resin-coated yarn after melting and solidification. Figure 20 (b) is an enlarged cross-sectional view. Figure 20 (c) is an enlarged back view of the dorsal side.

[0049] Figure 21 This is a cross-sectional view showing an example of a double-coated line according to the third embodiment.

[0050] Figure 22 It is a schematic diagram for explaining the manufacturing method of the above-mentioned double-layer coating line.

[0051] Figure 23 1 is a flow chart showing the process of a method for manufacturing socks involving the double-layer coated yarn.

[0052] Figure 24 (a) to (d) are photographs for explaining the method of the peeling test of the material constituting the resin coating of the double-coated wire.

[0053] Figure 25 This is a graph showing the results of isolation tests on the materials constituting the above-mentioned resin coating.

[0054] Figure 26 This is a graph showing the results of isolation tests on other materials constituting the above-mentioned resin coating.

[0055] Figure 27 This is a graph showing the results of isolation tests on yet another material constituting the above-mentioned resin coating.

[0056] Figure 28 This is a graph showing the results of additional isolation tests on yet another material constituting the above-mentioned resin coating.

[0057] Figure 29 This is a graph showing the results of additional isolation tests on yet another material constituting the above-mentioned resin coating.

[0058] Figure 30 This is a graph showing the results of additional isolation tests on yet another material constituting the above-mentioned resin coating.

[0059] Figure 31 (a) is an enlarged surface view of the surface yarn side of the knitted fabric of the socks using the double-layer coated yarn before melting and solidification. Figure 31 (b) is an enlarged cross-sectional view. Figure 31 (c) is an enlarged back view of the dorsal side.

[0060] Figure 32 (a) is an enlarged surface view of the surface line side of the knitted fabric of the socks using the double-layer coated yarn after melting and solidification. Figure 32 (b) is an enlarged cross-sectional view. Figure 32 (c) is an enlarged back view of the dorsal side.

[0061] Figure 33 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned double-layer coated yarn before melting and solidification. Figure 33 (b) is an enlarged cross-sectional view. Figure 33 (c) is an enlarged back view of the dorsal side.

[0062] Figure 34 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned double-layer coated yarn after melting and solidification. Figure 34 (b) is an enlarged cross-sectional view. Figure 34 (c) is an enlarged back view of the dorsal side.

[0063] Figure 35 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned double-layer coated yarn before melting and solidification. Figure 35 (b) is an enlarged cross-sectional view. Figure 35 (c) is an enlarged back view of the dorsal side.

[0064] Figure 36 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned double-layer coated yarn after melting and solidification. Figure 36 (b) is an enlarged cross-sectional view. Figure 36 (c) is an enlarged back view of the dorsal side.

[0065] Figure 37 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned double-layer coated yarn before melting and solidification. Figure 37 (b) is an enlarged cross-sectional view. Figure 37 (c) is an enlarged back view of the dorsal side.

[0066] Figure 38 (a) is an enlarged surface view of the surface yarn side of another knitted fabric of socks using the above-mentioned double-layer coated yarn after melting and solidification. Figure 38 (b) is an enlarged cross-sectional view. Figure 38 (c) is an enlarged back view of the dorsal side. DETAILED DESCRIPTION

[0067] [Implementation Method 1]

[0068] The following is based on Figures 1 to 4 , an embodiment of the present invention is described in detail.

[0069] (Overview of Textile Products)

[0070] Figure 1 : is a diagram showing an example of a fiber product according to an embodiment of the present invention. Figure 1 1 shows a sock 1. As an example, the sock 1 may be a running sock.

[0071] exist Figure 1 In the sock 1 shown in FIG, the toe portion 11, the sole portion 12 (also referred to as the toe base), and the heel portion 13 are knitted with a core-sheath composite yarn described later, and the remaining portions are knitted with a knitting yarn.

[0072] It should be noted that the toe portion 11 , the sole portion 12 and the heel portion 13 may also be knitted from a core-sheath composite yarn and a knitted yarn.

[0073] (Core-sheath composite wire)

[0074] Figure 2 : is a diagram showing an example of the core-sheath composite wire. As an example, the core-sheath composite wire of this embodiment is Figure 2 The core-sheath composite wire 10 is shown in FIG.

[0075] The core-sheath composite yarn 10 includes a core 101 and a sheath 102 covering the core 101. The diameter of the core-sheath composite yarn 10 is arbitrarily set according to the thickness of the knitting yarn used in the sock 1. As an example, the diameter can be approximately 300 μm.

[0076] As an example, Figure 2 As shown, core 101 is composed of multiple synthetic fibers. Specifically, core 101 is composed of 48 polyester fibers, and the thickness of core 101 is 150 denier. It should be noted that the type and number of synthetic fibers used in core 101 are not limited to this example. By composing core 101 from multiple fibers, core-sheath composite yarn 10 can be made more flexible and easier to weave into fiber products.

[0077] The sheath 102 is made of a resin. Preferably, the resin has thermoplasticity and, when it is melted and then solidified, the friction coefficient becomes moderately high. As the resin, EVA (ethylene vinyl acetate copolymer) resin is particularly suitable, but PVC (polyvinyl chloride) resin or the like can also be used.

[0078] Figure 3 This diagram illustrates an example of manufacturing conditions for the core-sheath composite wire 10. The sweep speed can be arbitrarily adjusted based on the type of resin used in the sheath 102, the thickness of the sheath 102 (the thickness of the resin layer), the thickness of the core 101, and other factors. It should be noted that the core-sheath composite wire 10 may be manufactured under conditions different from these.

[0079] (Method for manufacturing fiber products)

[0080] Figure 4 This is a flowchart illustrating an example of a manufacturing process for socks 1 according to this embodiment. First, the socks 1 are knitted using a core-sheath composite yarn 10 and a knitting yarn (step S1). For example, when knitting the socks 1 using a hosiery knitting machine, the core-sheath composite yarn 10 is used to knit the toe portion 11, the sole portion 12, and the heel portion 13, while the knitting yarn is used to knit the remaining portions.

[0081] Next, the sock 1 is heated (step S2) to melt the sheath 102 of the core-sheath composite yarn 10. For example, the sock 1 is heated using a heat setting process commonly used in sock knitting. Specifically, the sock 1 is placed in a mold modeled after a human foot, and steam at approximately 100°C is applied for 10 to 20 seconds using a dedicated heat setting machine. Note that, in step S2, heat pressing can also be performed instead of the heat setting process. This ensures the smoothness of the sole of the foot.

[0082] Next, the sock 1 is cooled (step S3) to resolidify the molten resin. For example, the sock 1 can be placed in a room temperature environment to resolidify the resin. This completes the manufacturing of the sock 1.

[0083] (Action / Effect)

[0084] like Figure 4 As shown, the sock 1 knitted using the core-sheath composite yarn 10 is heated and cooled, so that the sheath 102 is melted and then solidified. As a result, the core 101 after knitting is coated with resin.

[0085] As mentioned above, the resin has a moderately high coefficient of friction, so the portion woven with the core-sheath composite yarn 10 exhibits a high anti-slip effect. Furthermore, this portion is highly resistant to abrasion and peeling, maintaining a high anti-slip effect. Furthermore, the thickness of the resin-coated portion (i.e., the portion woven with the core-sheath composite yarn 10) and the remaining portion is substantially the same. This prevents discomfort to the wearer of the sock 1.

[0086] Conventional anti-slip socks (e.g., socks printed and coated with vinyl chloride resin, silicone resin, etc.) offer an anti-slip effect on the skin, but when worn over stockings, they lack this anti-slip effect and may slip. In contrast, in the socks 1 of this embodiment, the core-sheath composite yarn 10 is knitted into the sock 1 and integrated into the sock, making it easier to follow the expansion and contraction of the sock 1. This allows the sock 1 to exhibit a high anti-slip effect and high grip even when not in direct contact with the skin, such as when worn over stockings in a so-called two-layered manner.

[0087] In addition, in running socks, such as Figure 1 By knitting the toe portion 11 , the sole portion 12 , and the heel portion 13 with the core-sheath composite yarn 10 , as in the sock 1 shown in FIG. 1 , a sock that improves exercise efficiency can be realized.

[0088] Specifically, when describing the relationship between the sole of the foot and the ground during running, (1) the heel strikes the ground, (2) the center of gravity shifts toward the toes, (3) the center of gravity reaches the base of the toes, the heel lifts, and (4) the toes push off the ground to advance. Wearing the socks 1 improves the grip (stepping force) between the foot and the sock at the heel, base of the toes, and toes, as well as the grip between the sock and the sole of the shoe. This improves exercise efficiency, as described above.

[0089] (Variation 1)

[0090] The sock 1 may be knitted using the core-sheath composite yarn 10 to knit at least one of the toe portion 11 , the sole portion 12 , and the heel portion 13 .

[0091] (Variation 2)

[0092] The fiber product of one embodiment of the present invention is not limited to the above-mentioned socks 1. Figure 5 , another example of the fiber product according to one embodiment of the present invention will be described. Figure 5 : is a diagram showing an example of a fiber product of this modification. As an example of a fiber product of this modification, Figure 5 A sock 2 is shown in FIG.

[0093] Figure 5 At least a portion of the sock opening 21 of the sock 2 shown in FIG. 1 is woven with the core-sheath composite yarn 10. It should be noted that in the manufacture of the sock 2, the sock opening 21 may be woven with the core-sheath composite yarn 10. Figure 4 The manufacturing method is shown in , so it will not be repeated here.

[0094] The cuff 21 is knitted with the core-sheath composite yarn 10 , so that the cuff 21 of the finished sock 2 is coated with resin, which increases the friction between the cuff 21 and the skin, thereby preventing the cuff 21 of the sock 2 from sliding down.

[0095] (Variation 3)

[0096] Reference Figure 6 , another example of the fiber product according to one embodiment of the present invention will be described. Figure 6 : is a diagram showing an example of a fiber product of this modification. As an example of a fiber product of this modification, Figure 6 The boat socks 3 are shown in FIG.

