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 rigidity and flexibility at a specific part of the product while suppressing an increase in the number of parts.SOLUTION: There is provided a fiber structure that is formed of linear bodies 5 and has a first region 41 and a second region 42 adjacent to each other, in which a density of the linear bodies 5 included in the second region 42 is smaller than a density of the linear bodies 5 included in the first region 41, the first regions 41 are arranged in a lattice pattern, the second region 42 is arranged between the first regions 41 arranged in the lattice pattern, and the linear bodies 5 included in the second region 42 connect the adjacent first regions 41.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] Various functions are required for products such as shoes, clothing, and bags depending on the intended use, etc. In the case of shoes, for example, the upper may be required to have rigidity and flexibility in specific areas.

[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] Increasing the number of parts required to provide rigidity and flexibility in specific areas of a product increases the amount of materials needed to join the parts, such as adhesives and sewing threads. Since an increase in the number of parts increases the number of processes and increases the environmental burden, it is desirable for products to be formed with a minimum number of parts.

[0006] The present disclosure aims to obtain a fiber structure for use in a product (for example, a shoe upper) that has rigidity and flexibility in a specific portion 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 formed of linear bodies and having first and second regions adjacent to each other, wherein the density of the linear bodies included in the second region is lower than the density of the linear bodies included in the first region, the first regions are arranged in a lattice pattern, the second regions are arranged in a lattice pattern and are positioned between a plurality of adjacent first regions, and the linear bodies included in the second region connect adjacent first regions. [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) that has rigidity and flexibility in a specific portion 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 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 diagram showing an example of the arrangement of carbon fibers in a knitted structure. [Figure 7] FIG. 7 is a diagram showing another example of the arrangement of carbon fibers in a knitted structure. [Figure 8] FIG. 8 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 9]FIG. 9 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 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 front view showing an example of the arrangement when the forming areas of the first and second areas are used in clothing. [Figure 16] FIG. 16 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. However, the present invention 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. Each figure, including Fig. 1, illustrates only the shoe 1 for the left foot. In this embodiment, only the shoe 1 for the left foot will be described, and a description of the shoe 1 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] <Schematic configuration of the first and second regions> 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 regions 41 are arranged in a lattice pattern. Two or more first regions 41 may be formed. The first region 41 is a knitted structure formed by knitting the linear bodies 5. In the knitted structure, the linear bodies 5 form multiple loops, and adjacent loops are formed so as to be hooked together. The density of the linear bodies 5 differs between the first region 41 and the second region. Specifically, the density of the linear bodies 5 included in the second region 42 is lower than the density of the linear bodies 5 included in the first region 41. The difference in density between the linear bodies 5 in the first region 41 and the second region 42 arises from the difference in the configuration of each region, which will be described later.

[0017] 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.

[0018] In the second region 42, the linear bodies 5 are provided so as to extend linearly. Note that the linear bodies 5 extending linearly includes not only cases in which the linear bodies 5 are completely straight, but also cases in which the linear bodies 5 are bent. The linear bodies 5 provided in the second region 42 connect adjacent first regions 41.

[0019] The second region 42 disposed between the first regions 41 adjacent in the knitting direction includes a plurality of first linear bodies 5a extending from the knitting structure of the first regions 41 along the knitting direction.

[0020] The second region 42, which is disposed between adjacent first regions 41 in a direction intersecting the knitting direction, includes a plurality of second linear bodies 5b different from the plurality of first linear bodies 5a. The plurality of second linear bodies 5b extend from the front surface, the back surface, or between the front and back surfaces of the knitting structure of the first region 41. When the plurality of second linear bodies 5b are disposed on the front surface of the knitting structure of the first region 41, the plurality of second linear bodies 5b can protect the knitting structure of the first region 41. When the plurality of second linear bodies 5b are disposed on the back surface of the knitting structure of the first region 41, the knitting structure of the first region 41 can protect the plurality of second linear bodies 5b. The length of the plurality of second linear bodies 5b is not limited as long as they connect the plurality of first regions 41. Note that the second linear bodies 5b are indicated by bold lines in Figure 2 and subsequent figures.

