Fiber structure and method for producing fiber structure

Abstract

To provide a fiber structure used for a product (for example, an upper of a shoe) having different stretchability for each part of the product while suppressing an increase in the number of parts.SOLUTION: A fiber structure includes a knitted structure and a woven structure adjacent to each other, in which the knitted structure is formed by a plurality of first linear bodies 5a, and the woven structure is formed continuously with the knitted structure by the plurality of first linear bodies 5a and a plurality of second linear bodies 5b that intersect with the plurality of first linear bodies 5a and are different from the plurality of first linear bodies 5a.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a fibrous structure and a method for manufacturing the fibrous structure. [Background technology]

[0002] In products such as shoes, clothing, and bags, various functions are required for different parts depending on the purpose of use, etc. For example, the upper of a shoe may be required to have different stretchability depending on the part.

[0003] The shoe disclosed in Patent Document 1 has a first member on the upper that extends in one direction. The first member has stretchability only in that one direction and is arranged in a non-jointed state. This configuration allows the stretchability of the upper to be partially changed. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2022 / 157894 Summary of the Invention [Problem to be solved by the invention]

[0005] In order to change the elasticity of a product depending on the part, increasing the number of parts requires more materials, such as adhesives and sewing threads, to join the parts together, which increases the environmental burden.

[0006] The present disclosure aims to obtain a fiber structure for use in a product (for example, a shoe upper) that has different stretchability in different parts of the product while suppressing an increase in the number of parts. [Means for solving the problem]

[0007] The fiber structure according to the present disclosure is a fiber structure having a knitted structure and a woven structure adjacent to each other, wherein the knitted structure is formed by a plurality of first linear bodies, and the woven structure is formed continuously with the knitted structure by a plurality of first linear bodies and a plurality of second linear bodies that intersect with the plurality of first linear bodies and are different from the plurality of first linear bodies. [Effects of the Invention]

[0008] According to the present disclosure, it is possible to provide a fiber structure for use in a product (for example, a shoe upper) having different stretchability in different parts of the product while suppressing an increase in the number of parts. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view showing the appearance of a shoe according to a first embodiment. [Figure 2] FIG. 2 is an enlarged view of a part of the upper body in the first embodiment. [Figure 3] FIG. 3 is an enlarged view of a portion of the upper body in the first embodiment, showing a first modified example of the first region and the second region. [Figure 4] FIG. 4 is an enlarged view of a portion of the upper body in the first embodiment, showing a second modified example of the first region and the second region. [Figure 5] FIG. 5 is an enlarged view of a portion of the upper body in the first embodiment, showing a third modified example of the first region and the second region. [Figure 6] FIG. 6 is a development view of the upper body according to the first embodiment. [Figure 7] FIG. 7 is a development view showing a first modified example of the upper body according to the first embodiment. [Figure 8] FIG. 8 is a diagram showing an example of the arrangement of carbon fibers in a knitted structure. [Figure 9] FIG. 9 is a diagram showing another example of the arrangement of carbon fibers in a knitted structure. [Figure 10]FIG. 10 is a development view of the upper body showing an example of the arrangement of the formation areas of the first and second regions. [Figure 11] FIG. 11 is a development view of the upper body showing an example of the arrangement of the formation areas of the first and second regions. [Figure 12] FIG. 12 is a development view of the upper body showing an example of the arrangement of the formation areas of the first and second regions. [Figure 13] FIG. 13 is a development view of the upper body showing an example of the arrangement of the formation areas of the first and second regions. [Figure 14] FIG. 14 is a development view of the upper body showing an example of the arrangement of the formation areas of the first and second regions. [Figure 15] FIG. 15 is a development view of the upper body showing an example of the arrangement of the formation areas of the first and second regions. [Figure 16] FIG. 16 is a development view of the upper body showing an example of the arrangement of the formation areas of the first and second regions. [Figure 17] FIG. 17 is a front view showing an example of the arrangement when the forming areas of the first and second areas are used in clothing. [Figure 18] FIG. 18 is a rear view showing an example of the arrangement when the forming areas of the first and second areas are used in clothing. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of a fiber structure and a method for manufacturing a fiber structure according to the present disclosure will be described in detail with reference to the drawings. Note that the present disclosure is not limited to these embodiments. In the following description, the same parts are denoted by the same reference numerals, and duplicated descriptions will be omitted.