[0097] Figure 6 The boat socks 3 shown in FIG have a The U-shaped region 31 is woven from the core-sheath composite yarn 10. It should be noted that in the manufacture of the boat socks 3, the Figure 4 The manufacturing method is shown in , so it will not be repeated here.

[0098] The region 31 is knitted with the core-sheath composite yarn 10 , so that the region 31 of the finished boat socks 3 is coated with resin, and the friction between the heel and the skin is increased, thereby preventing the boat socks 3 from falling off.

[0099] It should be noted that area 31 is not limited to For example, it may be in the shape of a "three". In other words, a plurality of (three) rectangular regions woven with the core-sheath composite yarns 10 may be formed in the heel portion.

[0100] (Variation 4)

[0101] The core-sheath composite wire 10 may have a second sheath (not shown) on the outside of the sheath 102 to cover the sheath 102. The purpose of the second sheath is to improve the braiding properties of the fiber product. Therefore, it is preferred that the second sheath has no adhesiveness and good sliding properties. In addition, the second sheath is removed after the fiber product is woven. As an example, the second sheath may also be removed during the heating process of the fiber product ( Figure 4 In the case of performing a heat setting process in this process, it is preferred that the second sheath portion is a water-soluble resin with a low melting point. As an example, the second sheath portion can be composed of micro-particles of EVA.

[0102] (Variant 5)

[0103] The core-sheath composite wire 10 can be used in a portion of a fiber product (hereinafter referred to as a piezoelectric fiber product) composed of a wire having piezoelectricity (hereinafter referred to as a piezoelectric wire). Specifically, the core-sheath composite wire 10 can be used in a portion of a fiber product that generates electric charge due to tensile stress generated by extension (extension) by an external force.

[0104] By using the core-sheath composite wire 10 in part of the piezoelectric fiber product, the stretchability of the portion braided with the core-sheath composite wire 10 is lost, generating tensile stress around the braided area. This allows efficient charge generation around the braided area of ​​the core-sheath composite wire 10.

[0105] Piezoelectric fiber products can sterilize by generating electric charge. The piezoelectric fiber product of this modified example is braided with the piezoelectric wire and the core-sheath composite wire 10. As described above, electric charge can be efficiently generated around the braided area of ​​the core-sheath composite wire 10, thereby achieving a piezoelectric fiber product with improved sterilization performance.

[0106] [Implementation Method 2]

[0107] The following is based on Figures 7 to 20 , to describe the second embodiment of the present invention in detail.

[0108] (Structure of Resin-Coated Wire 41 and Fiber Product)

[0109] Figure 7 This is a cross-sectional view showing an example of the resin coating wire 41 of the second embodiment. Figure 7 The resin coating line 41 shown in FIG corresponds to the Figure 2 The core-sheath composite wire 10 described in.

[0110] The resin coated wire 41 includes a core wire portion 42 formed of a fiber and a resin coating 43 covering the core wire portion 42. The core wire portion 42 corresponds to Figure 2 The core 101 described in the resin coating 43 corresponds to the Figure 2The sheath portion 102 described in .

[0111] The resin coating layer 43 contains a thermoplastic resin and an adhesion enhancer that enhances the adhesion of the thermoplastic resin for preventing slippage between the surface of the thermoplastic resin and a contact object.

[0112] The thermoplastic resin of the resin coating 43 includes an olefin resin, and the olefin resin is preferably an EVA (ethylene-vinyl acetate copolymer) resin.

[0113] Fiber products can be manufactured through the following processes: a weaving process of the resin-coated wire 41; a melting process of heating the resin coating 43 of the resin-coated wire 41 woven in the weaving process to melt it; and a forming process of cooling the resin coating 43 melted in the melting process to form a molten solidified area portion that prevents sliding with the contact object.

[0114] The fiber product thus manufactured comprises: a first core portion formed by fibers; a first resin coating layer formed by a thermoplastic resin and covering the first core portion; a second core portion formed by fibers; a second resin coating layer formed by the same material as the first resin coating layer and covering the second core portion; and a molten solidification region portion formed integrally with the first and second resin coating layers using the same material as the first and second resin coating layers to prevent slippage with a contact object.

[0115] The fiber product may be, for example, Figure 1 The socks 1 described above. Preferably, the socks 1 include a toe portion 11 , a sole portion 12 and a heel portion 13 , and the melt-solidified region is formed in at least one of the toe portion 11 , the sole portion 12 and the heel portion 13 .

[0116] The object with which the melted and solidified region of the fiber product contacts preferably includes the skin of the wearer of the fiber product, and the object with which the melted and solidified region of the socks contacts includes the skin of the wearer's feet.

[0117] Whether the resin-coated yarn 41 is left as is or formed in the melted and solidified area after knitting, the resin coating 43 maintains adhesiveness and a high coefficient of static friction. Consequently, fiber products using the resin-coated yarn 41 are less likely to shift against the skin and less likely to fall off. Compared to a case where the resin coating 43 is formed in the melted and solidified area, the contact area with the user's skin is increased, resulting in a greater anti-slip effect.

[0118] The high static friction coefficient of the resin coating 43 results in a high maximum static friction force against the contacting object before the object begins to move. Therefore, in the case of a fiber product such as a sock 1, when the sock 1 is worn and an external force exceeds the maximum static friction force of the resin coating 43, the sock 1 may be dislodged from the wearer's skin. However, due to the high static friction coefficient of the resin coating 43, the sock 1 is less likely to move from the wearer's skin. As a result, a sock that is less likely to fall off and shift is provided.

[0119] The resin coating 43 has thermoplasticity and can be applied to the core yarn portion 42 . Furthermore, a melted solidified region can be formed by knitting the resin coated yarn 41 and then heating and cooling it.

[0120] Figure 8 (a) Figure 8 (b) is a cross-sectional view for explaining the embedding effect of the resin coating 43 formed on the resin coating line 41 on the contact object 48 to be bonded. Figure 8 (c) is a graph for explaining the glass transition temperature.

[0121] The resin coating 43 has adhesive properties. Here, adhesiveness refers to a type of bonding, that is, bonding is performed at room temperature by applying only a small amount of pressure without using water, solvents, heat, etc. Figure 8 As shown in (a), the unevenness of the surface of the contact object 48 as the adherend presses the resin coating 43 with a very small pressure through the bubbles 49. And, through the molecular contact with the adherend based on covalent bonds, intermolecular forces, van der Waals forces, and London dispersion forces, as shown in FIG. Figure 8 As shown in (b) , the resin coating 43 is embedded in the unevenness of the surface of the contact object 48 , anchored, and bonded to the contact object 48 .

[0122] Viscosity is a property of liquids, while elasticity is a property of solids. Substances with a low glass transition temperature exhibit "viscoelasticity," a property that combines both viscosity and elasticity. For example, the glass transition temperature of tape adhesives ranges from -60°C to -40°C, while that of EVA resins ranges from -42°C to 40°C. A substance with a high molecular weight has a higher melting point, while a substance with a low molecular weight has a lower melting point. A substance with a high degree of polymerization is solid at room temperature, while a substance with a low degree of polymerization is liquid at room temperature.

[0123] Among the olefin resins included in the resin coating 43 , resins having adhesiveness at room temperature, such as EVA resin, also provide an anti-slip effect on the contact object of the resin coating wire 41 due to their molecular weight and degree of polymerization.

[0124] The fiber forming the core portion 42 uses a fiber having a higher melting point than the resin coating 43. For example, the core portion 42 can be formed from polyester fiber (PET) (melting point 260 degrees), polyurethane fiber (melting point 230 degrees), nylon 6 fiber (melting point 215 degrees), cotton (decomposition point 215 degrees), hemp (decomposes at 200 degrees), rayon (260 degrees until decomposition begins), and para-aramid fiber (carbonizes at 400 degrees or above).

[0125] The resin coating 43 of the resin-coated wire 41 has thermoplasticity, and therefore can be applied to the core wire portion 42 , and can also be melted and solidified to form a melt-solidified region.

[0126] The melting point of the resin coating 43 is lower than that of the core 42. Therefore, when the resin coating 43 is melted, the core 42 does not melt. The resin coating 43 has a low glass transition temperature, so the resin coating 43 has adhesiveness at room temperature.

[0127] When the resin coating 43 comprises an olefin resin, the olefin resin does not require the use of solvents that may cause skin irritation during coating and forming the melt-solidified region, thereby forming a skin-friendly fiber product. For example, EVA resin meets the above conditions, so it is preferred that the resin coating 43 comprises EVA resin.

[0128] (Manufacturing Method of Resin Coated Wire 41)

[0129] Figure 9 This is a schematic diagram for explaining a method for manufacturing a resin coating line 41. First, a thermoplastic resin and an adhesion enhancer for enhancing the adhesion of the thermoplastic resin are placed in a resin tank (not shown) within a resin coating material melting machine 50, and the resin tank is heated to liquefy the resin coating material.

[0130] The liquefied resin coating material is then pressed by a gear pump 46 provided in the melter 50 and supplied to the nozzle 47. The resin coating material pressed by the gear pump 46 and supplied to the nozzle 47 is then discharged around the core wire portion 42 supplied to the nozzle 47, forming a resin coating 43 covering the core wire portion 42.

[0131] The resin coated wire 41 having the resin coating 43 formed thereon is then supplied to the water tank 51, where the resin coating 43 of the wire 41 is cooled by the water in the water tank 51. The wire 41 with the resin coating 43 cooled is then wound around the winding unit 53 via the wire insertion unit 52.

[0132] According to this configuration, the gear pump 46 can increase the discharge speed of the resin coating material toward the core portion 42, thereby also increasing the drawing speed of the core portion 42 and improving the productivity of the resin-coated wire 41. Furthermore, the discharge amount and discharge speed can be freely adjusted from resin coating materials with low viscosity when melted (liquefied) to resin coating materials with high viscosity, thereby enabling rapid production of highly uniform resin-coated wire 41.

[0133] (Manufacturing method of socks 1)

[0134] Figure 10 This is a flowchart showing the process of the method for manufacturing the socks 1 involving the resin coated yarn 41. First, the resin coated yarn 41 (core sheath composite yarn) is knitted. Figure 1 The toe portion 11, sole portion 12, and heel portion 13 of the sock 1 described above are knitted using knitting yarn (step S4). The knitted sock 1 is then heated to a temperature higher than the melting point of the resin coating 43 using high-temperature steam (step S5). This causes the resin coating 43 to melt.

