EP4675025A2

EP4675025A2 - Fiber structure, shoe and method for producing fiber structure

Info

Publication number: EP4675025A2
Application number: EP25182575.8A
Authority: EP
Inventors: Chihaya SUZUKI
Original assignee: Asics Corp
Current assignee: Asics Corp
Priority date: 2024-06-14
Filing date: 2025-06-13
Publication date: 2026-01-07
Also published as: US20250382731A1; EP4675025A3; CN121137893A; JP2025187868A

Abstract

Provided is a fiber structure formed of linear bodies 5 and having 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.

Description

REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and incorporates by reference the entire contents of Japanese Patent Application No. 2024-096964 filed in Japan on June 14, 2024 .

BACKGROUND

Technical field

The present disclosure relates to a fiber structure and a method for producing a fiber structure.

Background Information

In products such as shoes, garments, and bags, various functions are required depending on the intended use and the like. In the shoe, for example, an upper may be required to have rigidity and flexibility at a specific part.
In the shoe disclosed in WO 2022/157894 A , the first member extending in one direction is disposed on the upper. The first member has stretchability only in the one direction and is arranged in a non-bonded state. This configuration partially changes the stretchability of the upper.
In order to impart rigidity and flexibility to a specific part of a product, as the number of parts increases, materials such as an adhesive and a sewing thread for combining the parts increase. Since an increase in the number of parts leads to an increase in the number of processes and an increase in environmental load, it is desirable that a product is formed with a small number of parts.
An object of the present disclosure is to obtain a fiber structure used for a product (for example, an upper of a shoe) having rigidity and flexibility at a specific part of the product while suppressing an increase in the number of parts.

SUMMARY

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

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a shoe according to a first embodiment;
FIG. 2 is an enlarged view of a part of an upper body in the first embodiment;
FIG. 3 is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a first modification of a first region and a second region;
FIG. 4 is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a second modification of the first region and the second region;
FIG. 5 is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a third modification of the first region and the second region;
FIG. 6 is a view illustrating an arrangement example of carbon fibers in a knitted structure;
FIG. 7 is a view illustrating another arrangement example of carbon fibers in a knitted structure;
FIG. 8 is a developed view of the upper body illustrating an arrangement example of a disposition region of a first region and a second region;
FIG. 9 is a developed view of the upper body illustrating an arrangement example of a disposition region of a first region and a second region;
FIG. 10 is a developed view of the upper body illustrating an arrangement example of a disposition region of a first region and a second region;
FIG. 11 is a developed view of the upper body illustrating an arrangement example of a disposition region of a first region and a second region;
FIG. 12 is a developed view of the upper body illustrating an arrangement example of a disposition region of a first region and a second region;
FIG. 13 is a developed view of the upper body illustrating an arrangement example of a disposition region of a first region and a second region;
FIG. 14 is a developed view of the upper body illustrating an arrangement example of a disposition region of a first region and a second region;
FIG. 15 is a front view illustrating an arrangement example in a case where a disposition region of a first region and a second region is used for a garment; and
FIG. 16 is a rear view illustrating an arrangement example in a case where a disposition region of a first region and a second region is used for a garment.

DETAILED DESCRIPTION

Hereinafter, embodiments of a fiber structure and a method for producing a fiber structure according to the present disclosure will be described in detail with reference to the drawings. Note that the present disclosure is not limited by these embodiments. In the following description, the same portions are denoted by the same reference numerals, and redundant description will be omitted.

Schematic Configuration of Shoe

FIG. 1 is a perspective view of a shoe according to a first embodiment of the present disclosure. In each drawing including FIG. 1, only a shoe 1 for a left foot is illustrated. In the present embodiment, only the shoe 1 for a left foot will be described, and the description of the shoe 1 for a right foot will be omitted.
In addition, in the anatomical position of the foot, a median side is referred to as a medial foot side, and a side opposite to the median side is referred to as a lateral foot side. That is, the side closer to the median line in the anatomical position is referred to as the medial foot side, and the side farther from the median line in the anatomical position is referred to as the lateral foot side. In addition, a vertical direction means a direction orthogonal to both a foot length direction and a foot width direction unless otherwise specified.
The shoe 1 includes an upper 2 and a sole 3. The upper 2 includes an upper body 4 that covers an upper surface of the sole 3 by disposing an internal space in which a foot of a wearer enters between the upper body 4 and the sole 3. The upper body 4 is fixed to the sole 3 by methods such as stitching, welding, and bonding. A foot insertion opening 21 is disposed in the upper body 4. The foot insertion opening 21 is an opening for inserting a foot of a wearer into the internal space of the upper body 4.