[0011] <Shoe outline> Fig. 1 is a perspective view of a shoe according to a first embodiment of the present disclosure. Only the shoe 1 for the left foot is shown in each drawing, including Fig. 1. In this embodiment, only the shoe 1 for the left foot will be described, and a description of the shoe for the right foot will be omitted.

[0012] In addition, in the anatomical orthotopic position of the foot, the midline side is referred to as the medial side, and the side opposite the median side is referred to as the lateral side. That is, the side closer to the midline in the anatomical orthotopic position is referred to as the medial side, and the side farthest from the midline in the anatomical orthotopic position is referred to as the lateral side. In addition, unless otherwise specified, the vertical direction refers to the direction perpendicular to both the foot length direction and the foot width direction.

[0013] The shoe 1 comprises an upper 2 and a sole 3. The upper 2 comprises an upper body 4 that covers the top surface of the sole 3, providing an internal space between the upper 2 and the sole 3 for the wearer's foot to fit into. The upper body 4 is fixed to the sole 3 by a method such as sewing, welding, or bonding. The upper body 4 has an opening 21 formed therein. The opening 21 is an opening for inserting the wearer's foot into the internal space of the upper body 4.

[0014] <Outline of knitted and woven structures> FIG. 2 is an enlarged view of a portion of the upper body in embodiment 1. The upper body 4 is a fabric formed using linear bodies 5. The linear bodies 5 are formed of, for example, polyester. The linear bodies 5 may be formed of a single polyester. The linear bodies 5 may be formed of PET (polyethylene terephthalate), PTT (polytrimethylene terephthalate), or PBT (polybutylene terephthalate). The linear bodies 5 may be polyurethane-based thermoplastic elastomer, polyurethane, nylon, spandex, Kevlar (registered trademark), ultra-high molecular weight polyethylene, or polyurethane-covered SCY (single covered yarn) or DCY (double covered yarn). The linear bodies 5 may also be a yarn formed by bundling multiple fibers, a linear resin yarn, a twisted yarn, or the like.

[0015] The upper body 4 has a first region 41 and a second region 42 adjacent to each other.

[0016] The first region 41 is a knitted structure formed by knitting the linear bodies 5. In the knitted structure, a plurality of loops are formed by the plurality of first linear bodies 5a, and adjacent loops are formed so as to be hooked together.

[0017] The second region 42 has a woven structure formed by weaving linear bodies 5. In the woven structure, the linear bodies 5 intersect with each other. The second region 42 is formed by a plurality of first linear bodies 5a forming the knitted structure in the first region 41 extending along the knitting direction of the knitted structure and intersecting the first linear bodies 5a with second linear bodies 5b different from the first linear bodies 5a. The knitted structure in the first region 41 and the woven structure in the second region 42 are formed continuously. The knitted structure in the first region 41 and the woven structure in the second region 42 are formed continuously by the same device.

[0018] Knitted structures have higher elasticity than woven structures. Therefore, by arranging the first region in a region of the upper body 4 where it is desired to increase the elasticity, and arranging the second region 42 in a region where it is desired to decrease the elasticity compared to the first region, it is possible to partially change the elasticity of the upper body 4. Furthermore, because woven structures are easier to make lighter than knitted structures, the second region 42 may be arranged in a region where it is desired to make the material lighter.