[0135] Next, the sock 1 is cooled (step S6). This aligns the shape of the sock 1 and solidifies a portion of the melted resin coating 43, forming a melted and solidified area that prevents slippage between the sock 1 and the contacting object. As a result, a sock 1 that maintains a sufficient anti-slip effect can be manufactured.

[0136] (Friction test results)

[0137] Figure 11 Schematic diagram of a friction test apparatus showing the material constituting the resin coating 43 of the resin-coated wire 41 . Figure 12 This is a graph showing the results of friction tests on the materials of the resin coating layer 43 .

[0138] Based on JISK7125, Figure 11 This friction test was conducted using the friction test apparatus shown in FIG. Three samples, H02, H03, and H04, were used. The resin forming the resin coating 43 applied to the core yarn portion 42 was directly melted and solidified into a sheet. The single-layer resin-coated yarn 41 had limited adhesiveness to a level that allowed it to be knitted on a knitting machine, making it impossible to measure in the "peel test." Therefore, only the "friction test" was conducted.

[0139] The following [Table 1] shows the pressing conditions of each sample H02 / H03 / H04 including pressure, temperature, and time.

[0140]

Table 1

[0141]

[0142] The sheet thickness of each of the prepared samples H02 / H03 / H04 is shown in the following [Table 2]. Depending on the viscosity of the resin, a sheet with a thickness of 0.5 mm or more was prepared.

[0143]

Table 2

[0144]

[0145]

[0146] The measured static friction coefficient, dynamic friction coefficient, etc. of each sample H02 / H03 / H04 are shown in the following [Table 3].

[0147]

Table 3

[0148]

[0149] The force increases linearly to provide friction, reaching the maximum load. This peak value represents the static friction force F S . Static friction coefficient μ s It is given by the following (Formula 1).

[0150] μ s =F S / F P ...(Formula 1)

[0151] Among them, F S : static friction (N),

[0152] F P : Normal force generated by the mass of the sliding piece (=1.96N).

[0153] Due to secondary effects associated with increasing travel distance, the friction force acting in sliding motion usually differs from the specified value exhibited under ideal conditions. D is the peak value F ignoring static friction S , the average value until the first 6 cm after the relative offset movement between the contact surfaces begins. D The calculation is performed from the dynamic friction force using the following (Formula 2).

[0154] μ D =F D / F P ...(Formula 2)

[0155] Among them, F D : dynamic friction (N),

[0156] F P: Normal force generated by the mass of the sliding piece (=1.96N).

[0157] Sample H02's static friction coefficient was as high as 0.84. Sample H03's was also as high as 1.20. Furthermore, Sample H04's was as high as 1.13. Therefore, Samples H02, H03, and H04 all exhibited excellent adhesion and anti-slip properties.

[0158] Regardless of whether the sample H02 / H03 / H04 is applied to the core portion 42 and then melted / solidified, or directly melted / solidified, the adhesiveness of the sample H02 / H03 / H04 is considered to be the same.

[0159] Therefore, through Figure 4 and Figure 10 The fiber product manufactured by the manufacturing method shown in the figure has the effect of not easily shifting from the skin and not easily falling off. The manufacturing method includes: a weaving step of weaving a resin-coated wire 41 having a resin coating 43 formed by coating a core wire portion 42 with any one of the samples H02 / H03 / H04; a melting step of heating and melting the resin coating 43 of the resin-coated wire 41 woven in the weaving step; and a forming step of cooling the resin coating 43 melted in the melting step to form a molten solidified area portion that prevents sliding with the contact object.

[0160] (Structure of Knitted Fabric of Socks Using Resin-Coated Yarn 41)

[0161] Figure 13 (a) is an enlarged surface view of the surface line side of the knitted fabric 61 of the socks using the resin coated yarn 41 before melting and solidification. Figure 13 (b) is an enlarged cross-sectional view. Figure 13 (c) is an enlarged back view of the back line side thereof. Components identical to the aforementioned components are denoted by the same reference numerals, and detailed descriptions thereof will not be repeated.

[0162] The knitted fabric 61 is woven with a resin-coated yarn 41 serving as a top thread and a resin-coated yarn 41 serving as a back thread. To distinguish between the top and back threads, the top and back threads 41 are depicted in white, while the back threads 41 are depicted in gray. Within the core thread 42, both the top and back threads 41 are represented by dashed lines. The top threads 41 are positioned on the side of the sock that contacts the shoe or floor. The back threads 41 are positioned on the side of the sock that contacts the wearer's foot.

[0163] Figure 14 (a) is an enlarged surface view of the surface line side of the knitted fabric 61 of the socks using the resin coated yarn 41 after melting and solidification. Figure 14 (b) is an enlarged cross-sectional view. Figure 14 (c) is an enlarged back view of the dorsal side.

[0164] As mentioned above Figure 13 As shown in (a) to (c), the resin coating 43 of the resin coated yarn 41 of the surface yarn and the resin coated yarn 41 of the back yarn woven in the knitting process are heated and melted in the melting process and then cooled, and the melted and solidified area 60 that prevents slippage between the socks and the contact object is formed. Figure 14 As shown in (a) to (c), the molten solidified region 60 is formed on the front and back sides of the entire braid 61 in a manner buried between the core wires 42. In this way, the molten solidified region 60 is formed integrally with the resin coating 43 of the surface wire and the resin coating 43 of the back wire using the same material as the resin coating 43 of the surface wire and the resin coating 43 of the back wire.

[0165] This prevents the core yarn 42 of the top and back threads from remaining melted and remaining as threads, and the molten resin coating 43 from melting and falling off, thereby forming melted and solidified regions 60 on the front and back sides of the entire knitted fabric 61. Furthermore, the use of resin-coated yarn 41 in the top threads creates a non-slip function between the outer surface of the shoe and the sock. Furthermore, the use of resin-coated yarn 41 in the back threads creates a non-slip function between the wearer's foot and the inner surface of the sock. Consequently, socks having knitted fabric 61 that is less likely to slip against shoes or floors and less likely to fall off the foot are achieved.

[0166] Figure 15 (a) is an enlarged surface view of the surface line side of the knitted fabric 61A of the socks using the resin coated yarn 41 before melting and solidification. Figure 15 (b) is an enlarged cross-sectional view. Figure 15 (c) is an enlarged back view of the back line side thereof. Components identical to the aforementioned components are denoted by the same reference numerals, and detailed descriptions thereof will not be repeated.

[0167] In knitted fabric 61A, resin-coated yarn 41 is used as the top yarn, and non-melting yarn 62 is used as the back yarn. Non-melting yarn 62 is a yarn that provides a good feel in addition to resin-coated yarn 41 used in sock knitting. It has a melting point higher than both the melting point of resin coating 43 of resin-coated yarn 41 and the heating temperature of the melting process.

[0168] To distinguish the top and bottom lines, the top resin-coated thread 41 is depicted in gray, while the back non-melting thread 62 is depicted in white. The core thread 42 of the top resin-coated thread 41 is indicated by a dotted line. The top resin-coated thread 41 is located on the side of the sock that contacts the shoe or floor. The back non-melting thread 62 is located on the side of the sock that contacts the wearer's foot.

[0169] Figure 16 (a) is an enlarged surface view of the surface line side of the knitted fabric 61A of the socks using the resin coated yarn 41 after melting and solidification. Figure 16 (b) is an enlarged cross-sectional view. Figure 16 (c) is an enlarged back view of the dorsal side.

[0170] As mentioned above Figure 15 (a) to Figure 15 As shown in (c), the resin coated yarn 41 of the surface thread and the non-melting yarn 62 of the back thread are knitted in the knitting process. Then, the resin coating 43 of the resin coated yarn 41 is heated and melted in the melting process and then cooled, and the melted and solidified area 60 that prevents the sock from sliding against the contact object is formed. Figure 16 As shown in (a) to (c), the molten solidified region 60 is formed on the surface side of the braid 61A so as to be buried between the core wires 45. In this way, the molten solidified region 60 is formed integrally with the resin coating 43 of the surface wire using the same material as the resin coating 43 of the surface wire.

[0171] This prevents the core yarn 42 of the top thread and the non-melting yarn 62 of the back thread from remaining unmelted and causing the melted resin coating 43 to melt and fall off, thereby forming a melted and solidified area 60 on the top side of the knitted fabric 61A. Furthermore, the use of the resin-coated yarn 41 in the top thread creates a non-slip function between the outer surface of the shoe and the sock. Furthermore, the exposed portion of the non-melting yarn 62 at the back thread maintains the feel of the yarn, resulting in a sock with a pleasant wearing feel.

[0172] Figure 17 (a) is an enlarged surface view of the surface line side of the knitted fabric 61B of the socks using the resin coated yarn 41 before melting and solidification. Figure 17 (b) is an enlarged cross-sectional view. Figure 17 (c) is an enlarged back view of the back line side thereof. Components identical to the aforementioned components are denoted by the same reference numerals, and detailed descriptions thereof will not be repeated.

[0173] In knitted fabric 61B, non-melting yarn 62 is used as the top yarn, and resin-coated yarn 41 is used as the back yarn. Non-melting yarn 62 is a yarn that provides a good feel in addition to resin-coated yarn 41 used when knitting socks. It has a melting point higher than the melting point of resin coating 43 of resin-coated yarn 41 and the heating temperature of the melting process.

[0174] To distinguish the top and bottom threads, the non-melting thread 62, the top thread, is depicted in white, while the resin-coated thread 41, the back thread, is depicted in gray. The core thread 42 of the resin-coated thread 41 of the back thread is indicated by a dotted line. The top non-melting thread 62 is located on the side of the sock that contacts the shoe or floor. The back thread 41 is located on the side of the sock that contacts the wearer's foot.

