`Orei et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 7,051.460 B2
`May 30, 2006
`
`USOO7051460B2
`
`(54) LIGHT WEIGHT SHOES
`
`(75) Inventors: Takeshi Orei, Osaka (JP): Takeshi
`Matsuzaki, Osaka (JP); Tetsuo
`s
`s
`Yamamoto, Osaka (JP)
`Aft
`.
`.
`.
`(73) Assignee: Mizuno Corporation, Osaka (JP)
`(*) Notice:
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 114 days.
`(21) Appl. No.: 10/749.454
`
`(22) Filed:
`
`Dec. 31, 2003
`
`(65)
`
`- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2003-004903
`
`- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2003-394.141
`
`Prior Publication Data
`US 2005/0081402 A1
`Apr. 21, 2005
`Foreign Application Priority Data
`(30)
`Jan. 10, 2003
`(JP)
`Nov. 25, 2003 (JP)
`(51) Int. Cl.
`(2006.01)
`A43B I/02
`(2006.01)
`A43B 7/06
`(2006.01)
`A43B 23/00
`(2006.01)
`A43B 23/26
`(52) U.S. Cl. ..................... 36/84; 36/3 A: 36/45; 36/54;
`36/9 R
`(58) Field of Classification Search .................... 36/84,
`36/88,97, 3 A, 45, 48, 9 R, 54
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`1956,969 A * 5/1934 Ayers ............................ 36/45
`
`
`
`4,785,559 A * 11/1988 Hentschel .................... 37,189
`5,345,638 A
`9, 1994 Nishida ......................... 36/45
`5,385,036 A *
`1/1995 Spillane et al. ...
`... 602,63
`5,566,396 A * 10/1996 Leib ....
`... 2,239
`6,401,364 B1* 6/2002 Burt ....
`... 36/3 A
`6,482.492 B1 * 1 1/2002 Hung ........
`... 36/3 A
`6,630,414 B1 * 10/2003 Matsumoto .................... 442/1
`6,931,762 B1
`8/2005 Dua ............................ 36/9 R
`
`FOREIGN PATENT DOCUMENTS
`
`JP
`7, 1993
`5-176804
`JP
`O5176804 A * 7, 1993
`JP
`254.8713
`9, 1997
`* cited by examiner
`Primary Examiner—Anthony Stashick
`(74) Attorney, Agent, or Firm—Hamre, Schumann, Mueller
`& Larson, P.C.
`
`(57)
`
`ABSTRACT
`
`A shoe including an upper material using a double raschel
`warp knitted fabric is provided. The upper material includes
`a first Surface having a non-mesh structure and a second
`Surface having a non-mesh structure part (A) and mesh
`structure parts (B, C). The burst strengths burst strengths A,
`B and C of the parts (A, B and C) satisfy the relationship:
`A>B>C. The non-mesh structure part (A) is disposed in a
`part Surrounding the tiptoe, a part connecting to a shoe sole
`and disposed in both sides of the foot for example, in a
`stripe. The mesh structure part (B) is disposed in the vicinity
`of the surface of the toe and the mesh structure part (C) is
`disposed in the both sides of the foot for example, in a stripe.
`Thus, a shoe having lightweight, air permeability and dura
`bility and a double raschel knitted fabric used for the shoe
`are provided.
`
`7 Claims, 5 Drawing Sheets
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`May 30, 2006
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`Sheet 1 of 5
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`Sheet S of 5
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`F.G. 5
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`1.
`LIGHT WEIGHT SHOES
`
`FIELD OF THE INVENTION
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`US 7,051.460 B2
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`2
`disposed partially in the both sides of the foot; and at least
`the parts A to C are disposed in one continuous knitted
`fabric.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`10
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`15
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`FIG. 1 is a plan view showing a shoe pattern using a
`double raschel warp knitted fabric according to Embodiment
`1 of the present invention.
`FIG. 2 is a side view showing a sport shoe according to
`Embodiment 2 of the present invention.
`FIG. 3 is a perspective view showing the shoe shown in
`FIG. 2 when a tongue part is taken out of the shoe.
`FIG. 4 is a side view showing the shoe of FIG. 2 seen from
`the opposite side.