[0019] The types of knitting structure that make up the first region 41 include warp knitting, which is knitted on a warp knitting machine, and weft knitting, which is knitted on a flat knitting machine. Figure 2 shows an example in which the first region 41 is warp knitting, which is knitted on a warp knitting machine. The knitting direction of the knitting structure is indicated by arrow X. The direction that intersects with the knitting direction is indicated by arrow Y. In warp knitting, the knitting direction is also referred to as the vertical direction, and the direction that intersects with the knitting direction is also referred to as the horizontal direction. In weft knitting, the knitting direction is also referred to as the horizontal direction, and the direction that intersects with the knitting direction is also referred to as the vertical direction.

[0020] The plurality of first linear bodies 5a that formed loops in the first region 41 extend along the knitting direction X without forming loops in the second region 42. In addition, the second region 42 is provided with a plurality of second linear bodies 5b that extend in a direction intersecting the knitting direction and intersect with the plurality of first linear bodies 5a to form a weave.

[0021] Fig. 3 is an enlarged view of a portion of the upper body in embodiment 1, showing a first modified example of the first region and the second region. In the example shown in Fig. 3, the knitting structure in the first region 41 is formed by weft knitting.

[0022] The plurality of first linear bodies 5a that formed loops in the first region 41 are extended along the knitting direction X without forming loops in the second region 42. Furthermore, the second region 42 is provided with a plurality of linear bodies 5b different from the first linear bodies 5a, and the first linear bodies 5a and the second linear bodies 5b intersect to form a weave.

[0023] Fig. 4 is an enlarged view of a portion of the upper body in embodiment 1, showing a second modified example of the first region and the second region. In the second modified example, the knitting structure in the first region 41 is formed by weft knitting, similar to the first modified example shown in Fig. 3. Furthermore, in the second modified example, unlike the first modified example, the third linear body 5c is not provided in the first region 41.

[0024] Some of the first linear bodies 5a that formed loops in the first region 41 are extended along the knitting direction X in the second region 42 without forming loops.

[0025] The plurality of second linear bodies 5b extend in a direction intersecting the knitting direction X in the second region 42 and are folded back in the direction intersecting the knitting direction X at ends 51 and the like of the second region 42. The folded back plurality of second linear bodies 5b are arranged side by side along the knitting direction X. As a result, although the second linear bodies 5b appear bent when viewed locally, they can be regarded as extending in a direction intersecting the knitting direction X, and a weave can be formed by the plurality of first linear bodies 5a extending along the knitting direction X and the second linear bodies 5b extending in a direction intersecting the knitting direction.

[0026] Fig. 5 is an enlarged view of a portion of the upper body in embodiment 1, illustrating a third modified example of the first region and the second region. As shown in Fig. 5, the first region 41 may include a plurality of third linear bodies 5c extending along the second linear bodies 5b. Because the plurality of first linear bodies 5a form loops in the first region 41, no weave is formed between the plurality of first linear bodies 5a and the plurality of third linear bodies 5c.

[0027] 2 to 5 can be manufactured by the following steps: forming a knitting structure using a plurality of first linear bodies 5a, extending the plurality of first linear bodies 5a from the knitting structure in the knitting direction, intersecting the plurality of second linear bodies 5b with the plurality of first linear bodies 5a, and forming a woven structure continuous with the knitting structure.

[0028] <Example of the arrangement of the first region (knitted structure) and the second region (woven structure) in the upper body> 6 is a development view of the upper body according to embodiment 1. The upper body 4 includes an upper forefoot section R1 that covers the forefoot of the wearer, an upper midfoot section R2 that covers the midfoot of the wearer, and an upper rearfoot section R3 that covers the rearfoot of the wearer. The upper forefoot section R1, upper midfoot section R2, and upper rearfoot section R3 are arranged in this order from the front to the rear of the upper 2. In addition, the direction in which a shoe center axis C, which is a straight line passing through the center of the shoe 1 when viewed in a plan view, extends is referred to as the foot length direction, and the direction perpendicular to the center axis when viewed in a plan view of the shoe 1 is referred to as the foot width direction.