[0175] Figure 18 (a) is an enlarged surface view of the surface line side of the knitted fabric 61B of the socks using the resin coated yarn 41 after melting and solidification. Figure 18 (b) is an enlarged cross-sectional view. Figure 18 (c) is an enlarged back view of the dorsal side.

[0176] As mentioned above Figure 17 As shown in (a) to (c), the non-melting yarn 62 of the surface thread and the resin-coated yarn 41 of the back thread are knitted in the knitting process. Then, the resin coating 43 of the resin-coated yarn 41 is heated and melted in the melting process and then cooled, and the melted and solidified area 60 that prevents the sock from sliding against the contact object is formed. Figure 18 (a) to Figure 18 As shown in (c), the molten solidified region 60 is formed on the back side of the braid 61B so as to be buried between the core wires 45. Thus, the molten solidified region 60 is formed integrally with the resin coating 43 of the back wire using the same material as that of the resin coating 43 of the back wire.

[0177] This prevents the core yarn 42 of the back thread and the non-melting yarn 62 of the top thread from remaining unmelted and causing the molten resin coating 43 to melt and fall off, thereby forming a molten and solidified area 60 on the back side of the knitted fabric 61B. Furthermore, the use of the resin-coated yarn 41 in the back thread creates an anti-slip function between the wearer's foot and the inner surface of the sock. Furthermore, since the non-melting yarn 62 is partially exposed on the top thread, the socks have a good and aesthetically pleasing appearance.

[0178] Figure 19 (a) is an enlarged surface view of the surface line side of the knitted fabric 61C of the socks using the resin coated yarn 41 before melting and solidification. Figure 19 (b) is an enlarged cross-sectional view. Figure 19 (c) is an enlarged back view of the back line side thereof. Components identical to the aforementioned components are denoted by the same reference numerals, and detailed descriptions thereof will not be repeated.

[0179] In the braid 61C, the resin coated yarn 41 is used as the surface yarn, and there is no back yarn. The resin coated yarn 41 as the surface yarn is drawn in gray. The core yarn 42 is shown by a dotted line.

[0180] Figure 20 (a) is an enlarged surface view of the surface line side of the knitted fabric 61C of the socks using the resin coated yarn 41 after melting and solidification. Figure 20 (b) is an enlarged cross-sectional view. Figure 20 (c) is an enlarged back view of the dorsal side.

[0181] As mentioned above Figure 19As shown in (a) to (c), the resin coated yarn 41 of the surface yarn is knitted in the knitting process. Then, the resin coating 43 of the resin coated yarn 41 is heated and melted in the melting process and then cooled, and the melted and solidified area 60 that prevents the sock from sliding with the contact object is formed. Figure 20 As shown in (a) to (c), the molten solidified region 60 is formed on the front and back sides of the entire braid 61C in a manner buried between the core wires 45. In this way, the molten solidified region 60 is formed integrally with the resin coating 43 of the surface wire using the same material as the resin coating 43 of the surface wire.

[0182] This prevents the core yarn 42 of the surface thread from remaining unmelted and the molten resin coating 43 from melting and falling off, thereby forming melted and solidified regions 60 on the front and back sides of the entire knitted fabric 61C. Therefore, a sock having the knitted fabric 61C that is less likely to slip against shoes or floors and less likely to fall off the foot can be obtained.

[0183] The knitted fabric 61 / 61A / 61B / 61C described above may be used in at least a part of the socks. It may be used in the entire socks or only in a part of the socks.

[0184] [Implementation Method 3]

[0185] The following is based on Figures 21 to 38 , to describe the third embodiment of the present invention in detail.

[0186] (Composition of Double-Layer Coated Wire 44 and Fiber Products)

[0187] Figure 21 1 is a cross-sectional view showing an example of a double-coated wire 44 according to Embodiment 3. Components identical to those described above are denoted by the same reference numerals, and detailed description thereof will not be repeated.

[0188] Double-layer coated wire 44 includes a core wire portion 42 formed of fibers, a resin coating 43 (first resin coating) covering core wire portion 42, and a water-soluble resin layer 45 (second resin coating) covering resin coating 43. Resin coating 43 includes a thermoplastic resin and an adhesion enhancer that enhances the adhesion of the thermoplastic resin to prevent slippage between the thermoplastic resin and an object of contact.

[0189] The double-coated wire 44 corresponds to the core-sheath wire 10 having the second sheath portion described in the fourth modification of the first embodiment, and the water-soluble resin layer 45 corresponds to the second sheath portion.

[0190] The water-soluble resin layer 45 is thermoplastic, allowing it to be applied to the resin coating 43. Furthermore, the water-soluble resin layer 45 is water-soluble, allowing it to be removed from the resin coating 43 by applying water vapor. The water-soluble resin layer 45 has a low coefficient of dynamic friction, making it easy to knit using a knitting machine. For example, water-soluble EVA resin satisfies the above-mentioned conditions, and therefore, the water-soluble resin layer 45 preferably comprises a water-soluble EVA resin.

[0191] (Manufacturing Method of Double-Coated Wire 44)

[0192] Figure 22 This is a schematic diagram for explaining a method for manufacturing a double-coated wire 44. Components identical to those described above are denoted by the same reference numerals, and detailed description thereof will not be repeated.

[0193] First, a first resin coating material containing a thermoplastic resin and an adhesion enhancer for enhancing the adhesion of the thermoplastic resin is added to a resin tank (not shown) in a melter 50 , and the resin tank is heated to liquefy the first resin coating material.

[0194] The liquefied first resin coating material is then pressed by the gear pump 46 provided in the melter 50 and supplied to the nozzle 47. The first resin coating material pressed by the gear pump 46 and supplied to the nozzle 47 is then discharged around the core wire portion 42 supplied to the nozzle 47, thereby forming a resin coating 43 (first resin coating) covering the core wire portion 42.

[0195] Thereafter, the resin-coated wire 41 having the resin coating 43 formed thereon is supplied to the water tank 51, where the resin coating 43 of the resin-coated wire 41 is cooled by the water in the water tank 51. The resin-coated wire 41, after the resin coating 43 has been cooled, is then supplied to the nozzle 47A via the wire insertion portion 52 and the roller 54.

[0196] Next, the liquefied second resin coating material is pressed by a gear pump provided in the melting machine 50A and supplied to the nozzle 47A. The second resin coating material may be supplied to the nozzle 47A by a press machine instead of the melting machine 50A.

[0197] Next, the second resin coating material, which is pressed by a gear pump and supplied to nozzle 47A, is discharged around resin coating 43 of resin-coated wire 41 supplied to nozzle 47A, forming double-layer coated wire 44 having water-soluble resin layer 45 (second resin coating) covering resin coating 43. Water-soluble resin layer 45 of double-layer coated wire 44 is naturally cooled. Then, double-layer coated wire 44 is wound around winding unit 53 via wire insertion unit 52.

[0198] The water-soluble resin layer 45 of the resin coating 43 of the double-layer coated yarn 44 manufactured using this manufacturing method has a low coefficient of dynamic friction. Consequently, the friction generated when the double-layer coated yarn 44 rubs against the knitting machine's yarn path is reduced, allowing for uniform feeding of the double-layer coated yarn 44. Consequently, defects and yarn breakage are reduced, making it easier to knit the double-layer coated yarn 44 on the knitting machine.

[0199] (Manufacturing method of socks 1)

[0200] Figure 23 This is a flow chart showing the process of the method for manufacturing the socks 1 using the double-layer coated yarn 44. First, the double-layer coated yarn 44 is knitted. Figure 1 The toe portion 11, the sole portion 12, and the heel portion 13 of the sock 1 are knitted, and the remaining portion of the sock 1 is knitted using the knitting yarn (step S7).

[0201] Next, a selection is made as to whether or not to melt and resinify the resin coating 43 of the double-layer coating yarn 44 in the toe portion 11, sole portion 12, and heel portion 13 of the sock 1 (step S8). If resinification of the resin coating 43 is selected (yes in step S8), the temperature of the water vapor applied to the knitted sock 1 is set to a temperature higher than the melting point of the resin coating 43 (step S9). Next, water vapor is applied to the sock 1 knitted with the double-layer coating yarn 44 to remove the water-soluble resin layer 45 of the double-layer coating yarn 44 knitted in the toe portion 11, sole portion 12, and heel portion 13 of the sock 1 from the resin coating 43. The resin coating 43, whose melting point is lower than the water vapor temperature, is then melted and resinified (step S10). Subsequently, when the sock 1 is cooled, a melt-solidified region is formed where a portion of the melted resin coating 43 solidifies (step S11).

[0202] Thus, a sock 1 having a melted and solidified region for preventing slippage with a contact object can be obtained. This melted and solidified region prevents the sock from sliding down the wearer's skin, thereby improving the grip of the sock on the wearer's skin.

[0203] When knitting the double-coated yarn 44, the removal of the water-soluble resin layer 45 reduces the dynamic friction generated by the double-coated yarn 44 rubbing against the knitting machine's track, making it easier to knit the yarn on the knitting machine. Furthermore, after knitting, the static friction of the resin coating 43 exposed after the removal of the water-soluble resin layer 45 is high, preventing slippage with contacting objects.

[0204] If the selection is made not to resinify the resin coating 43 (No in step S8), the temperature of the water vapor applied to the sock 1 is set to a temperature lower than the melting point of the resin coating 43 (step S12). Next, water vapor is applied to the knitted sock 1 to remove the water-soluble resin layer 45 of the double-layer coating yarn 44 knitted in the toe portion 11, sole portion 12, and heel portion 13 of the sock 1 from the resin coating 43. Since the melting point of the resin coating 43 is higher than the temperature of the water vapor, it does not melt (step S13). Thereafter, the sock 1 is cooled (step S14). This results in a sock 1 in which the resin coating 43 exposed by the removal of the water-soluble resin layer 45 has a high static friction force, thereby preventing slippage with contacting objects.

[0205] In this manner, a double-layer coated yarn 44 having a high-friction resin coating 43 and covered with a water-soluble resin layer 45 having a low-friction coefficient is knitted into a desired portion of a fiber product, and then heat-set to remove the water-soluble resin layer 45. This results in a sock 1 with the high-friction resin coating 43 exposed, providing excellent anti-slip properties.