Schematic Configuration of First Region and Second Region

FIG. 2 is an enlarged view of a part of the upper body in the first embodiment. The upper body 4 is a cloth formed using a linear body 5. The linear body 5 is formed of, for example, polyester. The linear body 5 may be formed of a single polyester. The linear body 5 may be formed of polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), or polybutylene terephthalate (PBT). The linear body 5 may be a polyurethane-based thermoplastic elastomer, polyurethane, nylon, spandex, Kevlar (registered trademark), ultra-high-molecular-weight polyethylene, a single covered yarn (SCY) or double covered yarn (DCY) obtained by covering polyurethane, or the like. In addition, the linear body 5 may be a yarn obtained by bundling a plurality of fibers, a yarn obtained by making a resin linear, a twisted yarn, or the like.
The upper body 4 has a first region 41 and a second region 42 adjacent to each other.
The first regions 41 are arranged in a lattice pattern. Two or more first regions 41 may be disposed. 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 linear bodies 5, and adjacent loops are disposed so as to hook each other. A density of the linear bodies 5 differs between the first region 41 and the second region 42. Specifically, the density of the linear bodies 5 included in the second region 42 is smaller than the density of the linear bodies 5 included in the first region 41. The difference between the density of the linear bodies 5 in the first region 41 and the density of the linear bodies 5 in the second region 42 is caused by a difference in the configuration of each region described below.
The types of knitted structure constituting the first region 41 include warp knitting knitted by a warp knitting machine and weft knitting knitted by a flat knitting machine. FIG. 2 illustrates an example in which the first region 41 is warp knitting knitted by a warp knitting machine. Note that a knitting direction of the knitted structure is indicated by an arrow X. In addition, a direction intersecting with the knitting direction is indicated by an arrow Y.
In the second region 42, the linear bodies 5 are disposed to extend linearly. Note that the linear bodies 5 extending linearly include not only a case where the linear bodies 5 are completely linear but also a state where the linear bodies 5 are bent. The linear bodies 5 disposed in the second region 42 connect the adjacent first regions 41.
The second region 42 arranged between the first regions 41 adjacent in a knitting direction includes a plurality of first linear bodies 5a extending along the knitting direction from the knitted structure of the first region 41.
The second region 42 arranged between the first regions 41 adjacent in a direction intersecting with 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 a front surface or a rear surface of the knitted structure in the first region 41, or between the front surface and the rear surface. When the plurality of second linear bodies 5b are arranged on the surface of the knitted structure in the first region 41, the plurality of second linear bodies 5b may protect the knitted structure in the first region 41. When the plurality of second linear bodies 5b are arranged on the rear surface of the knitted structure of the first region 41, the knitted structure of the first region 41 can protect the plurality of second linear bodies 5b. The plurality of second linear bodies 5b may connect the plurality of first regions 41, and a length is not limited. Note that the second linear body 5b is indicated by a thick line in FIG. 2 and subsequent drawings.
FIG. 3 is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a first modification of the first region and the second region. In the first modification, the knitted structure of the first region 41 is formed by weft knitting.
The second region 42 arranged between the first regions 41 adjacent in a direction intersecting with the knitting direction includes a plurality of first linear bodies 5a extending in the direction intersecting with the knitting direction from the knitted structure of the first region 41.
The second region 42 arranged between the first regions 41 adjacent 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 arranged between the first regions 41 adjacent in the knitting direction extend from the front surface or the rear surface of the knitted structure in the first region 41, or between the front surface and the rear surface.
FIG. 4 is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a second modification of the first region and the second region. In the second modification, the knitted structure of the first region 41 is formed by warp knitting.
The first region 41 includes a warp knitted structure formed by the plurality of first linear bodies 5a. The second region 42 arranged between the first regions 41 adjacent in a knitting direction includes a plurality of first linear bodies 5a extending along the knitting direction from the knitted structure of the first region 41.
The second region 42 arranged between the first regions 41 adjacent in a direction intersecting with 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 arranged between the first regions 41 adjacent in the direction intersecting with the knitting direction extend from the front surface or the rear surface of the knitted structure in the first region 41, or between the front surface and the rear surface.
FIG. 5 is an enlarged view of a part of the upper body in the first embodiment and is a view illustrating a third modification of the first region and the second region. In the third modification, the knitted structure of the first region 41 is formed by warp knitting.
The second region 42 arranged between the first regions 41 adjacent in a direction intersecting with the knitting direction includes a plurality of first linear bodies 5a extending along the direction intersecting with the knitting direction from the knitted structure of the first region 41.
The second region 42 arranged between the first regions 41 adjacent 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 arranged between the first regions 41 adjacent in the knitting direction extend from the front surface or the rear surface of the knitted structure in the first region 41, or between the front surface and the rear surface.
According to the upper body 4 illustrated in FIGS. 2 to 5, the density of the linear bodies 5 increases in the first region 41 in which the linear bodies 5 are woven, and the density of the linear bodies 5 decreases in the second region 42 in which the linear bodies 5 are linearly disposed. The first region 41 has higher rigidity than the second region 42, and the second region 42 has higher flexibility than the first region 41.
Therefore, the upper body 4 having rigidity and flexibility can be formed at a specific part of the upper body 4. In addition, when the linear body 5 used for forming the upper body 4 is formed of a single material, recyclability is improved.
Note that, in the first region 41 formed of the knitted structure, the density of the linear bodies may vary depending on a part. In addition, as the linear bodies 5 having different colors are used, the upper body 4 may have regions having different colors. For example, the colors of the linear bodies 5a and the linear bodies 5b may be different from each other. The upper body 4 may include a plurality of layers.
The first region 41 may be a woven fabric in which the linear bodies 5 are woven. In addition, in the first region 41, the linear bodies 5 may be formed by embroidering.
Note that the upper body 4 illustrated in FIGS. 2 to 9 can be produced by the following processes. The linear bodies 5 are woven to form a plurality of first regions 41 including a knitted structure. The first regions 41 formed in this case are aligned in a lattice pattern. The second region 42 is formed by connecting the plurality of aligned first regions 41 to the linear bodies 5 extending linearly.