[0029] The upper body 4 has a plurality of first regions 41 and a plurality of second regions 42. As shown in FIG. 6 , the second regions 42 may be provided in the upper forefoot portion R1, the upper midfoot portion R2, and the upper rearfoot portion R3. Because the second regions 42 formed with a woven structure have lower stretchability than the first regions 41, the second regions 42 may be disposed in regions of the upper body 4 where stretch is not desired. The first regions 41 and the second regions 42 may be disposed in one or more regions of the upper forefoot portion R1, the upper midfoot portion R2, or the upper rearfoot portion R3. The first regions 41 and the second regions 42 may be disposed in all or part of at least one region of the upper forefoot portion R1, the upper midfoot portion R2, or the upper rearfoot portion R3.

[0030] In this way, by arranging a plurality of first regions 41 and a plurality of second regions 42 in the upper body 4, it is possible to change the stretchability for each region of the upper body 4. Furthermore, since a woven structure is easier to make lighter than a knitted structure, the second regions 42 may be arranged in regions where lighter weight is desired.

[0031] Furthermore, the linear members 5 used to form the upper body 4 can be made of a single material, thereby improving recyclability. Furthermore, since the linear members 5 used in the knitting structure are also used in the weaving structure, there is no need to use adhesive to join the ends of the linear members, thereby further improving recyclability.

[0032] In the first region 41 formed by a knitting structure, the density of the linear bodies may be changed depending on the region of the upper. In the second region 42 formed by a woven structure, the density of the linear bodies may be changed depending on the region of the upper. By changing the density of the linear bodies depending on the region of the upper main body 4, it becomes possible to change the stretchability of the upper main body 4 more flexibly.

[0033] A throat portion 4a may be formed in the upper body 4. The throat portion 4a is an opening that extends forward from an opening 4b, into which the foot is inserted when putting on the shoe 1. The edges of the throat portion 4a and the opening 4b may be formed by cutting. The edges of the throat portion 4a and the opening 4b may also be formed without cutting.

[0034] By using linear bodies 5 of different colors, the upper body 4 may have regions of different colors. For example, the linear bodies 5a and 5b may have different colors. The upper body 4 may also be formed to have multiple layers.

[0035] Fig. 7 is a development view showing a first modified example of the upper body according to embodiment 1. In the example shown in Fig. 7, the region corresponding to the throat portion 4a shown in Fig. 6 is not an opening but a first region 41.

[0036] <About the use of carbon fiber> In at least one of the first region 41 and the second region 42, carbon fibers may be arranged along the linear body 5. The carbon fibers may be arranged linearly. The carbon fibers may be formed of a single carbon fiber, or may be a covering yarn in which the carbon fiber is used as a core yarn and is covered with a material that increases the strength of the carbon fiber. Carbon fibers have lower elongation and higher strength than fibers such as polyester. Therefore, in the region in which the carbon fibers are arranged, the upper body 4 is less likely to stretch in the direction in which the carbon fibers are arranged, thereby increasing the strength. FIG. 8 is a diagram showing an example of the arrangement of carbon fibers in a knitting structure. FIG. 8 shows an example in which carbon fibers 5d are arranged in a knitting structure 41 formed by weft knitting and arranged along a direction Y intersecting the knitting direction X. FIG. 9 is a diagram showing another example of the arrangement of carbon fibers in a knitting structure. FIG. 9 shows an example in which carbon fibers 5d are arranged in a knitting structure 41 formed by weft knitting and arranged along the knitting direction X.

[0037] <Examples of formation area placement> 10 to 16 are development views of the upper body showing examples of the arrangement of the formation regions. In the following description, the region where the first region 41 and the second region 42 are formed will be referred to as the formation region 43.