[0206] According to this manufacturing method, the sock 1 is shaped by applying high-temperature steam to it and then cooling it. Furthermore, the water-soluble resin layer 45 is removed, and a portion of the melted resin coating 43 solidifies, forming a melted and solidified region that prevents slippage between the sock 1 and the contacting object. As a result, a sock 1 can be manufactured that maintains a sufficient anti-slip effect.

[0207] The composition of the water-soluble resin layer 45 is not particularly limited as long as it is a water-soluble resin. The water-soluble resin layer 45 is applied to the resin coating layer 43 by a melter 50A or a press machine, and therefore needs to have thermoplasticity.

[0208] After weaving, the water-soluble resin layer 45 is removed from the resin coating 43 by heat setting using high-temperature steam.

[0209] When the resin coating layer 43 is not resinified, the melting point of the water-soluble resin layer 45 is preferably lower than the melting point of the resin coating layer 43. In this case, when the temperature during heat setting is set to be higher than the melting point of the water-soluble resin layer 45 and lower than the melting point of the resin coating layer 43, the resin coating layer 43 is not resinified, and socks can be provided that maintain the stretchability of the fabric and provide a comfortable feel.

[0210] When resin coating 43 is resinified, the melting point of water-soluble resin layer 45 is preferably equal to or higher than that of resin coating 43. In this case, while water-soluble resin layer 45 is being removed, resin coating 43 is melted and then cooled, forming a molten solidified region. This adhesive molten solidified region has a larger area in contact with the skin than the region of yarn woven with adhesive resin coating 43. This results in a sock with a more effective anti-slip effect.

[0211] In this manner, heat setting is performed to remove the water-soluble resin layer 45 from the resin coating 43. Heat setting conditions include, for example, applying steam at approximately 100°C to the water-soluble resin layer 45 for 10 to 25 seconds. The heat setting conditions, steam temperature, and duration can be appropriately modified depending on the melting points of the resin coating 43 and the water-soluble resin layer 45, as well as the thermal properties of other braided yarns.

[0212] However, the water-soluble resin layer 45 can also be removed by exposing it to liquid water instead of heat setting. For example, the water-soluble resin layer 45 can be removed by soaking it in hot water at 60°C to 80°C for 5 to 15 minutes. This makes it possible to remove the water-soluble resin layer 45 from knitted fabrics using heat-sensitive knitting yarn without heat setting.

[0213] Furthermore, a resin having a lower melting point than the olefin resin of the resin coating layer 43 may be used instead of the water-soluble resin layer 45. Thus, during heat setting, the second resin coating layer can be removed from the first resin coating layer (resin coating layer 43) by exposure to heat rather than by water vapor.

[0214] (Peel test results)

[0215] Figure 24 (a) to (d) are photographs for explaining the method of the peeling test of the material of the resin coating 43 constituting the double-layer coating line 44. The test method of the peeling test is based on JISZ0237. The peeling test was performed using three samples HM-A, HM-C and HM-D of the resin constituting the resin coating 43 of the double-layer coating line 44. The dimensions of each sample HM-A, HM-C and HM-D are 10 mm in width and approximately 300 mm in length. The tensile speed is 5±2 mm / s. As Figure 16 As shown in (d), the ends of the test pieces of each sample were clamped with a clip and peeled using an autograph. Since the adhesion of the double-coated wire 44, a two-layer coating type, was higher than that of the resin-coated wire 41, it could not be measured in the "friction test," so only the "peel test" was performed.

[0216] The thickness of each sample HM-A, HM-C, and HM-D is shown in the following [Table 4].

[0217]

Table 4

[0218] Thickness (mm) 1 2 3 average HM-A 0.55 0.55 0.52 0.54 HM-B 0.56 0.57 0.55 0.56 HM-C 0.55 0.54 0.54 0.54 PET film 0.06 0.06 0.05 0.06

[0219] The peel adhesive forces measured in the above-mentioned peel test are shown in the following [Table 5].

[0220]

Table 5

[0221] N / 10mm HM-A HM-B HM-C average value 2.0 5.9 9.3

[0222] Figure 25 It is a graph showing the peeling test results of the sample HM-A constituting the resin coating layer 43 . Figure 26 Graph showing the isolation test results of sample HM-C constituting the resin coating layer 43 . Figure 27 Graph showing the isolation test results of the sample HM-D constituting the resin coating layer 43 .

[0223] The measured value for the initial 25mm stroke of each sample was excluded. The average value of the subsequent 50mm peeling of the test piece was used as the peeling adhesion strength. However, the peeling distance in this test was insufficient to meet the JIS Z0237 standard, so the average value was calculated based on the range of peelability.

[0224] To mitigate the elongation of the test piece of each sample, a KOKOPITA (a Japanese sock brand) sewn fabric was attached to the sheet to perform an additional peel test. The peel adhesion measured in the additional peel test is shown in [Table 6] below.

[0225]

Table 6

[0226] N / 10mm HM-A HM-B HM-C average value 3.7 6.4 12.8

[0227] Figure 28 4 is a graph showing the results of an additional isolation test on the sample HM-A constituting the resin coating layer 43 . Figure 29 Graph showing the results of the additional isolation test on the sample HM-C constituting the resin coating layer 43 . Figure 30 Graph showing the results of the additional isolation test on the sample HM-D constituting the resin coating layer 43 .

[0228] For sample HM-A, the peeling distance was ensured by attaching and sewing the fabric. From this, the average value was calculated, as per the JIS Z 0237 standard. For samples HM-C and HM-D, the peeling distance was insufficient compared to the aforementioned standard, so the average value was calculated based on the range of peelability.

[0229] Sample HM-A exhibited a high peel adhesion of 3.7 N / cm. Sample HM-C also exhibited a high peel adhesion of 6.4 N / cm. Furthermore, Sample HM-D exhibited a high peel adhesion of 12.8 N / cm. Therefore, Samples HM-A, HM-C, and HM-D all exhibited excellent adhesion and anti-slip properties.

[0230] Regardless of whether the sample HM-A / HM-C / HM-D is applied to the core portion 42 and then melted / solidified or directly melted / solidified, the adhesiveness of the sample HM-A / HM-C / HM-D is considered to be the same.

[0231] Therefore, the fiber product has the effect of not easily being displaced from the skin and not easily falling off, and the fiber product comprises: a first core portion formed by fibers; a first resin coating formed using any one of samples HM-A / HM-C / HM-D to form and cover the first core portion; a second core portion formed by the fibers; a second resin coating formed from the same material as the first resin coating and covering the second core portion; and a molten solidification region portion formed integrally with the first and second resin coatings using the same material as the first and second resin coatings to prevent sliding with a contact object.

[0232] (Structure of knitted fabric of socks using double-coated yarn 44)

[0233] Figure 31 (a) is an enlarged surface view of the surface line side of the knitted fabric 71 of the socks using the double-layer coated yarn 44 before melting and solidification. Figure 31 (b) is an enlarged cross-sectional view. Figure 31 (c) is an enlarged back view of the back line side thereof. Components identical to the aforementioned components are denoted by the same reference numerals, and detailed descriptions thereof will not be repeated.

[0234] The knitted fabric 71 is woven with double-coated yarn 44, serving as a top thread, and double-coated yarn 44, serving as a back thread. To distinguish between the top and back threads, the top double-coated yarn 44 is depicted in white, while the back double-coated yarn 44 is depicted in gray. In the core yarn 42, both the top and back double-coated yarns 44 are indicated by dashed lines. The top double-coated yarn 44 is positioned on the side of the sock that contacts the shoe or floor. The back resin-coated yarn 44 is positioned on the side of the sock that contacts the wearer's foot.

[0235] Figure 32 (a) is an enlarged surface view of the surface line side of the knitted fabric 71 of the socks using the double-layer coated yarn 44 after melting and solidification. Figure 32 (b) is an enlarged cross-sectional view. Figure 32(c) is an enlarged back view of the dorsal side.

[0236] As mentioned above Figure 31 As shown in (a) to (c), water vapor or water is applied to the water-soluble resin layer 45 of the double-layer coated yarn 44 of the top and back yarns knitted in the knitting process to melt the water-soluble resin layer 45, thereby removing the resin layer 43. Then, the resin coating 43 of the double-layer coated yarn 44 of the top and back yarns 44 is heated and melted, and then cooled, and the molten solidified area 60 that prevents slippage between the socks and the contact object is formed. Figure 32 As shown in (a) to (c), the molten solidified region 60 is formed on the front and back sides of the entire braid 71 in a manner buried between the core wires 45. In this way, the molten solidified region 60 is formed integrally with the resin coating 43 of the surface wire and the resin coating 43 of the back wire using the same material as the resin coating 43 of the surface wire and the resin coating 43 of the back wire.

[0237] This prevents the core yarn 42 of the top and back threads from remaining unmelted and remaining as threads, and the molten resin coating 43 from melting and falling off, thereby forming melted and solidified regions 60 on the front and back sides of the entire knitted fabric 71. Furthermore, the use of double-layer coated yarn 44 in the top threads creates a non-slip function between the shoe and the outer surface of the sock. Furthermore, the use of double-layer coated yarn 44 in the back threads creates a non-slip function between the wearer's foot and the inner surface of the sock. Consequently, a sock having knitted fabric 71 is achieved that is less likely to slip against shoes or floors and less likely to fall off the foot.

[0238] Figure 33 (a) is an enlarged surface view of the surface line side of the knitted fabric 71A of the socks using the double-layer coated yarn 44 before melting and solidification. Figure 33 (b) is an enlarged cross-sectional view. Figure 33 (c) is an enlarged back view of the back line side thereof. Components identical to the aforementioned components are denoted by the same reference numerals, and detailed descriptions thereof will not be repeated.

[0239] In the knitted fabric 71A, the double-coated yarn 44 is used as the top yarn, and the non-melting yarn 62 is used as the back yarn. The non-melting yarn 62 is a yarn with a good feel other than the double-coated yarn 44 used in sock knitting, and has a higher melting point than the resin coating 43 of the double-coated yarn 44.