`FIG. 5 is a plan view showing a shoe pattern using a
`double raschel warp knitted fabric according to Embodiment
`3 of the present invention.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`The present invention relates to shoes. More particularly,
`the present invention relates to shoes incorporating a double
`raschel warp knitted fabric.
`
`BACKGROUND OF THE INVENTION
`
`Conventionally, a warp knitted fabric, a woven fabric, a
`mesh material, and the like, have been used for shoes (see,
`for example, application for utility model registration No.
`254.8713, JP5(1993)-176804A). In particular, in sport shoes,
`properties such as lightweight and air permeability are
`required. A warp knitted fabric having a mesh structure is
`preferred with respect to the above-mentioned properties,
`but, on the other hand, it does not have a satisfactory
`strength and needs reinforcement as a whole. At the present,
`in most cases, such reinforcement is carried out by using
`artificial leather, leather, a resin sheet, resin, a woven fabric,
`and the like, from the side of the front surface. Therefore, in
`general, the usual weight of one sport shoe is about 150 g to
`500 g.
`However, the weight of the conventional sport shoe is
`heavy for use in marathon, running, and indoor sports Such
`as badminton, ping-pong, etc. Therefore, there is a demand
`for shoes having lighter weight.
`
`SUMMARY OF THE INVENTION
`
`With the foregoing in mind, in order to solve the above
`mentioned conventional problem, it is an object of the
`present invention to provide a shoe having lightweight and
`air permeability and also having high durability, and a
`double raschel warp knitted fabric used for the shoe.
`In order to achieve the above-mentioned object, a shoe of
`the present invention includes an upper material using a
`double raschel warp knitted fabric. The upper material
`includes a first Surface having a non-mesh structure and a
`second Surface having a non-mesh structure part (A) and
`mesh structure parts (B, C); the burst strengths A, B and C
`of the parts (A, B and C) satisfy the relationship: Al-B>C:
`the non-mesh structure part (A) is disposed in a part Sur
`rounding the tiptoe and partially in both sides of the foot; the
`mesh structure part (B) is disposed in the vicinity of the
`surface of the toe; and the mesh structure part (C) is disposed
`partially in the both sides of the foot.
`Another shoe of the present invention including an upper
`material using a double raschel warp knitted fabric. The
`upper material includes a front Surface including a mesh
`structure part and a back Surface having a non-mesh struc
`ture; and a constituent yarn of the front Surface includes a
`yarn having a melting point that is lower than the melting
`point of a constituent yarn of the back Surface, and at least
`a part of the front surface is partially fused.
`Another aspect of the present invention relates to a double
`raschel warp knitted fabric adapted for use with a shoe. The
`warp knitted fabric includes one surface having a non-mesh
`structure and another Surface having a non-mesh structure
`part (A) and mesh structure parts (B, C); the burst strengths
`A, B and C of the parts (A, B and C) satisfy the relationship:
`A>B>C; the non-mesh structure part (A) is disposed in a part
`surrounding the tiptoe and partially in both sides of the foot;
`the mesh structure part (B) is disposed in the vicinity of the
`front surface of the toe; the mesh structure part (C) is
`
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`The present invention relates to a shoe including an upper
`material using a double raschel warp knitted fabric. The
`double raschel warp knitted fabric is a three-layer warp
`knitted fabric including a base fabric for a front surface, a
`base fabric for a back Surface and a connecting yarn con
`necting the front surface to the back surface. This warp
`knitted fabric is knitted by using a warp knitting machine
`with a double needle line so that the base fabric for a first
`Surface is knitted as a derivative weave that is jacquard
`controlled so as to include a non-mesh structure part (A) and
`mesh structure parts (B, C) and the base fabric for a second
`Surface is knitted as a homogeneous non-mesh structure. The
`second surface may be formed of one weave and may be
`formed with different weave mixed. A warp knitting
`machine for knitting this knitted fabric is commercially
`available from KARL MAYER Textilmaschinenfabrik
`GmbH in Germany (NIPPON MAYER LTD. (a Japan
`corporation) is included).