[0038] The forming region 43 is provided in at least a portion of the upper body 4. The forming region 43 may extend in the foot width direction or may be inclined relative to the shoe center axis C. The angle α of the direction in which the forming region 43 extends relative to the shoe center axis C is preferably in the range of 45° or more and less than 90°. By arranging the direction in which the forming region 43 extends inclined relative to the shoe center axis C, the forming region 43 can be flexibly positioned in response to the wearer's movements. As shown in FIG. 10, the forming region 43 may be provided in the upper midfoot portion R2. As shown in FIG. 11, the forming region 43 may be provided in the front of the upper midfoot portion R2. As shown in FIG. 12, the forming region 43 may be inclined relative to the shoe center axis C so that the medial side is more forward than the lateral side.

[0039] In the formation region 43, the carbon fibers may be arranged along the width direction of the foot, or may be arranged at an angle relative to the shoe center axis C. The angle α of the direction in which the carbon fibers extend relative to the shoe center axis C is preferably in the range of 45° or more and less than 90°. By arranging the carbon fibers so that the direction in which the carbon fibers extend is at an angle relative to the shoe center axis C, the carbon fibers can be arranged flexibly in response to the movement of the wearer. Note that the carbon fibers may also be arranged in regions other than the formation region 43.

[0040] As shown in Fig. 13, multiple formation areas 43 may be arranged side by side in the foot length direction in the upper midfoot portion R2. As shown in Fig. 14, multiple formation areas 43 may be arranged at an angle with respect to the shoe center axis C so that the medial side is more forward than the lateral side.

[0041] As shown in Figure 15, the multiple formation areas 43 are arranged at an angle with respect to the shoe center axis C so that the medial side of the foot is more forward than the lateral side of the foot, and may be arranged at positions offset from each other in the foot length direction.

[0042] As shown in FIG. 16, the forming region 43 may be formed in the upper midfoot portion R2 and the upper rearfoot portion R3.

[0043] 10 to 16, by providing the forming regions 43, different functions can be exerted in different parts of the upper body 4. Furthermore, when carbon fibers are arranged in the upper body 4, the carbon fibers are less likely to stretch in the extending direction, and an upper body 4 formed with high strength can be obtained.

[0044] 10 to 16 may be arranged in one or more regions of the upper forefoot portion R1, the upper midfoot portion R2, or the upper rearfoot portion R3. The formation region 43 can be arranged in all or part of at least one region of the upper forefoot portion R1, the upper midfoot portion R2, or the upper rearfoot portion R3.

[0045] The present disclosure can be applied not only to shoes, but also to clothing, bags, and the like. FIG. 17 is a front view showing an example of an arrangement when the formation region of the first region and the second region is used in clothing. FIG. 18 is a back view showing an example of an arrangement when the formation region of the first region and the second region is used in clothing. When the formation region 43 including the first region 41 and the second region 42 is arranged in a specific part of the clothing 9 as shown in FIGS. 17 and 18, the same effect as when the formation region 43 is arranged in the upper of a shoe can be obtained. Therefore, the stretchability of the clothing 9 can be partially changed by arranging the first region in a part of the clothing 9 where increased stretchability is desired and arranging the second region 42 in a part where lower stretchability is desired than the first region. Furthermore, since a woven structure is easier to reduce weight than a knitted structure, the second region 42 may be arranged in a part where weight reduction is desired.

[0046] Aspects of the present disclosure are described below.

[0047] (1) A textile structure having a knitted structure and a woven structure adjacent to each other, wherein the knitted structure is formed by a plurality of first linear bodies, and the woven structure is formed continuously with the knitted structure by the plurality of first linear bodies and a plurality of second linear bodies that intersect with the plurality of first linear bodies and are different from the plurality of first linear bodies.

[0048] (2) The textile structure described in (1) above, wherein the knitted structure is formed by warp knitting, the plurality of first linear bodies extend along the vertical direction, and the plurality of second linear bodies extend along the horizontal direction.

[0049] (3) The fiber structure described in (1) above, wherein the knitting structure is formed by weft knitting, the plurality of first linear bodies extend along the horizontal direction, and the plurality of second linear bodies extend along the vertical direction.

[0050] (4) The fiber structure according to (2) or (3) above, wherein the knitted structure includes a plurality of third linear members extending along the plurality of second linear members of the woven structure.