[0240] To distinguish the top and bottom lines, the double-coated thread 44, the top line, is depicted in gray, while the non-melting thread 62, the back line, is depicted in white. The core thread 42 of the double-coated thread 44 is shown as a dotted line. The double-coated thread 44 of the top line is located on the side of the sock that contacts the shoe or floor. The non-melting thread 62 of the back line is located on the side of the sock that contacts the wearer's foot.

[0241] Figure 34 (a) is an enlarged surface view of the surface line side of the knitted fabric 71A of the socks using the double-layer coated yarn 44 after melting and solidification. Figure 34 (b) is an enlarged cross-sectional view. Figure 34 (c) is an enlarged back view of the dorsal side.

[0242] As mentioned above Figure 33 As shown in (a) to (c), the double-layer coated yarn 44 of the top thread and the non-melting yarn 62 of the back thread are knitted in the knitting process. Then, water vapor or water is applied to the water-soluble resin layer 45 of the double-layer coated yarn 44 to melt it and remove it from the resin coating 43. Then, the resin coating 43 of the double-layer coated yarn 44 of the top thread is heated and melted and then cooled, and the molten solidified area 60 that prevents the sock from sliding between the sock and the contact object is formed. Figure 34 As shown in (a) to (c), the molten solidified region 60 is formed on the surface side of the braid 71A so as to be buried between the core wires 45. Thus, the molten solidified region 60 is formed integrally with the resin coating 43 of the surface wires using the same material as the resin coating 43 of the surface wires.

[0243] This prevents the core yarn 42 of the top thread and the non-melting yarn 62 of the back thread from remaining unmelted and causing the molten resin coating 43 to melt and fall off, thereby forming a melted and solidified area 60 on the top side of the knitted fabric 71A. Furthermore, the use of double-layer coated yarn 44 in the top thread creates a non-slip function between the outer surface of the shoe and the sock. Furthermore, the exposed portion of the non-melting yarn 62 at the back thread maintains the feel of the yarn, resulting in a sock with a pleasant wearing feel.

[0244] Figure 35 (a) is an enlarged surface view of the surface line side of the knitted fabric 71B of the socks using the double-layer coated yarn 44 before melting and solidification. Figure 35 (b) is an enlarged cross-sectional view. Figure 35 (c) is an enlarged back view of the back line side thereof. Components identical to the aforementioned components are denoted by the same reference numerals, and detailed descriptions thereof will not be repeated.

[0245] In knitted fabric 71B, non-melting yarn 62 is used as the top yarn, and double-coated yarn 44 is used as the back yarn. Non-melting yarn 62 is a yarn that provides a good feel in addition to double-coated yarn 44 used in sock knitting. It has a melting point higher than the melting point of the resin coating 43 of the double-coated yarn 44 and the heating temperature of the melting process.

[0246] To distinguish the top and bottom lines, the non-melting thread 62, the top line, is depicted in red, while the double-coated thread 44, the bottom line, is depicted in gray. The core thread 42 of the double-coated thread 44 of the bottom line is indicated by a dashed line. The non-melting thread 62 of the top line is located on the side of the sock that contacts the shoe or floor. The double-coated thread 44 of the bottom line is located on the side of the sock that contacts the wearer's foot.

[0247] Figure 36 (a) is an enlarged surface view of the surface line side of the knitted fabric 71B of the socks using the double-layer coated yarn 44 after melting and solidification. Figure 36 (b) is an enlarged cross-sectional view. Figure 36 (c) is an enlarged back view of the dorsal side.

[0248] As mentioned above Figure 35 As shown in (a) to (c), the non-melting yarn 62 of the surface thread and the double-layer coated yarn 44 of the back thread are knitted in the knitting process. Then, water vapor or water is applied to the water-soluble resin layer 45 of the double-layer coated yarn 44 to melt it and remove it from the resin coating 43. Then, the resin coating 43 of the double-layer coated yarn 44 of the back thread is heated and melted and then cooled, and the molten solidified area 60 that prevents the sock from sliding between the sock and the contact object is formed. Figure 36 As shown in (a) to (c), the molten solidified region 60 is formed on the back side of the braid 71B so as to be buried between the core wires 45. Thus, the molten solidified region 60 is formed integrally with the resin coating 43 of the back wire using the same material as that of the resin coating 43 of the back wire.

[0249] This prevents the non-melting threads 62 of the top and core threads 42 of the back from remaining unmelted, preventing the melted resin coating 43 from melting and falling off, thereby forming a melted and solidified region 60 on the back side of the knitted fabric 71B. Furthermore, the use of a double-layer coated thread 44 in the back creates an anti-slip function between the wearer's foot and the inner surface of the sock. Furthermore, the exposed portion of the non-melting threads 62 on the top surface results in a well-designed and aesthetically pleasing sock.

[0250] Figure 37 (a) is an enlarged surface view of the surface line side of the knitted fabric 71C of the socks using the double-layer coated yarn 44 before melting and solidification. Figure 37 (b) is an enlarged cross-sectional view. Figure 37 (c) is an enlarged back view of the back line side thereof. Components identical to the aforementioned components are denoted by the same reference numerals, and detailed descriptions thereof will not be repeated.

[0251] In the braid 71C, the double-coated yarn 44 is used as the top yarn, and there is no back yarn. The double-coated yarn 44 as the top yarn is drawn in gray. The core yarn 42 is shown in dotted lines.

[0252] Figure 38 (a) is an enlarged surface view of the surface line side of the knitted fabric 71C of the socks using the double-layer coated yarn 44 after melting and solidification. Figure 38 (b) is an enlarged cross-sectional view. Figure 38 (c) is an enlarged back view of the dorsal side.

[0253] As mentioned above Figure 37 As shown in (a) to (c), the double-layer coated yarn 44 of the surface yarn is knitted in the knitting process. Then, water vapor or water is applied to the water-soluble resin layer 45 of the double-layer coated yarn 44 to melt it and remove it from the resin coating 43. Then, the resin coating 43 of the double-layer coated yarn 44 is heated and melted in the melting process and then cooled, and the molten solidified area 60 that prevents the sock from sliding against the contact object is formed. Figure 38 As shown in (a) to (c), the molten solidified region 60 is formed on the front and back sides of the entire braid 71C in a manner buried between the core wires 45. In this way, the molten solidified region 60 is formed integrally with the resin coating 43 of the surface wire using the same material as the resin coating 43 of the surface wire.

[0254] Thus, the core yarn 42 of the surface thread remains melted without melting, forming melted and solidified regions 60 on the front and back sides of the knitted fabric 71C. Therefore, a sock having the knitted fabric 71C that is difficult to slide against shoes or floors and difficult to fall off the foot can be obtained.

[0255] The knitted fabric 71 / 71A / 71B / 71C described above may be used in at least a part of the socks. It may be used in the entire socks or only in a part of the socks.

[0256] 〔Summarize〕

[0257] A method for manufacturing a resin-coated wire according to one embodiment of the present invention includes the following steps: a liquefaction step, in which a resin coating material comprising a thermoplastic resin and an adhesion enhancer for enhancing the adhesion of the thermoplastic resin is heated to liquefy the material; a supply step, in which the resin coating material liquefied by the liquefaction step is pressed by a gear pump 46 and supplied to a nozzle 47; and a coating step, in which the resin coating material pressed by the gear pump 46 and supplied to the nozzle 47 is coated around a core wire portion 42 formed by fibers to form a resin coating 43 covering the core wire portion 42.

[0258] As a result, the discharge amount and discharge speed can be freely adjusted from resins with low viscosity when melted to resins with high viscosity, so a resin coating line with high uniformity can be manufactured quickly.

[0259] A resin-coated wire 41 according to one embodiment of the present invention includes a core wire portion 42 formed of fibers and a resin coating 43 covering the core wire portion 42. The resin coating 53 contains a thermoplastic resin and an adhesion enhancer that enhances the adhesion of the thermoplastic resin to prevent slippage between the surface of the thermoplastic resin and a contact object.

[0260] This enhances the adhesive force of the thermoplastic resin for preventing slippage between the surface of the thermoplastic resin and the contact object, thereby providing a resin-coated wire that sufficiently maintains an anti-slip effect.

[0261] In the resin-coated wire 41 according to one embodiment of the present invention, the thermoplastic resin preferably includes an olefin-based resin.

[0262] As a result, when the olefin resin is applied and the melted solidified region is formed, there is no need to use a solvent that may cause skin roughness, thereby providing a skin-friendly resin-coated thread.

[0263] In the resin-coated wire 41 according to one embodiment of the present invention, it is preferable that the static friction coefficient of the resin coating 43 be not less than 0.84 and not more than 1.20.

[0264] This makes it possible to obtain a resin-coated yarn for constituting a fiber product that is less likely to be displaced from the skin and less likely to fall off.

[0265] The fiber products (socks 1 and 2) according to one embodiment of the present invention are knitted using the resin-coated yarn 41 according to one embodiment of the present invention.

[0266] This increases the adhesive force of the fiber product to the contact object, and makes it possible to obtain a fiber product that is less likely to slide and less likely to fall off.

[0267] Preferably, in a fiber product of one embodiment of the present invention, the resin coating 43 has a first resin portion and a second resin portion formed along the core portion 42 at a position different from the first resin portion, and in order to prevent sliding with a contact object, a molten solidification area portion 60 is formed integrally with the first and second resin portions using the same material as the first and second resin portions.

[0268] Thus, since the melted and solidified region prevents slippage with the contact object, a fiber product capable of sufficiently maintaining an anti-slip effect can be obtained.

[0269] Preferably, the fiber product according to one embodiment of the present invention further includes another resin coated yarn 41 having the same structure as the resin coated yarn 41 , and is woven from the resin coated yarn 41 as a surface yarn and the other resin coated yarn 41 as a back yarn.

[0270] This makes it possible to obtain a fiber product that is less likely to slide and less likely to fall off.

[0271] Preferably, in the fiber product of one embodiment of the present invention, in order to prevent sliding with the contact object, a molten solidification region 60 is formed integrally with the resin coating 43 and the other resin coating 43 using the same material as the resin coating 43 and the other resin coating 43 .