`When the surface including the non-mesh structure part
`(A) and mesh structure parts (B, C) of the knitted fabric is
`used for the front surface of a shoe, the shoe has an excellent
`appearance and furthermore, a surface area is increased, thus
`improving air permeability. On the contrary, when the sec
`ond surface having a non-mesh structure is used for the front
`surface of the shoe, water can easily be prevented from
`entering the shoe from the Surface.
`The burst strengths A, B and C of the parts (A, B and C)
`of the double raschel warp knitted fabric satisfy the rela
`tionship: Al-BC. The non-mesh structure part (A) is dis
`posed in a part that requires a high strength, that is, a part
`Surrounding the tiptoe (i.e., a tiptoe region of the shoe) and
`a part connecting to a shoe Sole, and also to parts that face
`the sides of the foot (i.e., side regions of the shoe), the
`non-mesh structure part (A) is disposed in a stripe. Further
`more, to a part that may have moderate strength and air
`permeability, that is, a part in the vicinity of the surface of
`the toe (i.e., a toe region of the shoe), the mesh structure part
`(B) is placed. Furthermore, to a part that needs air perme
`ability, that is, the side surfaces of the foot (both sides), the
`mesh structure part (C) is placed, for example, in a stripe.
`Thus, as a whole, in the shoe, air permeability and durability
`are balanced.
`The burst strength according to the bursting test based on
`the JIS L 1096 A of the non-mesh structure part (A) is
`preferably about 1400 kPa to 1550 kPa with respect to shoes
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`Skechers EX1020-p.7
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`Such as marathon shoes, in which lightweight is particularly
`required. With respect to general shoes for running or
`jogging, the burst strength is preferably about 1600 kPa.
`Furthermore, with respect to shoes for a heavy use, for
`example, shoes for indoor sports such as badminton, ping
`pong, etc., the burst strength is preferably about 2400 kPa.
`It is preferable that the burst strength of the mesh structure
`part (C) is in the range from 900 kPa to 1000 kPa. The mesh
`structure part (B) may have any burst strength between the
`burst strength of (A) and that of (C).
`It is preferable that a tiptoe region, a heel region and an
`eyelet part of the sport shoe are reinforced. Among the
`above-mentioned parts, the heel part may not be reinforced
`in the case where lightweight is particularly important.
`It is preferable that a tongue part of the sport shoe includes
`the mesh structure part (C). It is further preferable that the
`tongue part may include a mesh structure part (D) having a
`burst strength that is lower than that of the part (C).
`The double raschel warp knitted fabric may have a
`property of being stretchable in the width direction of the
`foot and not stretchable in longitudinal direction of the foot.
`Thus, the effect of allowing a size of a shoe to be stable and
`preventing the tiptoe part from stretching when the toe
`touches to the part at the time of wearing. On the contrary,
`a property of not being stretchable in the width direction of
`the foot and stretchable in the longitudinal direction of the
`foot may be provided. Thus, fitness can be provided in the
`direction of the width. Furthermore, when a shoe is manu
`30
`factured by a process called a lasting method, in particular,
`the manufacturing process of the side part can be carried out
`easily.
`At least the parts A to C of the double raschel warp knitted
`fabrics of the present invention are disposed as one continu
`ous knitted fabric. Thus, when the fabrics are cut together
`with paper pattern, a shoe can be formed, thus enabling the
`efficiency in the formation to be improved.
`Then, on another Surface of the upper material (corre
`sponding to an instep cover) of the present invention, a fiber
`with a low melting point is used and at least a part thereof
`is fused. Since the fused part is reinforced by fixing knit
`Stitches, in the case of reinforcing a part with which the calx
`is brought into contact or a part with which the both sides of
`the foot are brought into contact, by heating only these parts
`45
`from the outside, the knit stitch can be reinforced. In this
`case, it is important that only outside of the upper material
`is fused. The inner surface side of the upper material is not
`preferably fused in order to maintain a flexible state because
`this side covers the foot. An example of the fiber with a low
`melting point includes, for example, an ethylene vinyl
`alcohol fiber yarn but is not limited thereto. It is preferable
`to use fibers whose melting point is 150° C. to 200° C. The
`fiber with a low melting point may be used for an entire
`surface of the front surface of the double raschel warp
`knitted fabric. The fiber with a low melting point can be
`produced by mixing together with a fiber with 20 wt.% or
`more of high melting point material Such as polyester. In the
`case of polyethylene terephthalate, the melting point is 260°
`C.
