EP4675026A2

EP4675026A2 - Fiber structure, shoe, garment, bag, and method for producing fiber structure

Info

Publication number: EP4675026A2
Application number: EP25182574.1A
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: US20250382730A1; JP2025187867A; CN121137892A; EP4675026A3

Abstract

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.

Description

REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and incorporates by reference the entire contents of Japanese Patent Application No. 2024-096963 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 for each part depending on the intended use and the like. An upper of a shoe may be required to have different stretchability depending on, for example, a 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 change the stretchability depending on the part of the product, as the number of parts increases, materials such as an adhesive and a sewing thread for combining the parts increase. An increase in the number of parts leads to an increase in environmental load.
An object of the present disclosure is to obtain 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.

SUMMARY

A fiber structure comprising 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.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating an appearance 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 developed view of the upper body according to the first embodiment;
FIG. 7 is a developed view illustrating a first modification of the upper body according to the first embodiment;
FIG. 8 is a view illustrating an arrangement example of carbon fibers in a knitted structure;
FIG. 9 is a view illustrating another arrangement example of carbon fibers in a knitted structure;
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 developed view of the upper body illustrating an arrangement example of a disposition region of a first region and a second region;
FIG. 16 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. 17 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. 18 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 an appearance 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 a shoe 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 Knitted Structure and Woven Structure

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 region 41 is a knitted structure formed by knitting the linear bodies 5. In the knitted structure, a plurality of loops are formed by a plurality of first linear bodies 5a, and adjacent loops are disposed so as to hook each other.
The second region 42 is a woven structure formed by weaving the linear bodies 5. In the woven structure, the linear bodies 5 intersect with each other. The second region 42 is formed by the plurality of first linear bodies 5a forming the knitted structure in the first region 41 extending along a knitting direction of the knitted structure and intersection of 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 continuously disposed. The knitted structure in the first region 41 and the woven structure in the second region 42 are continuously disposed by the same device.
The knitted structure has higher stretchability than the woven structure. Therefore, the stretchability of the upper body 4 can be partially changed by arranging the first region at a part where the stretchability of the upper body 4 is desired to be increased and arranging the second region 42 at a part where the stretchability of the upper body 4 is desired to be lower than that of the first region. In addition, since a weight of the woven structure is more easily reduced than the knitted structure, the second region 42 may be arranged at a part to be reduced in weight.
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 addition, in the warp knitting, the knitting direction is also referred to as a vertical direction, and the direction intersecting with the knitting direction is also referred to as a horizontal direction. In the weft knitting, the knitting direction is also referred to as a horizontal direction, and the direction intersecting with the knitting direction is also referred to as a vertical direction.
The plurality of first linear bodies 5a forming a loop in the first region 41 extend along the knitting direction X without forming a loop in the second region 42. In the second region 42, a plurality of second linear bodies 5b extending in a direction intersecting with the knitting direction are arranged and intersect with the plurality of first linear bodies 5a to form a woven structure.
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 example illustrated in FIG. 3, the knitted structure in the first region 41 is formed by weft knitting.
The plurality of first linear bodies 5a forming a loop in the first region 41 extend along the knitting direction X without forming a loop in the second region 42. In addition, in the second region 42, a plurality of second linear bodies 5b different from the first linear bodies 5a are disposed, and the first linear bodies 5a and the second linear bodies 5b intersect with each other to form a woven structure.
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, similarly to the first modification illustrated in FIG. 3, the knitted structure in the first region 41 is formed by weft knitting. In addition, in the second modification, unlike the first modification, third linear bodies 5c are not disposed in the first region 41.
Some of the first linear bodies 5a forming a loop in the first region 41 extend along the knitting direction X without forming a loop in the second region 42.
The plurality of second linear bodies 5b extend along the direction intersecting with the knitting direction X in the second region 42, and are folded back along the direction intersecting with the knitting direction X at an end 51 and the like of the second region 42. In addition, the plurality of folded second linear bodies 5b are disposed side by side along the knitting direction X. Thus, although the second linear bodies 5b are locally bent, the second linear bodies 5b can be regarded as extending in the direction intersecting with the knitting direction X, and the plurality of first linear bodies 5a extending along the knitting direction X and the second linear bodies 5b extending in the direction intersecting with the knitting direction can form a woven structure.
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. As illustrated in FIG. 5, the first region 41 may include a plurality of third linear bodies 5c extending along the second linear bodies 5b. Since the plurality of first linear bodies 5a form a loop in the first region 41, a woven structure is not disposed between the plurality of first linear bodies 5a and the plurality of third linear bodies 5c.
Note that the upper body 4 illustrated in FIGS. 2 to 5 can be produced by the following processes. That is, a knitted structure is formed by the plurality of first linear bodies 5a, the plurality of first linear bodies 5a extend in the knitting direction from the knitted structure, the plurality of second linear bodies 5b intersect with the plurality of first linear bodies 5a, and a woven structure is formed continuously with the knitted structure.