[0272] Thus, by using a resin-coated thread in the top thread, a non-slip function is generated between the contact object and the outer surface of the fiber product. In addition, by using another resin-coated thread in the back thread, a non-slip function is generated between the skin of the wearer of the fiber product and the inner surface of the fiber product.

[0273] Preferably, the fiber product according to one embodiment of the present invention further includes a non-fusible yarn 62 woven from the resin-coated yarn 41 as a surface yarn and the non-fusible yarn 62 as a back yarn.

[0274] Thus, by using resin-coated yarn for the top thread, a non-slip function is achieved between the contact object and the outer surface of the fiber product. In addition, the non-melting yarn portion is exposed at the back thread, thereby retaining the feel of the yarn and achieving a fiber product with a good wearing feel.

[0275] Preferably, the fiber product according to one embodiment of the present invention further includes a non-fusible yarn 62 woven from the non-fusible yarn 62 as a surface yarn and the resin-coated yarn 41 as a back yarn.

[0276] Thus, by using the resin coating line at the back line, anti-slip function is produced between the skin of the wearer and the inner surface of the fiber product. In addition, the part of the state of the line of the non-melting line is exposed at the surface line, so good outward appearance, attractive in appearance fiber product can be obtained.

[0277] Preferably, in a fiber product of one embodiment of the present invention, the resin coating 43 has a first resin portion and a second resin portion formed along the core portion 42 at a position different from the first resin portion, and in order to prevent sliding with a contact object, a molten solidification area portion 60 is formed integrally with the first and second resin portions using the same material as the first and second resin portions.

[0278] Thereby, the anti-slip function is enhanced.

[0279] Preferably, in the fiber product according to one embodiment of the present invention, the fiber product is socks 1 , 2 .

[0280] This increases the adhesive force of the socks to the contact object, making it possible to obtain socks that are less likely to slip and fall off, and to provide socks that are less likely to fall off and shift.

[0281] Preferably, in the fiber product of one embodiment of the present invention, the fiber product is a sock 1 or 2, and the sock 1 or 2 includes a toe portion 11, a sole portion 12, and a heel portion 13, and the melt-solidified area 60 is formed in at least one of the toe portion 11, the sole portion 12, and the heel portion 13.

[0282] Thus, the melted and solidified region portion for the sock, which is difficult to fall off and difficult to shift, can be arranged in the main portion of the sock.

[0283] A method for manufacturing a fiber product according to one embodiment of the present invention includes the following steps: a weaving step of weaving the resin-coated yarn 41 according to one embodiment of the present invention; a melting step of heating and melting the resin coating 43 of the resin-coated yarn 41 woven in the weaving step; and a forming step of cooling the resin coating 43 melted in the melting step to form a molten solidified region portion that prevents slippage with a contact object.

[0284] Thus, since the melted and solidified region prevents slippage with the contact object, a fiber product capable of sufficiently maintaining an anti-slip effect can be manufactured.

[0285] A double-layer coated wire 44 according to one embodiment of the present invention includes a core wire portion 42 formed of a fiber, a first resin coating layer (resin coating layer 43) covering the core wire portion 42, and a second resin coating layer (water-soluble resin layer 45) covering the first resin coating layer (resin coating layer 43). The first resin coating layer (resin coating layer 43) includes a thermoplastic resin and an adhesion enhancer, which enhances the adhesion of the thermoplastic resin to prevent slippage between the thermoplastic resin and the contact object.

[0286] This makes it possible to provide a double-coated yarn in which the second resin coating layer is removed after weaving to expose the first resin coating layer that prevents slippage with a contact object.

[0287] Preferably, in the double-layer coated wire 44 according to one embodiment of the present invention, the peel adhesion of the first resin coating layer is not less than 3.7 N / cm and not more than 12.8 N / cm.

[0288] This makes it possible to obtain a double-coated yarn for constituting a fiber product that is less likely to be displaced from the skin and less likely to fall off.

[0289] Preferably, in the double-layer coating wire 44 according to one embodiment of the present invention, the thermoplastic resin includes a hydrocarbon resin.

[0290] As a result, when applying the olefin resin and forming the melted solidified region, there is no need to use a solvent that may cause skin roughness, thereby providing a skin-friendly resin-coated thread.

[0291] A method for manufacturing a double-layer coated wire according to one embodiment of the present invention includes the following steps: a liquefaction step of heating and liquefying a first resin coating material including a thermoplastic resin and an adhesion enhancer for enhancing the adhesion of the thermoplastic resin; a first supply step of pressing the first resin coating material liquefied by the liquefaction step by a gear pump 46 and supplying it to a first nozzle (nozzle 47); a first coating step of applying the first resin coating material pressed by the gear pump 46 and supplied to the first nozzle (nozzle 47) around a core wire portion 42 formed of fibers, thereby forming a first resin coating layer (resin coating layer 43) covering the core wire portion 42; a second supply step of supplying the liquefied second resin to a second nozzle (nozzle 47A); and a second coating step of applying the second resin supplied to the second nozzle (nozzle 47A) around the first resin coating layer (resin coating layer 43) applied to the core wire portion 42 in the first coating step, thereby forming a second resin coating layer (water-soluble resin layer 45) covering the first resin coating layer (resin coating layer 43).

[0292] Thus, it is possible to manufacture a double-coated yarn in which the second resin coating layer is removed after weaving to expose the first resin coating layer that prevents slippage with a contact object.

[0293] In a method for manufacturing a fiber product according to one embodiment of the present invention, the second resin coating (water-soluble resin layer 45) according to one embodiment of the present invention contains a soluble resin having solubility, and the method includes the following steps: a weaving step of weaving the double-layer coated wire 44 according to one embodiment of the present invention; a removal step of applying a fluid to the double-layer coated wire 44 woven in the weaving step to remove the soluble resin (water-soluble resin layer 45) from the first resin coating (resin coating 43); and a cooling step of cooling the woven first resin coating (resin coating 43) and the core wire portion 42.

[0294] Thus, the soluble resin having a low coefficient of dynamic friction and being easily knittable by a knitting machine can be removed after knitting is completed, thereby exposing the first resin coating layer that prevents slippage with a contact object.

[0295] Preferably, in a method for manufacturing a fiber product of one embodiment of the present invention, the soluble resin includes a water-soluble resin (water-soluble resin layer 45), and the removal process applies water vapor or water to the double-layer coating line 44 to melt the water-soluble resin (water-soluble resin layer 45), thereby removing the water-soluble resin (water-soluble resin layer 45) from the first resin coating (resin coating 43).

[0296] Thus, the second resin coating layer can be removed from the first resin coating layer with a simple configuration.

[0297] Preferably, in a method for manufacturing a fiber product of one embodiment of the present invention, the first resin coating (resin coating 43) has a first resin portion and a second resin portion formed along the core line portion 42 at a position different from the first resin portion, and after the removal process and before the cooling process, it also includes a melt-solidified region portion forming process, in order to prevent sliding with the contact object, a melt-solidified region portion 60 is formed integrally with the first and second resin portions by the same material as the first and second resin portions.

[0298] Thus, since the melted and solidified region prevents slippage with the contact object, a fiber product capable of sufficiently maintaining an anti-slip effect can be manufactured.

[0299] Preferably, in a method for manufacturing a fiber product of one embodiment of the present invention, there is also another double-layer coated wire 44 constructed in the same manner as the double-layer coated wire of one embodiment of the present invention, the other second resin coating (water-soluble resin layer 45) contains a soluble resin with solubility, the weaving process weaves the double-layer coated wire 44 as the surface wire and the other double-layer coated wire 44 as the back wire, and the removal process applies fluid to the double-layer coated wire 44 and the other double-layer coated wire 44 to remove the second resin coating (water-soluble resin layer 45) containing the soluble resin and the other second resin coating (water-soluble resin layer 45) from the first resin coating (resin coating 43) and the other first resin coating (resin coating 43), respectively.

[0300] This makes it possible to produce fiber products that are less likely to slide and fall off.

[0301] Preferably, in a method for manufacturing a fiber product of one embodiment of the present invention, after the removal process and before the cooling process, a molten solidification region portion forming process is further included, in which a molten solidification region portion 60 is formed integrally with the first resin coating (resin coating 43) and the other first resin coating (resin coating 43) by the same material as the first resin coating (resin coating 43) and the other first resin coating (resin coating 43) in order to prevent sliding with the contact object.

[0302] Thereby, the anti-slip function is enhanced.

[0303] Preferably, in the method for manufacturing a fiber product according to one embodiment of the present invention, a non-fusible yarn 62 is further provided, and the braiding step braids the double-layer coated yarn 44 as a surface yarn and the non-fusible yarn 62 as a back yarn.

[0304] Thus, using a double-coated yarn in the top thread creates a non-slip function between the contact object and the outer surface of the textile product. Furthermore, the non-melting yarn portion is exposed on the back thread, retaining the tactile feel of the yarn and enabling the production of a textile product with a good wearing feel.

[0305] Preferably, in the method for manufacturing a fiber product according to one aspect of the present invention, a non-fusible yarn 62 is further provided, and the braiding step braids the non-fusible yarn 62 as a surface yarn and the double-coated yarn 44 as a back yarn.

[0306] Thus, by using a double-layer coated thread in the back thread, a non-slip function is generated between the wearer's skin and the inner surface of the fiber product. In addition, the thread state of the non-melting thread used in the top thread is partially exposed, thereby obtaining a fiber product with a good appearance and good appearance.

[0307] In a method for manufacturing a fiber product according to one embodiment of the present invention, the first resin coating (resin coating 43) has a first resin portion and a second resin portion formed along the core line portion 42 at a position different from the first resin portion, and further includes a molten solidification region portion forming process, in which a molten solidification region portion 60 is formed integrally with the first and second resin portions using the same material as the first and second resin portions in order to prevent sliding with a contact object.

[0308] Thereby, the anti-slip function is enhanced.

[0309] In the method for producing a textile product according to one aspect of the present invention, the temperature of the fluid is preferably lower than the melting point of the first resin coating layer (resin coating layer 43 ).