`A constituent yarn of the back surface of the double
`raschel warp knitted fabric and a connecting yarn connecting
`the front surface to the back surface are preferably a poly
`ester fiber yarn, and more preferably a polyethylene tereph
`thalate fiber yarn. The other configuration of the present
`invention may be the same as that of the basic invention
`mentioned above.
`
`4
`The present invention can provide a shoe having light
`weight and air permeability and further having high dura
`bility, and a double raschel warp knitted fabric used therefor.
`
`EXAMPLE
`
`Hereinafter, the present invention will be explained in
`more detail by way of Examples. Note here that the present
`invention is not limited to the following Examples.
`Example 1
`
`FIG. 1 shows a double raschel warp knitted fabric (thin
`melon-net fabric and back-woven half-net) used for a sport
`shoe according to one Example of the present invention.
`Shoe patterns 10 matched to paper patterns are placed
`continuously on one knitted fabric as shown in FIG.1. In the
`shoe patterns 10, a non-mesh structure part (A) 1a to 1e are
`disposed in a part Surrounding the tiptoe and a part connect
`ing to the shoe sole and stripe-shaped parts on the side
`surface of the foot (both sides). That is to say, 1a denotes a
`part Surrounding the tiptoe and connected to the shoe sole;
`1b to 1e denote stripe-shaped parts arranged on both Sur
`faces of the foot (both sides); and 1f to 1g denote parts folded
`in the shoe sole. A cut 13 at the tip is a part that becomes
`circular shape at the site of the tiptoe when folded into the
`shoe sole. A constituent yarn of a front Surface and a back
`surface of this double raschel warp knitted fabric was a
`multifilament fiber yarn of polyethylene terephthalate (total
`diameter of fibers: 84 dtex and number of filaments: 24) and
`a connecting yarn connecting the front Surface to the back
`surface was a monofilament fiberyarn made of polyethylene
`terephthalate (total diameter of fibers: 33dtex and number of
`filament: 1). Gauge of a knitting machine was 24 gauges,
`and the weight per unit area of an entire knitted fabric was
`258.4 g/m.
`To a part that may have a moderate strength and air
`permeability, that is, a part in the vicinity of the surface of
`the toe, a mesh structure part (B) 2 was placed.
`To a part that needs air permeability, that is, the side
`surfaces of the foot (both sides), mesh structure parts (C) 3a
`to 3d were placed in a stripe.
`A tongue part 12 was formed of a mesh structure part (C)
`4 and a mesh structure part (D) 5 with higher air perme
`ability.
`The back surface was formed of the same weave as that
`of the non-mesh structure part (A) of the front surface.
`This double raschel warp knitted fabric had a structure
`that is stretchable in the X direction and not stretchable in
`the Y direction.
`When the bursting test was carried out in accordance with
`JIS L 1096. A method, the burst strength of the non-mesh
`structure part (A) was 1600 kPa; the burst strength of the
`mesh structure part (B) was 1500 kPa; the burst strength of
`the mesh structure part (C) was 1000 kPa; and the burst
`strength of the mesh structure part (D) was 930 kPa. When
`the air permeability test was carried out in accordance with
`the JIS L 1096 A method (“Frazil method”), air permeability
`of the non-mesh structure part (A) was 240 cm/cm/s; air
`permeability of the mesh structure part (B) was 255 cm/
`cm/s; air permeability of the mesh structure part (C) was
`278 cm/cm/s; and air permeability of the mesh structure
`part (D) was 340 cm/cm/s. The thickness of this knitted
`fabric was 5 mm. Furthermore, the weight of double raschel
`warp knitted fabric used for one shoe was 20 g (in the case
`of 26.0 cm-shoe).
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`US 7,051.460 B2
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`5
`Example 2
`
`6
`number of meshes (the number of holes per inch (25.4 mm))
`is described below. In the below explanation, X direction
`denotes a width direction and Y direction denotes a longi
`tudinal direction in FIG. 5.