[0021] 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 first modified example, the knitting structure of the first region 41 is formed by weft knitting.

[0022] The second region 42, which is arranged between adjacent first regions 41 in a direction intersecting the knitting direction, includes a plurality of first linear bodies 5a extending from the knitting structure of the first region 41 in a direction intersecting the knitting direction.

[0023] The second region 42, which is disposed between adjacent first regions 41 in the knitting direction, includes a plurality of second linear bodies 5b different from the plurality of first linear bodies 5a. The second linear bodies 5b in the second region 42, which is disposed between adjacent first regions 41 in a direction intersecting the knitting direction, extend from the front surface, the back surface, or between the front and back surfaces of the knitting structure of the first region 41.

[0024] 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 of the first region 41 is formed by warp knitting.

[0025] The first region 41 includes a warp knitting structure formed by a plurality of first linear bodies 5a. The second region 42, which is disposed between adjacent first regions 41 in the knitting direction, includes a plurality of first linear bodies 5a extending along the knitting direction from the knitting structure of the first region 41.

[0026] The second region 42, which is disposed between adjacent first regions 41 in a direction intersecting the knitting direction, includes a plurality of second linear bodies 5b different from the plurality of first linear bodies 5a. The second linear bodies 5b in the second region 42, which is disposed between adjacent first regions 41 in a direction intersecting the knitting direction, extend from the front surface, the back surface, or between the front and back surfaces of the knitting structure of the first region 41.

[0027] 5 is an enlarged view of a portion of the upper body in embodiment 1, showing a third modified example of the first region and the second region. In the third modified example, the knitting structure of the first region 41 is formed by warp knitting.

[0028] The second region arranged between adjacent first regions 41 in a direction intersecting the knitting direction includes a plurality of first linear bodies 5a extending from the knitting structure of the first region 41 along a direction intersecting the knitting direction.

[0029] The second region 42, which is disposed between adjacent first regions 41 in the knitting direction, includes a plurality of second linear bodies 5b different from the plurality of first linear bodies 5a. The plurality of second linear bodies 5b in the second region 42, which is disposed between adjacent first regions 41 in the knitting direction, extend from the front surface, the back surface, or between the front and back surfaces of the knitting structure of the first region 41.

[0030] 2 to 5, the density of the linear bodies 5 is high in the first region 41 where the linear bodies 5 are knitted, and the density of the linear bodies 5 is low in the second region 42 where the linear bodies 5 are arranged in a straight line. The first region 41 is more rigid than the second region 42, and the second region 42 is more flexible than the first region 41.

[0031] Therefore, it is possible to form an upper body 4 that has rigidity and flexibility in a specific portion of the upper body 4. Furthermore, when the linear body 5 used to form the upper body 4 is formed from a single material, it is possible to improve recyclability.

[0032] The density of the linear bodies may vary depending on the location in the first region 41 formed by the knitting structure. Also, 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 be different colors. The upper body 4 may be formed to have multiple layers.

[0033] The first region 41 may be a woven fabric into which the linear bodies 5 are woven. Alternatively, the first region 41 may be formed by embroidering the linear bodies 5.

[0034] The upper body 4 illustrated in Figures 2 to 9 can be manufactured by the following process. Linear bodies 5 are knitted to form a plurality of first regions 41 having a knitted structure. The first regions 41 formed at this time are arranged in a lattice pattern. Second regions 42 are formed by connecting the arranged first regions 41 with linear bodies 5 extending linearly.

[0035] <About the use of carbon fiber> Carbon fibers may be arranged along the linear bodies 5 in at least one of the first region 41 and the second region 42. 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. 6 is a diagram showing an example of the arrangement of carbon fibers in a knitting structure. FIG. 6 shows an example in which carbon fibers 5d are arranged in second linear bodies 5b arranged in a knitting structure 41 formed by weft knitting and extending along a direction Y intersecting the knitting direction X. FIG. 7 is a diagram showing another example of the arrangement of carbon fibers in a knitting structure. FIG. 7 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.

[0036] <Examples of formation area placement> 8 to 14 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.