Use of Carbon Fibers

In at least one of the first region 41 and the second region 42, carbon fibers may be arranged along the linear bodies 5. The carbon fibers may be disposed linearly. The carbon fibers may be formed of a carbon fiber alone, or may be a covered yarn in which the carbon fiber is used as a core yarn and the core yarn is covered with a material that enhances the strength of the carbon fiber. Since carbon fibers have lower extensibility and higher strength than fibers such as polyester fibers, the upper body 4 is less likely to extend in a direction in which the carbon fibers are arranged in a region in which the carbon fibers are arranged, and the strength is increased. FIG. 6 is a view illustrating an arrangement example of carbon fibers in a knitted structure. FIG. 6 illustrates an example in which carbon fibers 5d are arranged in the first linear bodies 5a disposed in the first region 41 formed by weft knitting and extending along the direction Y intersecting with the knitting direction X. FIG. 7 is a view illustrating another arrangement example of carbon fibers in a knitted structure. FIG. 7 illustrates an example in which the carbon fibers 5d are disposed in the first region 41 formed by weft knitting and arranged along the knitting direction X.

Arrangement Example of Disposition Region

FIGS. 8 to 14 are developed views of the upper body illustrating an arrangement example of a disposition region. Note that, in the following description, a region where the first region 41 and the second region 42 are disposed is referred to as a disposition region 43.
The disposition region 43 is disposed in at least a part of the upper body 4. The disposition region 43 may extend in the foot width direction, or may be inclined with respect to a shoe center axis C. An angle α of inclination in a direction in which the disposition region 43 extends with respect to the shoe center axis C is preferably in a range of 45° or more and less than 90°. By arranging the direction in which the disposition region 43 extends to be inclined with respect to the shoe center axis C, the disposition region 43 can be flexibly arranged corresponding to the movement of the wearer. As illustrated in FIG. 8, the disposition region 43 may be disposed in the upper middle foot position R2. As illustrated in FIG. 9, the disposition region 43 may be disposed in the fore of the upper middle foot position R2. As illustrated in FIG. 10, the disposition region 43 may be disposed to be inclined with respect to the shoe center axis C so that the medial foot side is located further forward than the lateral foot side.
In the disposition region 43, the carbon fibers may be arranged along the foot width direction, or may be disposed to be inclined with respect to the shoe center axis C. An angle α of inclination in a direction in which the carbon fibers extend with respect to the shoe center axis C is preferably in a range of 45° or more and less than 90°. By arranging the direction in which the carbon fibers extend to be inclined with respect to the shoe center axis C, the carbon fibers can be flexibly arranged corresponding to the movement of the wearer. Note that the carbon fibers may be arranged in a region other than the disposition region 43.
As illustrated in FIG. 11, a plurality of disposition regions 43 may be disposed side by side in the foot length direction in the upper middle foot position R2. As illustrated in FIG. 12, the plurality of disposition regions 43 may be disposed to be inclined with respect to the shoe center axis C so that the medial foot side is located further forward than the lateral foot side.
As illustrated in FIG. 13, as for the plurality of disposition regions 43, the plurality of disposition regions 43 may be disposed to be inclined with respect to the shoe center axis C so that the medial foot side is located further forward than the lateral foot side, and may be arranged at positions shifted from each other in the foot length direction.
As illustrated in FIG. 14, the disposition region 43 may be disposed in the upper middle foot position R2 and the upper rear foot position R3.
By disposing the disposition region 43 as illustrated in FIGS. 8 to 14, it is possible to exhibit different functions for each part of the upper body 4. In addition, when the carbon fibers are disposed in the upper body 4, the upper body 4 is hardly stretched in a direction in which the carbon fibers extend, and thus, the upper body 4 having high strength can be obtained.
Note that the disposition region illustrated in FIGS. 8 to 14 may be arranged in one or more regions of the upper fore foot position R1, the upper middle foot position R2, or the upper rear foot position R3. The disposition region 43 can be arranged in all or a part of at least one region of the upper fore foot position R1, the upper middle foot position R2, or the upper rear foot position R3.