`(1) a part 31a1 located above the toe, stripe parts 31a2 and
`32a1 of the side part of the foot, a part 32a2 for covering the
`calx, and a part through which a shoelace passes in a tongue
`part 33c. 5.5 meshes in the lateral direction and 3 meshes in
`the longitudinal direction
`(2) a tip part 31b of the toe, a side part 32b1 of the foot
`and a stripe part 32b2, and a part 34 to be attached to the side
`face of the posterior side of the calx: 11 meshes in the lateral
`direction and 6 meshes in the longitudinal direction
`(3) an anterior side 31c1 folded into a shoe sole and a
`stripe part 31 c2, a reinforcing part 32c1 of a side part of the
`calx and an edge part 32c2: 12 meshes in the lateral direction
`and 12 meshes in the longitudinal direction
`(4) a central part 33a of the tongue part: 5 meshes in the
`lateral direction and 2 meshes in the longitudinal direction.
`(5) a part 33b except for a central part and a part through
`which a shoelace passes: 6 meshes in the lateral direction
`and 3.5 meshes in the longitudinal direction.
`This double raschel warp knitted fabric has a structure
`that is not stretchable in the X direction and the Y direction.
`A shoe that is the same as that shown in FIGS. 2 to 4 is
`formed by using the shoe patterns 30 of a knitted fabric.
`Thereafter, side parts of the foot corresponding to the parts
`1c and 1d of FIG. 2 are fused and processed by heating
`thereof at 170° C. As a result, in the heated part, knit stitch
`structure became rigid, and thus reinforcement can be car
`ried out.
`The weight of one of the obtained 26-cm shoes was 133
`g. A test in terms of feeling of wearing, air permeability and
`durability was carried out by actually wearing the formed
`26-cm shoes for one month. As a result, it was confirmed
`that the feeling of wearing, air permeability and durability
`were good and that the shoes had excellent functional
`properties as sport shoes. In particular, the shoes were
`Suitable as shoes to be worn in long-distance running Such
`as marathon.
`The invention may be embodied in other specific forms
`without departing from the spirit or essential characteristics
`thereof The embodiments disclosed in this application are to
`be considered in all respects as illustrative and not restric
`tive, the scope of the invention being indicated by the
`appended claims rather than by the foregoing description, all
`changes that come within the meaning and range of equiva
`lency of the claims are intended to be embraced therein.
`What is claimed is:
`1. A shoe comprising:
`an upper material using a double raschel warp knitted
`fabric;
`the upper material including a first Surface having a
`non-mesh structure and a second Surface having a
`non-mesh structure part (A) and mesh structure parts
`(B, C):
`the non-mesh structure part (A) and the mesh structure
`parts (B, C) respectively having burst strengths A, B
`and C that satisfy the relationship: Al-BC:
`the shoe including a tiptoe region, a toe region positioned
`adjacent to the tiptoe region, a heel region, and two side
`regions that extend between the heel and toe regions;
`the non-mesh structure part (A) being disposed at the
`tiptoe region and partially at both side regions;
`the mesh structure part (B) being disposed adjacent the
`toe region; and
`
`Sport shoes were formed by using the warp knitted fabrics
`obtained in Embodiment 1. FIG. 2 is a side view showing a
`shoe for a right foot. References numerals given to elements
`except for the elements of the shoe pattern in FIG. 1 will be
`mentioned below. Reference numeral 6 denotes a reinforc
`ing cloth (artificial leather) for a tiptoe part; 7 denotes a
`reinforcing cloth (artificial leather) for reinforcing eyelets
`for shoelace 11; 8 denotes a leather part for reinforcing the
`calx; 9 denotes a cushion part for covering the tarsus; and 14
`denotes a shoe sole part formed of synthetic elastomer (EVA
`resin). FIG. 3 is a perspective view showing the shoe of FIG.
`2 when the tongue portion is taken out of the shoe. FIG. 4
`is a side view showing the shoe of FIG. 2 seen from the
`opposite side.
`The weight of a 26-cm shoe was 133.1 g, which was
`significantly lighter as compared with the weight of about
`150g to 200 g of one of the conventional sport shoes of the
`same kind. This reduction in weight can be achieved by
`reducing the upper material by minimizing the amount of
`reinforcing materials as possible and by disposing a part
`requiring a satisfactory strength and a part requiring air
`permeability on one continuous warp knitted fabric So as to
`reduce sewing parts.