Arrangement Example of First Region (Knitted Structure) and Second Region (Woven Structure) in Upper Body

FIG. 6 is a developed view of the upper body according to the first embodiment. The upper body 4 includes an upper fore foot position R1 covering a fore foot position of a foot of a wearer, an upper middle foot position R2 covering a middle foot position of the foot of the wearer, and an upper rear foot position R3 covering a rear foot position of the foot of the wearer. The upper fore foot position R1, the upper middle foot position R2, and the upper rear foot position R3 are arranged in this order from the fore to the rear of the upper 2. In addition, a direction in which a shoe center axis C, which is a straight line passing through the center of the shoe 1 in a plan view of the shoe 1, extends is referred to as a foot length direction, and a direction orthogonal to the center axis in the plan view of the shoe 1 is referred to as a foot width direction.
The upper body 4 has a plurality of first regions 41 and a plurality of second regions 42. As illustrated in FIG. 6, the second region 42 may be disposed in the upper fore foot position R1, the upper middle foot position R2, and the upper rear foot position R3. Since the second region 42 formed of the woven structure has lower stretchability than the first region 41, the second region 42 may be arranged in a region of the upper body 4 that is not desired to be stretched. The first region 41 and the second region 42 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. Note that the first region 41 and the second region 42 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.
As such, the stretchability can be changed for each part of the upper body 4 by arranging the plurality of first regions 41 and the plurality of second regions 42 in the upper body 4. In addition, since a weight of the woven structure is more easily reduced than the knitted structure, the second region 42 may be arranged at a part to be reduced in weight.
In addition, since the linear bodies 5 used for forming the upper body 4 can be formed of a single material, recyclability is improved. In addition, since the linear bodies 5 used for the knitted structure are also used for the woven structure, it is not required to use an adhesive for joining the ends of the linear bodies, and the recyclability is further improved.
In the first region 41 formed of the knitted structure, a density of the linear bodies may be changed according to the part of the upper. In the second region 42 formed of the woven structure, the density of the linear bodies may be changed according to the part of the upper. The stretchability of the upper body 4 can be more flexibly changed by changing the density of the linear bodies for each part of the upper body 4.
A throat portion 4a may be disposed in the upper body 4. The throat portion 4a is an opening extending forward from a foot insertion opening 4b into which a foot is inserted when the shoe 1 is worn. In addition, the edges of the throat portion 4a and the foot insertion opening 4b may be formed by cutting. The edges of the throat portion 4a and the foot insertion opening 4b may be formed without cutting.
By using the linear bodies 5 having different colors, 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. In addition, the upper body 4 may include a plurality of layers.
FIG. 7 is a developed view illustrating a first modification of the upper body according to the first embodiment. In the example illustrated in FIG. 7, a region corresponding to the throat portion 4a illustrated in FIG. 6 is not an opening but a first region 41.

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. 8 is a view illustrating an arrangement example of carbon fibers in a knitted structure. FIG. 8 illustrates an example in which carbon fibers 5d are disposed in the first region 41 formed by weft knitting and arranged along the direction Y intersecting with the knitting direction X. FIG. 9 is a view illustrating another arrangement example of the carbon fibers in the knitted structure. FIG. 9 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. 10 to 16 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 the 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. 10, the disposition region 43 may be disposed in the upper middle foot position R2. As illustrated in FIG. 11, the disposition region 43 may be disposed in the fore of the upper middle foot position R2. As illustrated in FIG. 12, 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. 13, 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. 14, 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. 15, 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. 16, 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. 10 to 16, 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. 10 to 16 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. 17 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. 18 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. 17 and 18, 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. Therefore, the stretchability of the garment 9 can be partially changed by arranging the first region at a part where the stretchability of the garment 9 is desired to be increased and arranging the second region 42 at a part where the stretchability of the garment 9 is desired to be lower than that of the first region. In addition, since a weight of the woven structure is more easily reduced than the knitted structure, the second region 42 may be arranged at a part to be reduced in weight.
Hereinafter, various aspects of the present disclosure will be described.