[0051] (5) The fiber structure according to (3), wherein the plurality of second linear elements of the weave include linear elements folded back along a direction intersecting the knitting direction.

[0052] (6) A fiber structure according to any one of (1) to (5) above, wherein the knitted structure and the woven structure are formed continuously by the same device.

[0053] (7) A fiber structure according to any one of (1) to (6) above, wherein at least one of the plurality of first linear bodies and the plurality of second linear bodies has carbon fibers arranged along the filaments of at least one of the plurality of first linear bodies and the plurality of second linear bodies.

[0054] (8) The fiber structure according to (7) above, wherein the carbon fiber is a core thread and the core thread is covered with a material different from the carbon fiber, and the carbon fiber is arranged as a covering thread.

[0055] (9) Shoes employing the fiber structure described in any one of (1) to (8) above.

[0056] (10) The shoe according to (9) above, wherein the forming region including the knitted structure and the woven structure is provided in at least one of the midfoot and rearfoot parts of the shoe.

[0057] (11) A shoe as described in (9) or (10) above, wherein the formation area extends in the width direction of the shoe and is tilted relative to the shoe center axis so that the medial side is more forward than the lateral side.

[0058] (12) Clothing employing the fiber structure described in any one of (1) to (8) above.

[0059] (13) A bag using the fiber structure described in any one of (1) to (8) above.

[0060] (14) A method for manufacturing a fiber structure, comprising the steps of: forming a knitted structure using a plurality of first linear bodies; extending the plurality of first linear bodies from the knitted structure in the knitting direction; and intersecting a plurality of second linear bodies with the plurality of first linear bodies to form a woven structure continuous with the knitted structure. [Explanation of symbols]

[0061] 1 shoes, 2 upper, 3 sole, 4 upper body, 4a throat portion, 4b shoe opening, 41 first region, 42 second region, 43 forming region, 5 linear body, 5a first linear body, 5b second linear body, 5c third linear body, 51 end portion.

Claims

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

2. The knitted structure is formed by warp knitting, the plurality of first linear bodies extend along a vertical direction, The fiber structure according to claim 1 , wherein the plurality of second linear members extend in a horizontal direction.

3. The knitting structure is formed by weft knitting, the plurality of first linear bodies extend in a horizontal direction, The fiber structure according to claim 1 , wherein the plurality of second linear members extend in a vertical direction.

4. The textile structure according to claim 1 , wherein the knitted structure includes a plurality of third linear members extending along the plurality of second linear members of the woven structure.

5. The fiber structure according to claim 3 , wherein the plurality of second linear elements of the weave include linear elements folded back in a direction intersecting the knitting direction.

6. The fiber structure according to claim 1 , wherein the knitted structure and the woven structure are formed continuously by the same device.

7. 2. The fiber structure according to claim 1, wherein at least one of the plurality of first linear bodies and the plurality of second linear bodies has carbon fibers arranged along the filaments of at least one of the plurality of first linear bodies and the plurality of second linear bodies.

8. The fiber structure according to claim 7 , wherein the carbon fibers are arranged as covering yarns in which the carbon fibers serve as core yarns and the core yarns are covered with a material different from the carbon fibers.

9. A shoe employing the fiber structure according to any one of claims 1 to 8.

10. The shoe according to claim 9, wherein the forming region including the knitted structure and the woven structure is provided in at least one of the midfoot and rearfoot portions of the shoe.

11. The shoe according to claim 10, wherein the formation region is provided extending in the width direction of the shoe and is provided at an angle with respect to the shoe center axis.

12. A garment comprising the fiber structure according to any one of claims 1 to 8.

13. A bag employing the fiber structure according to any one of claims 1 to 8.

14. forming a knitted structure using a plurality of first linear bodies; extending the plurality of first linear bodies in a knitting direction from the knitting structure; and crossing a plurality of second linear bodies over the plurality of first linear bodies to form a woven structure continuous with the knitted structure.

Images