`A test in terms offeeling of wearing, air permeability and
`durability was carried out by actually wearing the formed
`26-cm shoes for one month. As a result, it was confirmed
`that the feeling of wearing, air permeability and durability
`were good and that the shoes had excellent functional
`properties as sport shoes. In particular, the shoes were
`suitable as shoes to be worn in long-distance running such
`as marathon.
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`FIG. 5 shows double raschel warp knitted fabric (thin
`melon-net fabric and back-woven half-net) used for sport
`shoes according to one Example of the present invention. A
`constituent yarn of a front surface of the double raschel warp
`40
`knitted fabric is a multi-filament yarn made of ethylene vinyl
`alcohol (total diameter of fibers: 84 dtex, number of fila
`ments: 24, amount of yarns: 78.76 g/m, and total ratio:
`30.4%), and a constituent yarn of the back surface of the
`double raschel warp knitted fabric is a multi-filament yarn
`made of polyethylene terephthalate (total diameter of fibers:
`84 dtex, number of filaments: 24, amount of yarns: 94.52
`g/m, and total ratio. 36.5%); and a connecting yarn con
`necting the front Surface to the back Surface is a monofila
`ment fiber yarn made of polyethylene terephthalate (total
`diameter offibers: 33dtex, number of filament: 1, amount of
`yarns: 85.73 g/m, and total ratio. 33.1%). Gauge of a
`knitting machine was 24 gauges, and the weight per unit area
`was 259.0 g/m. The thickness of this knitted fabric was 5
`.
`In FIG. 5, reference numeral 30 denotes a shoe pattern on
`knitted fabric. On one knitted fabric, respective parts are
`placed continuously. For reducing the excess parts So as to
`increase the yield, the arrangement is changed from that
`shown in FIG. 1. Reference numeral 31 denotes a part for
`covering the anterior side of the foot and 32 denotes a part
`for covering the posterior side of the foot. The configuration
`is different from that shown in FIG. 1 in that two parts are
`combined into one continuous part. Reference numeral 33
`denotes a tongue part; and 34 denotes a part to be attached
`to the posterior side face of the calx. The burst strength of
`each part is substantially the same as that in Example 1. The
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`the mesh structure part (C) being disposed partially at
`both side regions.
`2. The shoe according to claim 1, wherein in accordance
`with a bursting test based on JISL 1096A Method, the burst
`strength of the non-mesh structure part (A) is 1400 kPa or
`more and the burst strength of the mesh structure part (C) is
`900 kPa to 1200 kPa.
`3. The shoe according to claim 1, wherein the tiptoe
`region, the heel region and an eyelet part of the shoe are
`reinforced.
`4. The shoe according to claim 1, wherein a tongue part
`of the shoe comprises the mesh structure part (C).
`5. The shoe according to claim 1, wherein a constituent
`yarn of the first Surface and the second Surface, and a
`connecting yarn connecting the first Surface to the second
`Surface are polyester fiber yarns.
`6. A shoe comprising:
`a double raschel warp knitted fabric including one surface
`having a non-mesh structure and another Surface hav
`ing a non-mesh structure part (A) and mesh structure 20
`parts (B, C):
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`8
`the non-mesh structure part (A) and the mesh structure
`parts (B, C) including burst strengths A, B and C satisfy
`the relationship: Al-B>C:
`the shoe including a tiptoe region, a toe region positioned
`adjacent to the tiptoe region, a heel region, and two side
`regions that extend between the heel and toe regions;
`the non-mesh structure part (A) being disposed at the
`tiptoe region and partially at the side regions of the
`shoe;
`the mesh structure part (B) being disposed in the vicinity
`of the toe region of the shoe;
`the mesh structure part (C) being disposed partially at the
`side regions of the shoe; and
`at least the parts A to C being disposed in one continuous
`knitted fabric.
`7. The shoe according to claim 6, wherein a constituent
`yarn of the first Surface and the second Surface and a
`connecting yarn connecting the first Surface to the second
`Surface is a polyester fiber yarn.
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`Skechers EX1020-p.10
`Skechers v Nike
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