Note that the present disclosure can be applied not only to shoes but also to garments, bags, and the like. FIG. 15 is a front view illustrating an arrangement example in a case where a disposition region of a first region and a second region is used for a garment. FIG. 16 is a rear view illustrating an arrangement example in a case where a disposition region of a first region and a second region is used for a garment. As illustrated in FIGS. 15 and 16, when a disposition region 43 including a first region 41 and a second region 42 is arranged in a specific region of a garment 9, the same effect as when the disposition region 43 is arranged in the upper of the shoe can be obtained. That is, the first region 41 of the garment 9 has higher rigidity than the second region 42, and the second region 42 has higher flexibility than the first region 41. Therefore, the garment having rigidity and flexibility can be formed at a specific part of the garment 9.
Hereinafter, various aspects of the present disclosure will be described.

(1) A fiber structure formed of linear bodies and having a first region and a second region adjacent to each other,
- wherein a density of the linear bodies included in the second region is smaller than a density of the linear bodies included in the first region,
- the first region are arranged in a lattice pattern,
- the second region is arranged between the first regions arranged in the lattice pattern, and
- the linear bodies included in the second region connect the adjacent first regions.
(2) The fiber structure according to (1), wherein the first region includes a weft knitted structure formed by a plurality of first linear bodies,
- the second region arranged between the first regions adjacent in a knitting direction includes the plurality of first linear bodies extending along the knitting direction from the first region, and
- the second region arranged between the first regions adjacent in a direction intersecting with the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.
(3) The fiber structure according to (1), wherein the first region includes a weft knitted structure formed by a plurality of first linear bodies,
- the second region arranged between the first regions adjacent in a direction intersecting with a knitting direction includes the plurality of first linear bodies extending along the direction intersecting with the knitting direction from the first region, and
- the second region arranged 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 fiber structure according to (1), wherein the first region includes a warp knitted structure formed by a plurality of first linear bodies,
- the second region arranged between the first regions adjacent in a knitting direction includes the plurality of first linear bodies extending along the knitting direction from the first region, and
- the second region arranged between the first regions adjacent in a direction intersecting with the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.
(5) The fiber structure according to (1), wherein the first region includes a warp knitted structure formed by a plurality of first linear bodies,
- the second region arranged between the first regions adjacent in a direction intersecting with a knitting direction includes the plurality of first linear bodies extending along the direction intersecting with the knitting direction from the first region, and
- the second region arranged 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 any one of (2) to (5), wherein the plurality of second linear bodies are arranged on a front surface or a rear surface of the knitted structure in the first region, or between the front surface and the rear surface.
(7) The fiber structure according to any one of (1) to (6), wherein the first region is formed by welding the linear bodies.
(8) The fiber structure according to any one of (1) to (7), wherein the first region is formed by embroidering using the linear bodies.
(9) The fiber structure according to any one of (1) to (8), wherein carbon fibers are arranged along the linear bodies in at least one of the first region and the second region.
(10) The fiber structure according to (9), wherein the linear body formed using the carbon fibers is a covered yarn in which the carbon fiber is used as a core yarn and the core yarn is covered with a material different from the carbon fiber.
(11) A shoe comprising the fiber structure according to any one of (1) to (10).
(12) The shoe according to (11), wherein a direction in which the first region and the second region are adjacent to each other is 0° or more and less than 45° with respect to a foot width direction.
(13) The shoe according to (11) or (12), wherein a disposition region including the first region and the second region is disposed in at least one of a middle foot position and a rear foot position of a foot.
(14) The shoe according to any one of (11) to (13), wherein the disposition region is disposed to extend in a width direction of the foot and is disposed to be inclined with respect to a shoe center axis.
(15) A garment comprising the fiber structure according to any one of (1) to (10).
(16) A bag comprising the fiber structure according to any one of (1) to (10).
(17) A method for producing a fiber structure, the method comprising:
- forming a plurality of first regions including a knitted structure by weaving linear bodies; and
- forming a second region connecting the first regions aligned by the linear bodies that are extend linearly,
- wherein the first regions are arranged in a lattice pattern, and
- a density of the linear bodies included in the second region is smaller than a density of the linear bodies included in the first region.