[0037] 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. 8, the forming region 43 may be provided in the upper midfoot portion R2. As shown in FIG. 9, the forming region 43 may be provided in the front of the upper midfoot portion R2. As shown in FIG. 10, 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.

[0038] 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 inclined relative to the shoe center axis C, the carbon fibers can be arranged flexibly in response to the wearer's movements. 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°. The carbon fibers may also be arranged in regions other than the formation region 43.

[0039] As shown in Fig. 11, 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. 12, 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.

[0040] As shown in Figure 13, 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 positioned at offset positions relative to each other in the foot length direction.

[0041] As shown in FIG. 14, the forming region 43 may be formed in the upper midfoot portion R2 and the upper rearfoot portion R3.

[0042] 8 to 14, 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.

[0043] 8 to 14 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.

[0044] The present disclosure can be applied not only to shoes but also to clothing, bags, and the like. FIG. 15 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. 16 is a rear 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 portion of the clothing 9 as shown in FIGS. 15 and 16, the same effect as when the formation region 43 is arranged in the upper of a shoe can be obtained. That is, the first region 41 of the clothing 9 is more rigid than the second region 42, and the second region 42 is more flexible than the first region 41. Therefore, a clothing having both rigidity and flexibility can be formed in a specific portion of the clothing 9.

[0045] Various aspects of the present invention are described below.

[0046] (1) A fiber structure formed of linear bodies and having first and second regions adjacent to each other, wherein the density of the linear bodies included in the second region is lower than the density of the linear bodies included in the first region, the first region is arranged in a lattice pattern, the second region is arranged between the first regions arranged in the lattice pattern, and the linear bodies included in the second region connect adjacent first regions.

[0047] (2) The fiber structure described in (1) above, wherein the first region includes a weft knitting structure formed by a plurality of first linear bodies, the second region arranged between adjacent first regions in the knitting direction includes the plurality of first linear bodies extending along the knitting direction from the first region, and the second region arranged between adjacent first regions in a direction intersecting the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.

[0048] (3) The fiber structure described in (1) above, wherein the first region includes a weft knitting structure formed by a plurality of first linear bodies, the second region arranged between adjacent first regions in a direction intersecting the knitting direction includes the plurality of first linear bodies extending from the first region along a direction intersecting the knitting direction, and the second region arranged between adjacent first regions in the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.

[0049] (4) The fiber structure described in (1) above, wherein the first region includes a warp knitting structure formed by a plurality of first linear bodies, the second region arranged between adjacent first regions in the knitting direction includes the plurality of first linear bodies extending along the knitting direction from the first region, and the second region arranged between adjacent first regions in a direction intersecting the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.

[0050] (5) The fiber structure described in (1) above, wherein the first region includes a warp knitting structure formed by a plurality of first linear bodies, the second region arranged between adjacent first regions in a direction intersecting the knitting direction includes the plurality of first linear bodies extending from the first region along a direction intersecting the knitting direction, and the second region arranged between adjacent first regions in the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.

[0051] (6) A fiber structure described in any one of (2) to (5) above, wherein the plurality of second linear bodies are arranged on the front surface, back surface, or between the front surface and back surface of the knitted structure of the first region.

[0052] (7) The fiber structure according to any one of (1) to (6) above, wherein the first region is formed by welding the linear members.

[0053] (8) The fiber structure according to any one of (1) to (7) above, wherein the first region is formed by embroidery using the linear body.

[0054] (9) A fiber structure according to any one of (1) to (8) above, wherein at least one of the first region and the second region has carbon fibers arranged along the linear body.

[0055] (10) The fiber structure described in (9) above, wherein the linear body formed using the carbon fiber is a covering yarn in which the carbon fiber is a core yarn and the core yarn is covered with a material different from the carbon fiber.

[0056] (11) Shoes employing the fiber structure described in any one of (1) to (10) above.

[0057] (12) The shoe according to (11) above, wherein the direction in which the first region and the second region are adjacent is at an angle of 0° or more and less than 45° with respect to the foot width direction.

[0058] (13) A shoe according to (11) or (12) above, wherein the forming area including the first area and the second area is provided in at least one of the midfoot and rearfoot areas of the foot.