[0310] Thus, the soluble resin can be removed from the first resin coating layer by the fluid.

[0311] In the method for producing a textile product according to one aspect of the present invention, the temperature of the fluid is preferably higher than the melting point of the first resin coating layer (resin coating layer 43 ).

[0312] Thus, the soluble resin can be removed from the first resin coating layer by the fluid, and the first resin coating layer can be melted and solidified to form a melted and solidified region that prevents slippage with a contact object.

[0313] Preferably, in the method for producing a fiber product according to one embodiment of the present invention, the fiber product is socks 1 or 2 .

[0314] This increases the adhesive force of the socks to the contact object, making it possible to obtain socks that are less likely to slip and fall off, and to provide socks that are less likely to fall off and shift.

[0315] Preferably, in a method for manufacturing a fiber product according to one embodiment of the present invention, the fiber product is a pair of socks 1 or 2, wherein the socks 1 or 2 include a toe portion 11, a sole portion 12, and a heel portion 13, and the melt-solidified region 60 is formed in at least one of the toe portion 11, the sole portion 12, and the heel portion 13.

[0316] Thus, the melted and solidified region portion for the sock, which is difficult to fall off and difficult to shift, can be arranged in the main portion of the sock.

[0317] The present invention is not limited to the above-described embodiments. Various modifications can be made within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also within the technical scope of the present invention. Furthermore, new technical features can be formed by combining the technical means disclosed in each embodiment.

[0318] Description of Reference Numerals

[0319] 1, 2...socks

[0320] 3. Boat socks

[0321] 10...Core-sheath composite wire

[0322] 11…Toes

[0323] 12… the soles of the feet

[0324] 13...Heel

[0325] 21...sock opening

[0326] 31...area

[0327] 41......Resin coating line

[0328] 42...core wire

[0329] 43……resin coating (first resin coating)

[0330] 44...Double coating line

[0331] 45: Water-soluble resin layer (second resin coating layer)

[0332] 46...Gear pump

[0333] 47...Nozzle

[0334] 60...melting and solidification area

[0335] 62……Non-melting line

[0336] 101...Core

[0337] 102... sheath

Claims

1. A fiber product, characterized in that: The resin coated wire is braided and includes a core portion formed of fibers and a resin coating covering the core portion, wherein: The resin coating layer includes a thermoplastic resin and an adhesion enhancer that enhances adhesion of the thermoplastic resin to prevent slippage between a surface of the thermoplastic resin and a contact object, wherein The resin coating layer includes a first resin portion and a second resin portion formed along the core portion at a position different from the first resin portion. In order to prevent slippage with a contact object, a melted solidified region is formed integrally with the first and second resin portions using the same material as the first and second resin portions.

2. The fiber product according to claim 1, wherein It also includes another resin-coated wire having the same structure as the resin-coated wire, The resin coated yarn is braided as the surface yarn and the other resin coated yarn is braided as the back yarn.

3. The fiber product according to claim 1, wherein It also has a non-melting line. The resin-coated yarn is braided as a surface yarn and the non-fusible yarn is braided as a back yarn.

4. The fiber product according to claim 1, wherein The invention further comprises a non-fusible thread braided from the non-fusible thread as a surface thread and the resin-coated thread as a back thread.

5. The fiber product according to claim 1, wherein The fiber product is socks.

6. The fiber product according to claim 1, wherein The fiber product is socks, The socks include a toe portion, a sole portion and a heel portion. The melted and solidified region is formed in at least one of the toe portion, the sole portion, and the heel portion.

7. The fiber product according to claim 1, wherein The thermoplastic resin includes an olefin resin.

8. The fiber product according to claim 1, wherein The static friction coefficient of the resin coating is not less than 0.84 and not more than 1.

20.

9. A fiber product, characterized in that: The resin coated wire is braided and includes a core portion formed of fibers and a resin coating covering the core portion, wherein: The resin coating layer includes a thermoplastic resin and an adhesion enhancer that enhances the adhesion of the thermoplastic resin to prevent slippage between the surface of the thermoplastic resin and a contact object. The fiber product further comprises another resin coated wire having the same structure as the resin coated wire. The resin coated wire is woven from the surface wire and the other resin coated wire is woven from the back wire. In order to prevent slippage with a contact object, a melted solidified region is formed integrally with the resin coating of the resin coating and the other resin coating wires using the same material as the resin coating of the resin coating and the other resin coating wires.

10. A method for manufacturing a fiber product, characterized in that: The process includes the following steps: Weaving process, weaving resin coated wire; a melting step of heating and melting the resin coating of the resin-coated yarn braided in the braiding step; and The forming step is to cool the resin coating melted in the melting step to form a melted solidified region that prevents slipping with a contact object, wherein The resin-coated wire includes a core portion formed of a fiber and a resin coating covering the core portion. The resin coating layer includes a thermoplastic resin and an adhesion enhancer that enhances adhesion of the thermoplastic resin for preventing slippage between a surface of the thermoplastic resin and a contact object.

11. The method for producing a fiber product according to claim 10, wherein: The manufacturing method of the resin-coated wire comprises the following steps: a liquefaction step of heating a resin coating material comprising a thermoplastic resin and an adhesion enhancer for enhancing the adhesion of the thermoplastic resin to liquefy the resin; a supplying step of pressing the resin coating material liquefied in the liquefaction step with a gear pump and supplying the resin coating material to a nozzle; and In the coating step, the resin coating material, which is pressed by the gear pump and supplied to the nozzle, is applied around the core portion formed of the fiber to form a resin coating covering the core portion.

12. A double-layer coating line, characterized in that: The invention comprises a core portion formed of a fiber, a first resin coating layer covering the core portion, and a second resin coating layer covering the first resin coating layer. The first resin coating layer includes a thermoplastic resin and an adhesion enhancer that enhances adhesion of the thermoplastic resin to prevent slippage between the thermoplastic resin and a contact object. The second resin coating layer is a water-soluble resin layer that can be removed from the first resin coating layer upon application of water vapor.

13. The double-layer coated wire according to claim 12, wherein: The peel adhesive strength of the first resin coating layer is 3.7 N / cm or more and 12.8 N / cm or less.

14. The double-layer coated wire according to claim 12, wherein The thermoplastic resin includes an olefin resin.

15. A method for manufacturing a double-layer coating line, characterized in that: Including the following steps: a liquefaction step of heating a first resin coating material comprising a thermoplastic resin and an adhesion enhancer for enhancing the adhesion of the thermoplastic resin to liquefy the material; a first supplying step of pressing the first resin coating material liquefied in the liquefaction step by a gear pump and supplying the material to a first nozzle; a first coating step of applying a first resin coating material pressed by the gear pump and supplied to the first nozzle around a core portion formed of fibers to form a first resin coating covering the core portion; a second supplying step of supplying the liquefied second resin to the second nozzle; and In a second coating step, a second resin supplied to the second nozzle is applied around the first resin coating applied to the core portion in the first coating step to form a second resin coating covering the first resin coating. The second resin coating layer is formed of the same material as the first resin coating layer, or the second resin coating layer is a water-soluble resin layer that can be removed from the first resin coating layer when water vapor is applied.

16. A method for manufacturing a fiber product, characterized in that: The method comprises the following steps: a braiding step of braiding the double-layer coated wire according to claim 12; a removing step of applying steam to the double-layer coated yarn woven in the weaving step to remove the water-soluble resin layer from the first resin coating layer; as well as The cooling step cools the braided first resin coating and the core wire portion.

17. The method for producing a fiber product according to claim 16, wherein: The removal step applies steam or water to the double-coated wire to dissolve the water-soluble resin, thereby removing the water-soluble resin from the first resin coating.

18. The method for producing a fiber product according to claim 16, wherein: The first resin coating layer includes a first resin portion and a second resin portion formed along the core portion at a position different from the first resin portion. It also includes a molten solidification area forming step, in which, after the removal step and before the cooling step, in order to prevent sliding with the contact object, a molten solidification area is formed integrally with the first and second resin parts using the same material as the first and second resin parts.

19. The method for producing a fiber product according to claim 16, wherein: Another double-layer coating line having the same structure as the double-layer coating line, The second resin coating of the other double-coated wire comprises a water-soluble resin having solubility, The braiding step is to braid the double-layer coated wire as the surface wire and the other double-layer coated wire as the back wire. The removal process applies water vapor to the double-coated wire and the other double-coated wire to remove the second resin coating containing the water-soluble resin and the second resin coating of the other double-coated wire from the first resin coating and the first resin coating of the other double-coated wire, respectively.

20. The method for producing a fiber product according to claim 19, wherein: It also includes a molten solidification area portion forming process, in which, after the removal process and before the cooling process, in order to prevent sliding with the contact object, a molten solidification area portion is formed integrally with the first resin coating and the first resin coating of the other double-layer coating line using the same material as the first resin coating and the first resin coating of the other double-layer coating line.

21. The method for producing a fiber product according to claim 16, wherein: It also has a non-melting line. The braiding step braids the double-layer coated yarn as the surface yarn and the non-melting yarn as the back yarn.

22. The method for producing a fiber product according to claim 16, wherein: It also has a non-melting line. The braiding step braids the non-melting yarn as the surface yarn and the double-layer coated yarn as the back yarn.

23. The method for producing a fiber product according to claim 21 or 22, wherein: The first resin coating layer includes a first resin portion and a second resin portion formed along the core portion at a position different from the first resin portion. The method further includes forming a melt-solidified region portion by forming a melt-solidified region portion integrally formed with the first and second resin portions using the same material as the first and second resin portions in order to prevent slippage with a contact object.

24. The method for producing a fiber product according to claim 16, wherein: The temperature of the water vapor is lower than the melting point of the first resin coating layer.

25. The method for producing a fiber product according to claim 16, wherein: The temperature of the water vapor is higher than the melting point of the first resin coating layer.

26. The method for producing a fiber product according to claim 16, wherein: The fiber product is socks.

27. The method for producing a fiber product according to claim 18, wherein: The fiber product is socks, The socks include a toe portion, a sole portion and a heel portion. The melted and solidified region is formed in at least one of the toe portion, the sole portion, and the heel portion.

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