According to the present disclosure, it is possible to provide a fiber structure used for a product (for example, an upper of a shoe) having rigidity and flexibility at a specific part of the product while suppressing an increase in the number of parts.
Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.

Claims

A fiber structure formed of linear bodies (5) and having a first region (41) and a second region (42) adjacent to each other,
wherein a density of the linear bodies included in the second region is smaller than a density of the linear bodies included in the first region,

the first region are arranged in a lattice pattern, the second region is arranged between the first regions arranged in the lattice pattern, and

the linear bodies included in the second region connect the adjacent first regions.
The fiber structure according to claim 1, wherein the first region includes a weft knitted structure formed by a plurality of first linear bodies (5a),
the second region arranged between the first regions adjacent in a knitting direction includes the plurality of first linear bodies extending along the knitting direction from the first region, and

the second region arranged between the first regions adjacent in a direction intersecting with the knitting direction includes a plurality of second linear bodies (5b) different from the plurality of first linear bodies.
The fiber structure according to claim 1, wherein the first region includes a weft knitted structure formed by a plurality of first linear bodies,
the second region arranged between the first regions adjacent in a direction intersecting with a knitting direction includes the plurality of first linear bodies extending along the direction intersecting with the knitting direction from the first region, and

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

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

the second region arranged between the first regions adjacent in the knitting direction includes a plurality of second linear bodies different from the plurality of first linear bodies.
The fiber structure according to any one of claims 2 to 5, wherein the plurality of second linear bodies are arranged on a front surface or a rear surface of the knitted structure in the first region, or between the front surface and the rear surface.
The fiber structure according to claim 1, wherein the first region is formed by welding the linear bodies.
The fiber structure according to claim 1, wherein the first region is formed by embroidering using the linear bodies.
The fiber structure according to claim 1, wherein carbon fibers are arranged along the linear bodies in at least one of the first region and the second region.
The fiber structure according to claim 9, wherein the linear body formed using the carbon fibers is a covered yarn in which the carbon fiber is used as a core yarn and the core yarn is covered with a material different from the carbon fiber.
A shoe (1) comprising the fiber structure according to any one of claims 1 to 5.
The shoe according to claim 11, wherein a direction in which the first region and the second region are adjacent to each other is 0° or more and less than 45° with respect to a foot width direction.
The shoe according to claim 11, wherein a disposition region including the first region and the second region is disposed in at least one of a middle foot position and a rear foot position of a foot.
The shoe according to claim 13, wherein the disposition region is disposed to extend in a width direction of the foot and is disposed to be inclined with respect to a shoe center axis.
A method for producing a fiber structure, the method comprising:
forming a plurality of first regions including a knitted structure by weaving linear bodies; and

forming a second region connecting the first regions aligned by the linear bodies that are extend linearly,

wherein the first regions are arranged in a lattice pattern, and

a density of the linear bodies included in the second region is smaller than a density of the linear bodies included in the first region.