[0059] (14) The shoe according to any one of (11) to (13) above, wherein the formation area is provided extending in the width direction of the foot and is provided at an angle with respect to the shoe center axis.

[0060] (15) Clothing employing the fiber structure described in any one of (1) to (14) above.

[0061] (16) A bag using the fiber structure described in any one of (1) to (14) above.

[0062] (17) A method for manufacturing a fiber structure, comprising: weaving linear bodies to form a plurality of first regions having a knitted structure; forming second regions connecting the first regions arranged by the linearly extending linear bodies; the first regions are arranged in a lattice pattern; and the density of the linear bodies included in the second regions is lower than the density of the linear bodies included in the first regions. [Explanation of symbols]

[0063] 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, 5a1, 5a2 first linear body, 5b second linear body, 5c third linear body.

Claims

1. A fiber structure formed of a linear body and having a first region and a second region adjacent to each other, the density of the linear bodies included in the second region is lower than the density of the linear bodies included in the first region; the first regions are arranged in a grid pattern, the second regions are disposed between the first regions arranged in the grid pattern, A fiber structure in which the linear bodies included in the second region connect adjacent first regions.

2. the first region includes a weft knitting structure formed by a plurality of first linear bodies, the second region disposed between the first regions adjacent in the knitting direction includes the plurality of first linear bodies extending along the knitting direction from the first region, The fiber structure according to claim 1 , wherein the second region arranged between the first regions adjacent in a direction intersecting the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.

3. the first region includes a weft knitting structure formed by a plurality of first linear bodies, the second region disposed between the first regions adjacent to each other in a direction intersecting the knitting direction includes the plurality of first linear bodies extending from the first region along the direction intersecting the knitting direction, The fiber structure according to claim 1 , wherein the second region disposed between the first regions adjacent in the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.

4. the first region includes a warp knitting structure formed by a plurality of first linear bodies, the second region disposed between the first regions adjacent in the knitting direction includes the plurality of first linear bodies extending along the knitting direction from the first region, The fiber structure according to claim 1 , wherein the second region arranged between the first regions adjacent in a direction intersecting the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.

5. the first region includes a warp knitting structure formed by a plurality of first linear bodies, the second region disposed between the first regions adjacent to each other in a direction intersecting the knitting direction includes the plurality of first linear bodies extending from the first region along the direction intersecting the knitting direction, The fiber structure according to claim 1 , wherein the second region disposed between the first regions adjacent in the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.

6. The fiber structure according to claim 2 , wherein the plurality of second linear bodies are arranged on the front surface, the back surface, or between the front surface and the back surface of the knitted structure of the first region.

7. The fiber structure according to claim 1 , wherein the first region is formed by welding the linear members.

8. The fiber structure according to claim 1 , wherein the first region is formed by embroidery using the linear body.

9. The fiber structure according to claim 1 , wherein at least one of the first region and the second region has carbon fibers arranged along the linear body.

10. The fiber structure according to claim 9, wherein the linear body formed using the carbon fiber is a covering yarn in which the carbon fiber is a core yarn and the core yarn is covered with a material different from the carbon fiber.

11. A shoe employing the fiber structure according to any one of claims 1 to 5.

12. The shoe according to claim 11, wherein the direction in which the first region and the second region are adjacent to each other is at an angle of 0° or more and less than 45° with respect to the foot width direction.

13. The shoe according to claim 11, wherein the forming region including the first region and the second region is provided in at least one of the midfoot and rearfoot regions of the foot.

14. The shoe according to claim 13, wherein the formation area is provided extending in the width direction of the foot and is provided at an angle with respect to a shoe center axis.

15. A garment comprising the fiber structure according to any one of claims 1 to 5.

16. A bag employing the fiber structure according to any one of claims 1 to 5.

17. knitting the linear body to form a plurality of first regions having a knitted structure; forming a second region connecting the first regions arranged by the linear bodies extending linearly; the first regions are arranged in a grid pattern, A method for producing a fiber structure, wherein the density of the linear bodies included in the second region is lower than the density of the linear bodies included in the first region.

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