(1) A fiber structure comprising 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.
(2) The fiber structure according to (1), wherein the knitted structure is formed by warp knitting,
- the plurality of first linear bodies extend along a vertical direction, and
- the plurality of second linear bodies extend along a horizontal direction.
(3) The fiber structure according to (1), wherein the knitted structure is formed by weft knitting,
- the plurality of first linear bodies extend along a horizontal direction, and
- the plurality of second linear bodies extend along a vertical direction.
(4) The fiber structure according to (2) or (3), wherein the knitted structure includes a plurality of third linear bodies extending along the plurality of second linear bodies of the woven structure.
(5) The fiber structure according to (3), wherein the plurality of second linear bodies of the woven structure include linear bodies folded back along a direction intersecting with a knitting direction.
(6) The fiber structure according to any one of (1) to (5), wherein the knitted structure and the woven structure are continuously formed by a same device.
(7) The fiber structure according to any one of (1) to (6), wherein in at least one of the plurality of first linear bodies and the plurality of second linear bodies, carbon fibers are arranged along linear bodies of at least one of the plurality of first linear bodies and the plurality of second linear bodies.
(8) The fiber structure according to (7), wherein the carbon fibers are arranged as 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.
(9) A shoe comprising the fiber structure according to any one of (1) to (8).
(10) The shoe according to (9), wherein a disposition region including the knitted structure and the woven structure is disposed in at least one of a middle foot position and a rear foot position of the shoe.
(11) The shoe according to (9) or (10), wherein the disposition region is disposed to extend in a width direction of the shoe and is disposed to be inclined with respect to a shoe center axis.
(12) A garment comprising the fiber structure according to any one of (1) to (8).
(13) A bag comprising the fiber structure according to any one of (1) to (8).
(14) A method for producing a fiber structure, the method comprising:
- forming a knitted structure by a plurality of first linear bodies;
- extending the plurality of first linear bodies from the knitted structure in a knitting direction; and
- forming a woven structure continuously with the knitted structure by allowing the plurality of second linear bodies to intersect with the plurality of first linear bodies.

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 different stretchability for each 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 comprising a knitted structure and a woven structure adjacent to each other,
wherein 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 and a plurality of second linear bodies (5b) that intersect with the plurality of first linear bodies and are different from the plurality of first linear bodies.
The fiber structure according to claim 1, wherein the knitted structure is formed by warp knitting,
the plurality of first linear bodies extend along a vertical direction, and

the plurality of second linear bodies extend along a horizontal direction.
The fiber structure according to claim 1, wherein the knitted structure is formed by weft knitting,
the plurality of first linear bodies extend along a horizontal direction, and

the plurality of second linear bodies extend along a vertical direction.
The fiber structure according to claim 1, wherein the knitted structure includes a plurality of third linear bodies (5c) extending along the plurality of second linear bodies of the woven structure.
The fiber structure according to claim 3, wherein the plurality of second linear bodies of the woven structure include linear bodies folded back along a direction intersecting with a knitting direction.
The fiber structure according to claim 1, wherein the knitted structure and the woven structure are continuously formed by a same device.
The fiber structure according to claim 1, wherein in at least one of the plurality of first linear bodies and the plurality of second linear bodies, carbon fibers are arranged along linear bodies of at least one of the plurality of first linear bodies and the plurality of second linear bodies.
The fiber structure according to claim 7, wherein the carbon fibers are arranged as 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 8.
The shoe according to claim 9, wherein a disposition region (43) including the knitted structure and the woven structure is disposed in at least one of a middle foot position and a rear foot position of the shoe.
The shoe according to claim 10, wherein the disposition region is disposed to extend in a width direction of the shoe and is disposed to be inclined with respect to a shoe center axis.
A garment comprising the fiber structure according to any one of claims 1 to 8.
A bag comprising the fiber structure according to any one of claims 1 to 8.
A method for producing a fiber structure, the method comprising:
forming a knitted structure by a plurality of first linear bodies;

extending the plurality of first linear bodies from the knitted structure in a knitting direction; and

forming a woven structure continuously with the knitted structure by allowing the plurality of second linear bodies to intersect with the plurality of first linear bodies.